And finally… Costain uses 3D printed concrete on Teesside project

The firm has teamed up with civil and structural engineering delivery specialist A E Yates to bring on board Hyperion Robotics to deliver low-carbon concrete sleepers for a landmark East Coast Cluster project on Teesside.

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.

Hyperion will oversee its role in the project from Forge I, its new UK manufacturing facility near Scunthorpe, Lincolnshire.

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.”

Fernando De los Rios, CEO at Hyperion Robotics, said: “Working alongside Costain, A E 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.”

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.”