This underground Structure Built by Robots

Brief 

UK-based tech startup hyperTunnel unveiled what is being called the first underground structure built entirely by robots, using a fleet of so-called hyperBots to 3D-print the tunnel. The automated construction method is aimed at constructing tunnels faster and at a lower cost, in addition to improving sustainability through materials such as low-carbon concrete.

Insight

Tech start-up hyperTunnel has revealed the world’s first entirely robot-constructed underground structure, built at its research and development facility in the North Hampshire Downs.hyperTunnel’s new automated construction method is designed to build tunnels more than 10 times faster and at half the cost of conventional methods.

The approach is significantly friendlier to the environment and will use sustainable materials such as low-carbon concrete. Without any human needing to enter the structure during construction, the hyperTunnel method could also transform safety in the tunnelling industry.

Using swarm construction methods according to a digital twin of the tunnel, a fleet of ‘hyperBot’ robots enters the ground via an arch of pipes. Once inside, the robots 3D-print the tunnel shell by deploying construction material directly into the ground. The 6m-long, 2m-high and 2m-wide Peak XV pedestrian-scale tunnel has been delivered as part of a project for Network Rail.

The Network Rail project has been demonstrating the hyperTunnel process, investigating the technologies that are key to low-disruption tunnel repairs for the UK’s regional railway infrastructure, which includes approximately 650 Victorian age tunnels.

Network Rail network technical head (mining and tunnels) David Castlo said: “Our large portfolio of Victorian tunnels requires increasing levels of work to meet the needs of the railway network.

However, we want to reduce the level of disruption to our passengers so we are constantly searching for new approaches to enlarging or repairing tunnels that reduce the length of time a tunnel will be closed to trains. Peak XV moves us a step closer to that goal and, crucially, with a method that reduces workforce safety risk.”