Public Funding for Tunnel Engineering Services (U.K.) LTD.

**_Robotic Fabrication of Tunnel Services using Industry 4.0 for Intelligent Distributed Manufacturing (_**_RoFab-4iDM) addresses safety and productivity problems that occur when fabricating customised mechanical and electrical (M&E) installation bracketry within rail and infrastructure tunnels._ **_RoFab-4iDM will radically improve productivity and worker safety by integrating survey, inspection, machining and additive manufacturing operations within an integrated, autonomous "survey-\>design-\>manufacture-\>install" system._** **_South Korean partners will apply this technology automating metal pipework repairs within tunnels._** We will combine conventional test techniques with machine learning (ML) and artificial intelligence (AI) to create a digital control environment capable of assessing and designing welds, fabrication, machining and additive manufacturing without human decision-making. **_Innovating to solve real-world problems: Improve worker safety; saving UK taxpayers £16,000 per km_ tunnel built.** RoFab-4iDM has immediate application for tunnelling projects including HS2, capturing benefits of autonomous robotics, while forming tunnel structures using conventional, cost-effective, precast concrete (PCC). No other system of this kind is available. **The issue:** Rail tunnel M&E services are fitted to racking bolted to inserts cast into PCC tunnel sections. Installation tolerance build-up (due to 'roll' of PCC sections) means inserts are often out of position. Safety rules forbid welding and deter drilling new inserts inside tunnels. Therefore, many brackets need bespoke adaptions. **Our proposal:** RoFab-4iDM will combine tunnel design models with as-constructed 3D survey data, using AI to automate design and manufacture of customised bracketry. Each bracket will precisely suit the as-installed inserts, enabling fast robotic installation. * **Precisely determine as-installed position of each insert** - automated scanning rig survey creates digital 3D representation. * **Position-specific, customised standard bracket design** created by AI using digital twin. * **Fabricate bracketry offsite** -- autonomous, adaptive robotic fabrication. The project integrates proven techniques/technologies with a novel digital twin. The demonstrator will develop the digital twin integration from TRL5 to TRL7\. **Further markets:** **_Enhancing construction productivity by creating a method for off-site mass manufactured components that are cost-efficient and bespoke._** Bridging the variance between designed ideal/predicted dimensions and as-installed would accelerate wide adoption of pre-manufactured products on construction projects. **_Autonomous repair to regulated standards within hazardous environments._** Applying RoFab-4iDM technologies to other sectors will provide a solution for welding/AM within hazardous environments, avoiding disruption from having to move damaged components to a repair workshop. Future development would be to combine all stages into a **survey-\>design-\>manufacture-\>install** platform, with applications in any industry that requires assessment, repair and remanufacture of steel materials, including rail and civil nuclear decommissioning.

**Project Background** Infrastructure tunnels are usually constructed using Tunnel Boring Machine's (TBM's) which are highly automated, used for cutting through the ground, producing a tunnel lining behind the TBM. However, once the tunnel is constructed, the fitting out of the tunnel for mechanical, electrical and communication services (M&E) are traditionally installed manually in a labour intensive manner, involving the fixing of bracketry and containment to support services. This traditional process has been found to be time consuming, unproductive, costly and it exposes workers to unsafe working environments and activities, (e.g. confined spaces, hand arm vibrations, dust, etc). The need for automating M&E service installations within tunnels led to the successful feasibility project of the Automated Tunnel Robotic Installation Solution (A-TRIS), which is now ready to be developed, a prototype built and demonstrated. **Project Aims** * To build and demonstrate a robotics and artificial Intelligence (RAI) process, to automate the traditional process of (M&E) service installations within an existing or recently constructed tunnel environment. Hence, eliminating the need for humans in unsafe and hazardous working environments, improving productivity across installation activities and promoting digitisation across the industry. * To capture the effectiveness and performance of the automated system through real-time demonstrations, showcasing how A-TRIS can be utilised in all types and sizes of tunnel construction, used for road, rail transportation and energy infrastructure. **Outputs** Outputs from this project will lead to minimised health & safety issues at the workplace, reduction of overall risk to operatives and increased levels of quality assurance and productivity for tunnelling related schemes. In addition to this the following key outputs shall be demonstrated: * reduced construction plant movement. * delivery reductions. * reduced installation costs and material waste. * carbon footprint reductions. * reductions of operatives within tunnelling environments. **Focus Areas** * The main area of focus will be the demonstrations of automating the installation process of M&E services in tunnels using robotics engineering and artificial intelligence to provide industrywide improvements. * A-TRIS will identify the whole life process (design, manufacturing and installation processes) for a RAI automation solution for mechanical, electrical and communication infrastructure services in tunnels and where this innovative technology can be used in other construction sectors. **Innovation** The build and demonstration of A-TRIS will show the real-world feasibility and how the use of robotics and AI integrated with positioning surveying and visual technology, logistics engineering and software can deliver the automated positioning, installation and fixing of M&E services in tunnel environments.

**Project Background** It is recognised in the industry that large transportation infrastructure tunnels are usually constructed using Tunnel Boring Machine's (TBM's) which are highly automated for cutting through the ground and installation of the tunnel lining behind the boring machine. However once the tunnel is constructed, the fitting out of the tunnel for mechanical, electrical and communication services are traditionally installed manually in a labour intensive manner, involving the fixing of bracketry and containment to support services. **Project Aims** The purpose and projected outcome of this feasibility study is to innovate, design and establish a robotics and artificial Intelligence (RAI) technology and process to deliver a robotic automated solution to facilitate the installation and maintenance of the mechanical, electrical and communication services within the constructed tunnel environment. The study shall also examine how this equipment can be utilised in all types of tunnel construction and sizes, used for road, rail transportation and energy infrastructure. **Outputs** Some of the key output objectives of the study are to minimise health & safety issues at the workface, reduction of overall risk to the operatives and increased levels of quality assurance and productivity. In addition to this the following key outputs shall be recognised: * reduced construction plant movement and number of visits to the workface. * delivery reductions. * reduced installation costs material waste. * carbon footprint reductions. * reductions of operatives within the tunnel. **Focus Areas** The main area of focus will be the automation of the installation process through the use of technology, robotics engineering and artificial intelligence to provide industrywide improvements. This feasibility study shall identify the whole life process for design, manufacturing and installation of the mechanical, electrical and communication containment services and where this innovative technolgoy can be used in other construction sector markets **Innovation** The feasibility will consider the use of modular services development, tunnel layout and positioning surveying technology, logistics engineering, tyre and track access to work face, software integration, automated positioning and fixing of services.