Innovative 3D-Printed Sleepers Revolutionize Carbon Capture Infrastructure

In a groundbreaking development for carbon capture and storage (CCS) infrastructure, Hyperion is supplying advanced sleepers to serve as pipe support foundations for a major pipeline project led by the Northern Endurance Partnership and A E Yates. This pipeline will transport captured carbon dioxide from industrial sources to secure subsea storage sites beneath the North Sea.

Cutting-Edge 3D Printing Enhances Efficiency and Sustainability

Utilizing state-of-the-art 3D printing technology, Hyperion eliminates the need for traditional formwork, enabling highly accurate and consistent production of the sleepers. Compared to conventional precast concrete methods, this innovative manufacturing process significantly reduces soil disturbance during installation, cuts down concrete and steel consumption by approximately 40%, and lowers carbon emissions by up to 50%-a substantial environmental benefit in line with global decarbonization goals.

Superior Strength and Lightweight Design Accelerate Installation

Despite being up to 60% lighter than traditional supports, these sleepers boast strength levels up to ten times greater, thanks to a meticulously engineered thin, reinforced base. This combination of durability and reduced weight facilitates quicker, safer installation procedures. Additionally, producing the sleepers offsite minimizes the need for extensive on-site labor and heavy machinery, further streamlining the construction timeline and reducing environmental impact.

Local Manufacturing Supports Regional Economic Growth

Hyperion will manage its contribution to the project from Forge I, its newly established manufacturing hub near Scunthorpe, Lincolnshire. This facility not only underscores the company’s commitment to innovation but also bolsters local employment and economic development in the Teesside region.

Industry Leaders Endorse the Technological Advancement

Mark Howard, Programme Director at Costain, emphasized the importance of supply chain innovation in delivering reliable, high-quality infrastructure solutions. He stated, “Hyperion’s 3D printing technology introduces numerous advantages in efficiency, sustainability, and safety for this critical project, while simultaneously fostering economic prosperity across Teesside.”