HyperTunnel has unveiled the world’s first underground structure constructed by robots, built at its R&D facility on the North Hampshire Downs in England. The presentation took place at the recently concluded Tunneling Society Conference & Exhibition in London.
Ten times faster and half as expensive
HyperTunnel’s automated construction method is designed to build tunnels more than 10 times faster. At the same time, construction costs are halved compared to conventional methods. The method is also significantly more environmentally and climate-friendly, as the robots use sustainable materials such as concrete with low carbon content.
Safety revolution
HyperTunnel also believes that their method will revolutionize safety in the tunnel industry, as tunnels can be built and maintained without sending people inside.
Robots work after a digital model
A “swarm” of 3D printing robots works after a digital model of the tunnel. A fleet of ‘hyperBot’ robots is sent into the ground through plastic pipes (HDPE). Once in the ground, the robots 3D print the tunnel shell by feeding construction material directly into the ground.
The prototype tunnel is six meters long, two meters high, and two meters wide. The prototype, named the Peak XV tunnel, was part of a project for the state-owned British infrastructure company Network Rail. The prototype was unveiled at the British Tunneling Society Conference & Exhibition in London in October.
Tunnels from the Victorian era
The Network Rail project has demonstrated the hyperTunnel process and investigated the technologies that are key to maintaining the UK’s regional rail infrastructure. It includes, among other things, 650 tunnels from the Victorian era.
– Our large portfolio of Victorian tunnels requires increasing maintenance to meet the needs of the rail network. However, we want to reduce the interruptions for our passengers, so we are constantly looking for new approaches to extending or repairing tunnels that reduce the time a tunnel will be closed to trains. Peak XV moves us one step closer to this goal and, crucially, with a method that reduces workforce safety risk, says David Castlo, Technical Director of Mining and Tunnels at Network Rail.
Big step for the industry
– Our first large-scale demonstration tunnel is a big step not only for hyperTunnel, but for the entire tunnelling and construction industry. While solely using robots to build underground structures is drastically different, the contributing technologies, such as digital models, robotics, 3D printing and digital underground surveying, supported by AI and VR, are all well-proven in other industries. In fact, the hyperTunnel in-situ method is about reducing the risk of construction projects, says Steve Jordan, Co-CEO and co-founder of HyperTunnel.
Vinci has invested
Earlier this year, hyperTunnel received €1.88 million in funding from the European Innovation Council (EIC) Accelerator scheme, Europe’s flagship innovation programme. The company has also received a financial investment from France’s Vinci, part of Femern Link Contractors (FLC).
