UK scales automated low carbon infrastructure manufacturing

The UK is advancing infrastructure delivery with the launch of its first automated low-carbon manufacturing facility, signalling a shift towards industrialised construction and scalable asset production. The development reflects increasing demand for efficient, standardised infrastructure solutions aligned with decarbonisation targets.

The facility, known as Forge I, is being developed in Flixborough through a partnership between Hyperion Robotics and LKAB Minerals. It will specialise in the off-site production of precast concrete foundation systems, using digital design and robotic manufacturing to support infrastructure assets across energy, utilities and data networks. This model integrates engineering, manufacturing and deployment into a more streamlined infrastructure supply chain.

Automation sits at the core of the facility’s infrastructure proposition. High levels of robotic production enable consistent output of large-scale foundation components, reducing variability associated with traditional site-based construction. This enhances delivery certainty, improves quality assurance and supports faster project timelines, particularly for critical infrastructure requiring repeatable design standards.

The project also embeds low-carbon principles within infrastructure manufacturing. By using alternative materials and optimised structural design, the facility aims to reduce embodied carbon in foundation systems. Centralised production further improves logistics efficiency, lowering transport emissions and material waste while enabling better coordination across infrastructure programmes.

From an infrastructure perspective, the factory represents a move towards modularisation and standardisation. Off-site production allows components to be replicated at scale, supporting the rapid deployment of assets such as substations, wind foundations and network infrastructure. This approach aligns with broader efforts to modernise infrastructure delivery and address capacity constraints within traditional construction models.

The development highlights a structural transition in infrastructure strategy, where manufacturing-led delivery models are increasingly integrated into project pipelines. As demand for resilient and low-carbon infrastructure grows, automated production facilities are expected to play a critical role in improving efficiency, reducing emissions and enabling large-scale deployment.