In a groundbreaking initiative spearheaded by a Spanish-led European Union project, autonomous heavy machinery and advanced drone technology are joining forces to revolutionise tunnel construction. The aim is to slash carbon emissions and dramatically enhance safety in an industry known for its significant environmental impact and inherent risks.
The construction sector is a major contributor to global carbon emissions, accounting for nearly 40% of all energy-related CO2. The carbon footprint of a single large-scale tunnel project can be staggering, equivalent to the emissions generated by hundreds of thousands of intercontinental flights. With ambitious projects like the Mediterranean Corridor in Spain and the Brenner Base Tunnel in the Alps currently underway, the urgency to adopt low-carbon, high-efficiency solutions has never been greater.
Tackling Tunnel Hazards with Automation
Tunnel construction, particularly in the immediate aftermath of a blast, presents extreme hazards. Visibility drops to near zero, and the persistent threat of unexploded charges poses a grave danger to human workers. This is precisely where the ‘BEEYONDERS’ project steps in, aiming to eliminate the “human factor” from these perilous zones.
A Controlled Environment for Innovation
For the crucial testing phase of this innovative technology, a pilot site was established at the Fundación Santa Bárbara in Ribera de Folgoso. This former quarry, now repurposed as a dedicated training and simulation facility, caters to technical teams involved in construction, maintenance, and emergency response in north-western Spain. This controlled setting provides researchers and engineers with a safe and realistic environment to rigorously test and refine their autonomous systems before their deployment in active, large-scale infrastructure projects.
The Dual Role of Drones in Tunnel Operations
Marco Montes Grova, Perception and AI Engineer at CATEC, elaborated on the multifaceted role of drones within the project:
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Digital Twin Creation:
Initially, drones are deployed to meticulously map the tunnel. This data is then used to construct a precise digital twin of the tunnel environment. This virtual replica is crucial for planning and simulation. -
Guiding Autonomous Machinery:
Following a detonation, when the air is thick with smoke and visibility is severely compromised, the drone acts as the vital sensory input for the autonomous loader. It guides the machinery through the hazardous conditions directly to the excavation front. -
Detecting Unexploded Ordnance:
A key safety feature is the drone’s integrated thermal camera. This advanced sensor capability allows it to detect unexploded ordnance (UXO), providing an invaluable layer of safety for both the autonomous equipment and any subsequent human presence.
Beyond Safety: Optimising the Construction Cycle
The integration of this advanced technology offers benefits that extend far beyond mere life-saving. It significantly optimises the entire construction cycle. By enabling autonomous machinery to enter the tunnel immediately after a blast, even when the air remains too hazardous for human workers, the technology dramatically reduces costly downtime. This streamlined process accelerates project timelines and improves overall efficiency.
Adapting Autonomous Technology for Surface Works
The innovation isn’t confined to underground operations. The same autonomous loader technology is being successfully adapted for surface works, with recent trials conducted along the Rome-L’Aquila highway in Italy.
On these surface sites, the autonomous loader operates within a sophisticated digital ecosystem:
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Photogrammetry for Site Mapping:
Drones are again employed, this time performing photogrammetry to precisely map the work site. This data informs the definition of the machine’s optimal operational path, ensuring efficient and safe movement. -
Real-Time Personnel Safety:
Human workers on site are equipped with wearable RTK (Real-Time Kinematic) sensors. These advanced sensors enable the autonomous loader to precisely identify and avoid personnel in real-time. If a worker is detected within the machine’s operational zone, the loader will automatically stop, guaranteeing a 100% safety record on site.
Fabrizio Federici, Project Manager at AISCAT Servizi, highlighted the economic and environmental advantages of this adaptation. “This mechanical loader, converted to autonomous driving, can cut fuel use by about 10% in a sector as energy-intensive as road construction,” he stated. “The information collected allows the digital twin to calculate the best and safest route, directly reducing environmental pollution.”
The Future of Infrastructure: High-Precision, Low-Emission Digital Environments
Through the automation of critical tasks such as inspections and heavy lifting, both in the challenging environments of underground tunnels and on active highways, these pioneering innovations are poised to transform infrastructure sites. The vision is to create high-precision, low-emission digital environments, ushering in a new era of safer, more efficient, and environmentally responsible construction.
