Infrastructure specialist Costain and civil engineering expert A E Yates have appointed Hyperion Robotics to provide innovative, low-carbon concrete sleepers for the Northern Endurance Partnership's (NEP) onshore CO2 gathering system.

The NEP project will establish the necessary transportation and storage infrastructure for carbon capture initiatives based in Teesside. As the delivery partner for NEP, Costain is working alongside A E Yates to install approximately 90 high-strength concrete pipe support bases—known as sleepers—along a 1.3km stretch of onshore CO2 pipelines.

Hyperion Robotics will utilise advanced robotic 3D printing and digital technology to manufacture the sleepers at its new UK facility, Forge I, located near Scunthorpe. This automated approach removes the need for traditional formwork and allows for highly precise, repeatable production.

When compared to conventional precast methods, this engineering-led solution reduces concrete and steel requirements by 40% and cuts carbon emissions by up to 50%. Despite being 60% lighter due to a thin, reinforced design, the structures are up to ten times stronger than traditional alternatives. The offsite manufacturing process also reduces on-site plant and labour requirements, facilitating a faster and safer installation.

-- Advertisement --

Mark Howard, Programme Director at Costain, said: "Our supply chain serves as a key enabler for innovation, ensuring that we continue to deliver predictable, best-in-class solutions across our projects. Hyperion's 3D printing solution will provide a myriad of efficiency, sustainability and safety benefits for this important project, while at the same time support economic growth and prosperity across Teesside. We're looking forward to collaborating with its team and working together with our other local supply chain partners as we continue to make strong progress in delivering a decarbonisation system that will be critical for creating a sustainable future for the UK."

Sven Till, Chief Executive Officer at A E Yates, added: "As a business, innovation and sustainability are fundamental to how we deliver for our customers, and having the opportunity to bring this innovative solution to Teesside for NEP, in collaboration with Costain and Hyperion, demonstrates this. We hope that this is the first of many innovative solutions we are able to provide to Northern Endurance Partnership as we deliver the wider OSBL civil engineering works."

Fernando De los Rios, CEO at Hyperion Robotics, highlighted that the project serves as a practical example of how combining digital design and automated manufacturing can meet high performance standards while reducing environmental impact.

Rich Denny, Managing Director at Northern Endurance Partnership, said: "By working with Costain and Hyperion Robotics to harness advanced manufacturing techniques, we are not only reducing the carbon footprint of construction itself but also supporting the development of a resilient UK supply chain. This kind of collaboration is critical to delivering a world‑class CCS network that will help decarbonise industry, protect jobs and drive long‑term economic growth in the region."

Costain is also currently managing the engineering, procurement, and construction (EPCm) elements for Net Zero Teesside Power. To date, 90% of subcontractor contracts for the project have been awarded to UK-based suppliers.