Projects
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| Reference Number | NIA2_NGET0070 | |
| Title | EcoBuild 3D: Sustainable Substation Foundations | |
| Status | Started | |
| Energy Categories | Other Cross-Cutting Technologies or Research 50%; Other Power and Storage Technologies (Electricity transmission and distribution) 50%; |
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| Research Types | Applied Research and Development 100% | |
| Science and Technology Fields | PHYSICAL SCIENCES AND MATHEMATICS (Computer Science and Informatics) 25%; ENGINEERING AND TECHNOLOGY (Electrical and Electronic Engineering) 50%; ENGINEERING AND TECHNOLOGY (Civil Engineering) 25%; |
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| UKERC Cross Cutting Characterisation | Not Cross-cutting 100% | |
| Principal Investigator |
Project Contact No email address given National Grid Electricity Transmission |
|
| Award Type | Network Innovation Allowance | |
| Funding Source | Ofgem | |
| Start Date | 01 September 2024 | |
| End Date | 30 September 2025 | |
| Duration | ENA months | |
| Total Grant Value | £556,964 | |
| Industrial Sectors | Power | |
| Region | London | |
| Programme | Network Innovation Allowance | |
| Investigators | Principal Investigator | Project Contact , National Grid Electricity Transmission (100.000%) |
| Industrial Collaborator | Project Contact , National Grid Electricity Transmission (0.000%) |
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| Web Site | https://smarter.energynetworks.org/projects/NIA2_NGET0070 |
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| Objectives | Phase 1: Design & engineering of structuresDesign of 3D printed foundations based on NGs specifications and construction drawings.Calculation of structure to Eurocodes (EN 1992, EN 1997, etc.).Planning of testing for certification for the UK market.Calculation report to be shared to NG for approval.Phase 2: Production of full-scale foundations for inspection, testing and site monitoring.Production of foundations for inspection and site assembly.Production of foundations for testing.3D printing production report.Phase 3: Lab-scale and full testing of structures.Collaboration with accredited independent laboratory.Testing for serviceability and ultimate limit state of all specimens.Testing report to be delivered to NG.Phase 4: Installation of units, monitoring and Micro-factory demo.Shipping of foundations and installation by National Grid for monitoring.Visit to site and inspection by Hyperions engineering team.Demonstration event of Micro-factory and printing for NGs teams and relevant stakeholders.Delivery of final project report. NG will specify the design requirements and the supplier will use their internal resources to optimise the designs. Optimised design foundations capable of resisting the same load will be modelled and approved by NG. Like the traditional foundation, the 3D printed one will incorporate standard reinforcement bars as per EN 1992-1. Supplier will produce an Engineering report based on all the calculations to local building codes and material properties along with the certified lab test results. Report will include relevant production steps, description of materials and technology used. Supplier will produce 3 different types of foundation units (75 in total) for testing and monitoring purposes. Lab and full-scale testing like mechanical and durability tests will be performed to verify the set standards. Foundations will then be delivered to Deeside for demonstration purposes. Site visits will be conducted during erection/construction, installation and reports will be published on the ease of installation and outcomes from civil contractor. Reports will also include laboratory/Site testing with findings for bolt pull-out and shear testing, crack control testing and recommendations of application of each. Micro-factory visits and 3D printing demonstration for National Grids relevant teams will be arranged. Lighting column foundations are low risk profile assets and are non-critical in case the design fails hence will be the first choice of foundations to be printed. The next stage will explore other substation foundation options which will be decided based on results from first set of foundations.Throughout the project, we will be monitoring the following KPIs and report them to wider NG teams. Main KPIs will measure sustainability, efficiency, and cost of the structures.eCO2: 40% reductions in CO2 emissions using 3D printed optimized foundations compared to traditional building technology. LCA detailed calculation to assess carbon savings.Time: 50% reduction in time for readiness of asset (production, shipment, excavation, and installation).Cost: 20% reduction in cost in comparison of entire value chain, from production to installation.Waste: 50% reduction of waste related to building material and reuse of excavated soil.Circularity: 20% recyclability/reusability of materials (as % of total weight).Final report will be published with all the learning outcomes and will be shared with all the licensees. A dissemination event will present all the results to relevant stakeholders with the recommendations of certain technologies ready to use in business as usual (BAU). The work will be delivered in discrete work packages each with a focus on different objectives linked to the overall aim to explore low carbon materials used in Civils. This project is planned to take 12 months with the following major objectives:Develop understanding of the possibility of integration of low carbon concrete and 3D concrete printing.Prove the specification requirements and design standards are achieved through 3D printing.Identify design requirements and changes in design compared to existing foundation designs.Like for like comparison of end foundation designs (weight, carbon footprint, ease of construction i.e., reduced asset management and decommissioning).Demonstration and testing of the foundations.Final recommendations to identify the potential benefits and implementation learning outcome. | |
| Abstract | The project aims to use a 3D printer to print substation foundations using low carbon concrete (Geo polymer mix) to reduce the construction driven carbon emissions. The supplier (Hyperion) has 3D printing mortar capable of resisting high forces with 50 years of design life. The project will optimize the design and will reduce the current material use by 50%. The foundations will be twice light as compared to the typical foundations. They will be transportable and can be precast near the site. The aim is to achieve the carbon emission reduction, concrete material reduction, weight reduction, labour reduction, and swiftness of the process. This project at first will explore the printability of lighting column foundation which is simple approach as compared to other foundations. | |
| Data | No related datasets |
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| Projects | No related projects |
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| Publications | No related publications |
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| Added to Database | 09/04/25 | |
