Hyperion Robotics has been contracted by infrastructure solutions company Costain and AE Yates, the civil and structural engineering delivery specialist, to deliver low-carbon concrete sleepers for a landmark East Coast Cluster project on Teesside.
Northern Endurance Partnership’s (NEP) onshore CO₂ gathering system will provide the CO₂ transportation and storage infrastructure for Teesside-based carbon capture projects. Costain is the delivery partner to NEP with AE Yates providing civil engineering services.
Costain and A E Yates will work with Hyperion to produce approximately 90 high-strength concrete pipe support bases, or sleepers, along 1.3km of onshore CO₂ pipelines across Teesside using its advanced robotic manufacturing and digital technology.
Through innovative robotic 3D printing, Hyperion’s technology eliminates formwork and enables precise, repeatable production of the sleepers. This approach, when compared to traditional precast solutions, will require less soil excavation, reduce concrete and steel use by 40% and carbon emissions by up to 50%.
The engineering-led solution is up to ten times stronger than traditional structures despite being up to 60% lighter thanks to a thin, reinforced base design. This will enable faster and safer installation of the sleepers, which will also be manufactured offsite to reduce on-site labour and plant.
Fernando De los Rios, CEO at Hyperion Robotics, said: “Working alongside Costain, AE Yates and the Northern Endurance Partnership on this project shows what is possible when forward-thinking organisations come together to deliver infrastructure in a different way. By combining engineering expertise, digital design and automated manufacturing, we can reduce material use and carbon emissions while meeting the highest standards of quality, performance and code compliance.
“This is more than a single project milestone. It is a practical example of how the UK can build critical infrastructure faster, more efficiently and with a lower carbon footprint by bringing together strong delivery partners, advanced technology and local manufacturing capability.”
Mark Howard, programme director at Costain, added: “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.”
Hyperion will oversee its role in the project from Forge I, its new UK manufacturing facility near Scunthorpe, Lincolnshire.
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