Tunnels have always been an important part of infrastructure, and although a significant number of tunnels have been built in many countries over the past few decades, traditional construction methods have often been limited. For example, the Channel Tunnel, which connects France and the United Kingdom, took over 15 years to complete and cost more than 15 billion euros.
Today, innovative technologies have the potential to change this approach. New methods may reduce construction time from 5-10 years to a period not exceeding 3-4 years, while maintaining high quality in constructions.
New technologies in tunnel construction.
One of the promising technologies in this field is the use of robotic systems and 3D printing. The process begins with the laying of 250 mm diameter pipes, in which robots form the future walls of the tunnels. Robot worms, about 3 meters wide, are equipped with milling heads to cut cavities in granite or clay soil, which are then filled with concrete or other materials.
Swarm robots work in collaboration: thousands of semi-autonomous devices perform tasks simultaneously, passing by each other in the confined spaces of tubular openings. They freely transition to locations, conducting surveys and setting control points to gather geological data. The robots cut precise cavities in the ground, filling them with appropriate materials, allowing for the creation of permanent structures—module by module—directly in the earth. Thus, new 3D structures are built step by step and block by block. After this process is complete, the soil can be safely removed from the worksite, and the walls of the tunnels are prepared for final use, leaving a “smart” structure that can be monitored and maintained throughout its entire life cycle.
However, that’s not all—thanks to seismic, tomographic, and thermal imaging data continuously transmitted by the robot worms to the central hub, a detailed picture of the underground architecture is created.
Thus, a fully parameterized 3D model (digital twin) of both the tunnel and the surrounding soil emerges. This digital twin, enhanced with Building Information Modeling (BIM), is executed with a level of detail that was previously unavailable in construction.
Do you think it’s science fiction? What about the company HyperTunnel—they are already working on relevant solutions:
Advantages of robot worms for tunnel construction:
This approach avoids the need for excavating significant amounts of soil, reducing time costs and minimizing negative impacts on the environment. The amount of resources spent on constructing underground facilities is reduced by up to 30%, while the efficiency of automated systems allows for work to be completed 50% faster than traditional methods.
The use of new technologies eliminates unpredictability associated with geological features and enhances overall construction safety. The integration of Building Information Modeling (BIM) enables the creation of accurate digital copies of projects, allowing potential issues to be identified at the planning stage, saving up to 20% of the project budget.
As a result, the construction of new facilities can take into account urban planning efforts, reducing social and economic costs for society.
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Thank you for your attention, Lumin Hopper
