Innovation in Tunnel Fit-Out, Maintenance & Refurbishment

This category recognises projects that are driving use of innovative methods and smart technologies within the industry to improve tunnel the final stages of tunnel construction or during the operational phase to maximise the lifespan of the asset.

Arup 
AI and Automated Tunnel Inspections for Fit-out and Maintenance: A Whole Life Cycle Case Study

Arup has been working with UK Power Networks (UKPN) and Metrolinx in Canada, to automate the end-to-end tunnel inspection process, combining tunnel knowhow with the latest advancements in AI. The resulting groundbreaking solution minimises human input within critical and hazardous spaces, whilst enhancing accuracy and repeatability of data collection and analysis. The automated approach has proven valuable through the entire tunnel lifecycle, from construction to Operation and Maintenance (O&M). The innovative framework comprises three key components: 1. Automated data capture with bespoke cameras and sensors apparatus on autonomous vehicles. 2. Deep Learning-powered predictive diagnostics and condition monitoring. 3. Loupe360 digital platform for asset management. This approach has shown high accuracy and consistency, reducing inspection durations by up to 70% and saving up to 40% of the O&M budget. UKPN and Metrolinx have highlighted the project’s potential for cost savings and improved safety standards, aiming to revolutionize the tunnelling industry.

AtkinsRéalis
Using and adapting available technologies to modernise inspection activities

Our inspection work depends on activities such as data collection, data management, data interpretation and reporting. In recent years there’s been a significant improvement in available technologies that can enhance the efficiency of these activities. During the Kingsway Tunnel Inspection, we utilised advances in reality capture technology such as the Leica BLK2GO and iPhone LiDAR to quickly and cost effectively create 3D photorealistic models of inspection assets which we hosted on a cloud-based common data environment and accompanying mobile application. This supported inspectors to navigate the models using iPads and embed standardised geo located defect information (images, data fields etc.) which was then synced back into an intuitive and data rich, single source of truth photorealistic model. With minimal risk and investment, using and adapting these technologies simply and seamlessly eliminated numerous inherent issues such as siloed and subjective data records and limited visualisation capability from traditional inspection workflows.

Barhale and Thames Water
Design and installation of ground-breaking temporary tunnel lining

On behalf of Thames Water, Barhale designed and installed a ground-breaking temporary tunnel lining to protect London’s Mid Level 2 trunk sewer (ML2), a vital part of Bazalgette’s sewer infrastructure, from the passing of HS2’s Tunnel Boring Machines. The team challenged conventional thinking to tackle the multiple constraints that included a tight timescale, potentially long and dangerous underground transits and significant variances in the tunnel’s geometry. Instead of defaulting to a reinforced concrete liner, Barhale developed a solution comprising a series of 175 adjustable steel rings to form a ribbed liner to protect the vulnerable section of the Victorian, brick-lined ML2 sewer closest to the lines of HS2’s upline and downline tunnels.

Heathrow
Adopting Modern Methods of Construction for Tunnel Refurbishment

Heathrow Airport’s Cargo Tunnel, a critical road link between the Central Terminal Area and Terminal 4, recently underwent a major refurbishment. The project faced unique challenges due to asset criticality, the busy operational environment, limited night-time working window and rigorous security requirements. To address these issues, the delivery strategy focused on collaboration, digital transformation and adopting Modern Methods of Construction (MMC). The project team has maximised offsite construction by using standardised factory-built modules. This approach reduced labour requirements, improved safety and allowed build completion a year earlier than traditional methods. The project’s success demonstrates the potential of MMC for future capital projects at Heathrow. The pre-manufactured value reached an impressive 88%, with productivity figures far exceeding industry norms. We have prioritised innovation, leveraging new technology, tools and processes. Underlying our achievements has been a truly collaborative culture which began with the end in mind.

Tunnel Engineering Services UK
ATRIS (Automated Tunnel Robotic Installation System)

Tunnel Engineering Services (UK) Ltd led a consortium of mechanical, civil engineering, and robotic automation industry leaders: i3D Robotics, MTC, Costain and VVB, to develop the first robotic and AI solution set to revolutionise the installation of mechanical and civil services in tunnels. Traditionally, installing these services in tunnels is challenging, labour-intensive and time-consuming. ATRIS (Automated Tunnel Robotic Installation System) a fully operational working prototype can autonomously pick, place and install M&E service brackets to the tunnel wall. To meet the industry requirements for accurate data logging and traceability, the team developed a digital twin (DATA-IS), to verify every asset installed within the tunnel. ATRIS offers health & safety benefits, cost savings and a carbon footprint reduction. Moving forward, our next stage is to develop and improve ATRIS from prototype to a fully operational industrialised system, with the robustness essential to withstand the heavy duty demands of a tunnelling environment.