Low-carbon foundations for Iberdrola energy plant

Hyperion Robotics partnered with Iberdrola and Peikko to create optimized foundations that use 75% less material compared to traditionally built concrete foundations.

Commissioned by Iberdrola, a leading international renewable energy company, the project aims at demonstrating the efficiency, eCO₂, and health & safety benefits associated with 3D-printed concrete.

Hyperion Robotics, Iberdrola, and Peikko have been working closely to collaborate on the design and engineering of the foundation. Taking into account the structural loads coming from the 132kV circuit breaker supported by the foundation, the team developed a design-by-testing approach to demonstrate the strength of the 3D-printed element.

Once printed in Hyperion’s facility in Helsinki, the element was transported to Peikko’s testing site in Lahti and pulled with horizontal and vertical forces. The live testing, which was witnessed by the client’s engineer, demonstrated that the foundation can withstand 3 times its design load whilst utilizing only 1/4 of the material typically used.

This project is a huge success in terms of eCO₂ footprint and construction methodology improvements for the long-term future of the industry. Hyperion is now working to scale up this application of 3D printing and apply it to energy infrastructures with the aim to minimise the environmental impact of these new facilities and decrease project costs and lead times.

This [3D-printed] foundation is very special. Being the first in the world – it is saving 75% of material compared to traditional pad foundations typically found in energy infrastructures.

— Henry Unterreiner, Co-founder at Hyperion Robotics