Innovative 3D-printed concrete components will be used for the first time on a major carbon capture project in Teesside, as Costain and A E Yates partner with Hyperion Robotics to deliver low‑carbon infrastructure for the East Coast Cluster.

The companies will use robotic 3D printing technology to manufacture approximately 90 high‑strength concrete pipe support bases, known as sleepers, along 1.3 kilometers of onshore carbon dioxide pipelines. The pipelines form part of the Northern Endurance Partnership’s onshore CO₂ gathering system, which will transport captured emissions from Teesside-based industrial sites for offshore storage.

Costain is the delivery partner to the Northern Endurance Partnership, while A E Yates is providing civil engineering services. Hyperion Robotics has been brought on board to supply the sleepers using its advanced digital design and automated manufacturing approach.

The 3D-printed sleepers will be produced at Hyperion’s Forge I manufacturing facility near Scunthorpe, Lincolnshire, and installed offsite, reducing on-site labor and heavy plant requirements. The technology eliminates the need for traditional form work and allows for precise, repeatable production.

Compared with conventional precast concrete solutions, the 3D-printed approach is expected to reduce soil excavation, cut concrete and steel use by about 40 percent and lower carbon emissions by up to 50 percent. Despite being up to 60 percent lighter, the sleepers are designed to be up to 10 times stronger due to their thin, reinforced structure, allowing for faster and safer installation.

“Our supply chain serves as a key enabler for innovation,” said Mark Howard, program director at Costain. “Hyperion’s 3D printing solution will provide a myriad of efficiency, sustainability and safety benefits for this important project while supporting economic growth across Teesside.”

Hyperion Robotics CEO Fernando De los Rios said the project demonstrates how advanced manufacturing can help transform infrastructure delivery. “By combining engineering expertise, digital design and automated manufacturing, we can reduce material use and carbon emissions while meeting the highest standards of performance and compliance,” he said.

A E Yates CEO Sven Till said the project reflects the company’s focus on innovation and sustainability, adding that the collaboration could pave the way for additional advanced construction solutions across the wider Northern Endurance Partnership program.

Northern Endurance Partnership Managing Director Rich Denny said the use of advanced manufacturing supports both decarbonization goals and the development of a resilient U.K. supply chain. “This kind of collaboration is critical to delivering a world-class CCS network that will help decarbonize industry, protect jobs and drive long-term economic growth in the region,” he said.

Costain is also delivering engineering, procurement and construction management services for Net Zero Teesside Power, which aims to become the world’s first gas-fired power station equipped with carbon capture and storage. About 200 Costain staff are currently working on the project, alongside approximately 100 designers and engineers based in Manchester, with the majority of subcontractor work awarded to U.K.-based suppliers.

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3D-Printed concrete to support Teesside carbon capture pipeline project

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