Pioneering robotic and AI tech set to boost productivity of services installation in tunnels by 40%

Atris is set to radically improve how services are installed inside tunnels, according to its creators. They comprise a consortium civil and mechanical engineering, and robotic automation industry leaders including Costain, Tunnel Engineering Services (UK) (TES), i3D robotics (i3D), the Manufacturing Technology Centre (MTC) and VVB Engineering.

They believe the automated solution will reduce the risks related to manual labour at the tunnel work face, for example, working at height in confined spaces, and hand-arm vibration experienced by workers during installation. Once developed, it can be deployed in tunnel construction for use in sectors including transport, water and energy. It is expected to increase productivity by 40% due to faster installation, reduce installation costs for new mechanical and electrical (M&E) systems by 30%, and cut construction plant movements by 40% to decrease embodied carbon.

The Atris prototype is the fruit of a 22-month project, partly funded by Innovate UK’s Smart grant and led by TES, which developed the initial concept in partnership with the consortium. Using its expertise in robotics and automation, MTC led the design and manufacture of the robot's end effectors.  i3D developed visualisation software for precise navigation, while Costain and VVB provided industry knowledge and expertise in tunnelling and fit-out requirements.

Tunnel Engineering Services (UK) design and project manager Alan Worsley said: “TES has over many years designed and manufactured mechanised tunnelling machines and special purpose equipment for the construction industry. Over this time, innovation has been at the forefront of our business, and the need for automation in traditionally manual M&E fit-out techniques has led us to develop Atris and make it commercially viable for the market. We believe the system can offer a safer, more cost-effective and sustainable solution for future infrastructure projects.”

MTC chief technologist for the Built Environment Steve Nesbitt said: “Like many sectors, construction has faced labour challenges over the past few years which has driven greater interest in using robots, beyond manufacturing and logistics, to address these issues. By contributing our expertise to this project, we are paving the way for construction companies to adopt technology for greater control and structuring of on-site works, making infrastructure delivery safer, more productive, and more sustainable.”

Developing an automated system to install infrastructure in tunnels has been a long-standing ambition for the construction sector, according to i3D lead engineer Jon Storey. He said that Atris had moved the sector significantly closer to that goal.

“The use of stereo vision with machine learning and robotics to place bolts precisely on a curved surface is an unprecedented achievement, with potential applications beyond the construction sector, such as nuclear decommissioning and defence.”

Costain mechanical and engineering manager and robotics lead Lee Bateson said: “Teaching the robots to learn seemingly simple tasks – such as how to avoid cross-threading the screws that go into the sockets – has been hugely fulfilling, thanks to the consortium’s collaborative spirit. Whether it’s carbon reduction, increasing productivity or improving workforce health and safety, this is transformative technology that will have enormous benefits for the customers that we build tunnels for.”

VVB Engineering group operations director Nicholas Beedle said: “Tunnel works historically are expensive to build and maintain, and in the higher risk bracket for safety during construction and operation. It is important that ongoing improvements are made to address both of these issues.  The development of the robotic AI solution is a step towards solving both of these industry challenges.”

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