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Projects: Projects for Investigator
Reference Number	NIA2_NGET0045
Title	Use of Innovative Materials and Construction Techniques in the Substation Environment to Accelerate Transition to Net-Zero
Status	Started
Energy Categories	Other Power and Storage Technologies(Electricity transmission and distribution) 100%;
Research Types	Applied Research and Development 100%
Science and Technology Fields	PHYSICAL SCIENCES AND MATHEMATICS (Metallurgy and Materials) 25%; ENGINEERING AND TECHNOLOGY (Electrical and Electronic Engineering) 25%; ENGINEERING AND TECHNOLOGY (Civil Engineering) 20%; ENGINEERING AND TECHNOLOGY (Architecture and the Built Environment) 30%;
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 2023
End Date	30 September 2025
Duration	ENA months
Total Grant Value	£950,000
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%)
Web Site	https://smarter.energynetworks.org/projects/NIA2_NGET0045
Objectives	We propose to explore the use of different materials in detail in the following stages: Availability of material and fabrication (supply-chain) Design requirements and changes in design compared to steel/aluminium/concrete Like for like comparison of end products (weight, carbon footprint, ease of construction i.e., reduced earthing, asset management, and decommissioning) Demonstration/testing of a product Feasibility study and proof of concept stage will include research for materials. The project will be split between structures and civil elements, with 3 topics for structures being explored and 4 topics for civils being explored. It is proposed to first have a feasibility study and proof of concept stage, then an implementation stage for the civil elements, mainly foundations and bunds, and then an implementation stage for structures, where these could be mounted on the foundations from the previous stage. The following structures and civils options will be explored for feasibility study and proof of concept topics. Each topic has the purpose of choosing specific topics as explained below: Weathering Steel for Structures – Weathering steel creates a layer of rust onto the steel surface which doesnt flake away over time and therefore protects the steel. If the steel can be bought in this form, it would save considerable time on fabrication, where the need for painting or galvanizing would be eliminated. There are also alleged sustainability benefits to using this method of steel protection. It is proposed to research into the feasibility of this material from a manufacture and delivery perspective as well as from a sustainability perspective. Generative Design and 3D Printing of Structures – Generative design of structures creates the lightest structure possible given set parameters to work to. In the past generative design has been done, but manufacturing of these designs has proved too difficult and therefore simpler structures are often reverted to. With 3D printing technology, it could be viable to design, and 3D print a very lightweight structure, which could have cost, sustainability, transport, and installation benefits. The structures could be polymer/plastic or even 3D printed from steel powder. Polymer Structures – Polymer materials (GRP and FRP) are already used in substations for light weight items including trench covers and platforms. We propose to use this material for equipment support structures. Bubble Slab Foundations – Bubble slabs use hollow plastic balls to reduce the volume of concrete required for different foundation type. They provide a sustainable solution as less concrete is required and therefore less transport and labour. Waffle Slab Foundations – Similar to bubble slabs, waffle slabs reduce the amount of concrete required for foundations by using grillages of concrete beams with a thin slab on top. Waffle slabs are common in industrial buildings but are rarely seen outside of this environment. Ashcrete and Ferrock Foundations – Ashcrete replaces the cement used in concrete with fly ash, which is a by-product of burning coal and is therefore a recycled material. Ferrock replaces the cement with waste steel dust and waste silica, both by products of construction processes. These could be used for foundations and would provide a more sustainable solution than traditional concrete foundations. Graphene Enhanced Concrete – Graphene enhanced concrete improves the strength of the concretesignificantly so that less concrete volume is used overall, greatly reducing the carbon impact of any foundations that it would be used on. Light-weight Foam Foundations – Foam foundations provide a quick and easy solution for foundations for fences, pedestrian segregation barriers, road signs and other light-weight structures, where an expanding foam is poured into the hole and expands around the fence post or structure. It could be more sustainable, is light weight so is easy to lift, has quick curing time and is easy to apply. The scope of the work is detailed below: Work Package 1: Feasibility Study/Proof of Concept Desktop study to explore different options with strong focus on supply chain of innovative materials for long run. Work Package 2: Implementation, Trial on Site & Laboratory Testing ​ Alternative Solutions for Substation Structures​ Site installation is involved for structures which includes design, site visits during erection/construction, follow up visits after installation, reports, and as built records of the trial stage for the structures. Laboratory testing with report of findings exposing steelwork to a corrosive environment to simulate seasonal/environmental effects to determine design life of steelwork as well as destructive testing of structures. Testing of reuse/recycling of above explored options will also be explored. Alternative Solutions for Substation Foundations​ Explore the light-weight Foam Foundations for Fence Post and the whole process will be conducted from procurement, delivery, and installation of fence post with light-weight foam foundation. Investigate bubble slab foundations with delivery and installation of the foundation for a typical substation structure. Waffle Slab Foundation Ashcrete, Ferrock and Graphene Enhanced Concrete Foundations will be studied for delivery and installation for typical substation structures. Work Package 3: Testing and Reporting of Implementations​ Demonstration and testing of the product at Deeside Innovation Centre will be implemented. 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. Work Package 4: Final report outlining recommendations to National Grid 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 and structures. This project is planned to take 2 years with the following major objectives: Successfully explore the supply chain for availability assessment for materials and fabrication.Identify design requirements and changes in design compared to steel/aluminium/concrete.Like for like comparison of end products (weight, carbon footprint, ease of construction i.e., reduced earthing, asset management, and decommissioning).Demonstration and testing of the product at Deeside innovation centre.Final recommendations to identify the potential benefits and implementation learning outcome. "
Abstract	This project aims to examine the use of low carbon construction materials in detail both at feasibility and trial stage for the reduction in carbon emissions associated with construction activities. This will include research for alternative materials like polymer structure, bubble slab foundations, waffle slabs, and others. The project will be split between structures and civil elements, with 3 topics for structures and 4 topics for civils being explored. It is proposed to first have a feasibility study and proof of concept stage, then an implementation stage for the civil elements, mainly foundations and bunds, and then an implementation stage for structures, where these could be mounted on the foundations from the previous stage. Further, this project looks to leverage the latest advances in structures and civil elements technology to ensure that the right asset investment decisions are made for future generations.
Publications	(none)
Final Report	(none)
Added to Database	12/10/23