3D printed concrete to be used in landmark Teesside carbon capture project

Costain and A E Yates have partnered with Hyperion Robotics to deliver low-carbon 3D printed concrete sleepers for a major carbon capture infrastructure scheme on Teesside.

The works form part of the Northern Endurance Partnership (NEP) onshore CO₂ gathering system, which will provide transport and storage infrastructure for carbon capture projects across the East Coast Cluster.

🤖 3D printing driving construction innovation

Around 90 concrete pipe support bases (sleepers) will be produced using Hyperion Robotics’ advanced robotic manufacturing technology at its Forge I facility near Scunthorpe.

The solution enables:

• up to 40% reduction in concrete and steel use

• up to 50% reduction in carbon emissions

• elimination of traditional formwork

• offsite manufacturing to reduce site activity

Despite being significantly lighter, the sleepers are designed to be up to 10x stronger than conventional precast solutions, improving both installation speed and safety.

🌍 Supporting UK carbon capture infrastructure

Costain is delivery partner for NEP, with A E Yates providing civil engineering expertise across the 1.3km onshore pipeline route.

The project is part of a wider push to establish a UK carbon capture and storage (CCS) network, supporting industrial decarbonisation and long-term energy transition goals.

🧠 Why this matters

This scheme highlights a wider shift across UK infrastructure towards:

• digital manufacturing in construction

• low-carbon material innovation

• offsite production and automation

• reduced site labour and plant requirements

It also reinforces Teesside’s role as a key hub in the UK’s emerging CCS and net zero infrastructure strategy.