PROJECT INFORMATION
Location
Teesside
Client
Costain & AE Yates
End Client
Northern Endurance Partnership
Year
2026
Energy Sector
Costain and A E Yates have partnered with Hyperion Robotics to deliver low-carbon 3D-printed concrete sleepers for the Northern Endurance Partnership’s onshore CO₂ gathering system on Teesside – a critical piece of the UK’s first operational carbon capture and storage network.
Working from Forge I, our new UK manufacturing facility in Flixborough, we are producing approximately 90 high-strength pipe support sleepers to carry 1.3km of onshore CO₂ pipeline. Each unit is digitally engineered and robotically manufactured, placing material only where structural performance demands it.
Compared with conventional precast, the sleepers are projected to reduce concrete and steel use by 40% and embodied carbon by up to 50%, while delivering up to ten times the structural performance of traditional units at up to 60% less weight.
Offsite manufacture eliminates formwork, reduces in-situ works, and lowers the on-site labour and plant footprint along the pipeline corridor – supporting a faster, safer install in a busy construction environment.
The project is a working example of what UK advanced manufacturing capability looks like when applied to national infrastructure: designed in collaboration with a global engineering partner, produced at a new UK facility, and installed by a UK-based supply chain.
Download the full case study here.
