Costain Uses Robots to Print 90 Concrete Bases for Teesside Captured CO2 Pipeline

Key Takeaways

• Robots printed 90 high‑strength concrete bases for 1.3 km CO₂ pipeline.
• Cuts concrete and steel use 40% and emissions up to 50%.
• Printed bases are up to 10× stronger while 60% lighter.
• Eliminates formwork, reduces excavation, and lowers onsite labour needs.
• Supports Northern Endurance Partnership’s CCS pipeline linking Teesside to offshore storage.

Pulse Analysis

The collaboration between Costain, A E Yates and Hyperion Robotics marks a turning point for civil engineering, as 3‑D‑printed concrete foundations replace traditional precast elements. By deploying autonomous robotic arms at Hyperion’s Forge I factory, the project produced 90 high‑strength bases without formwork, delivering tighter tolerances and repeatable quality. The technology slashes material consumption—cutting concrete and steel by roughly 40%—and trims carbon output up to half, while also reducing on‑site excavation and labour. Such efficiencies illustrate how digital design and automated manufacturing can accelerate sustainable infrastructure.

The printed foundations underpin the 1.3 km Teesside Carbon Capture Pipeline, a core component of the Northern Endurance Partnership’s ambition to transport captured CO₂ from heavy‑industry clusters to an offshore storage hub beneath the North Sea. Backed by energy majors BP, Equinor and TotalEnergies, the pipeline supports the UK’s net‑zero roadmap and safeguards regional employment. By integrating the bases into a compression facility and subsequent offshore line, the project demonstrates a scalable model for carbon capture and storage (CCS) that could be replicated across other industrial corridors.

Beyond this single scheme, robotic concrete printing offers a blueprint for faster, greener construction across sectors. The lighter yet ten‑times‑stronger bases illustrate how material efficiency can coexist with structural performance, potentially lowering capital costs for large‑scale projects such as the Net Zero Teesside Power plant, slated to be the world’s first gas‑fired plant with CCS. As regulators and investors increasingly demand carbon‑reduced delivery, the adoption of automated manufacturing could become a competitive differentiator, driving broader industry transformation toward net‑zero objectives.