An innovative machine for digitalization of shotcrete operations in tunnelling with real-time process control and 3D mapping.

This innovation had the aim to make the shotcrete operation in the ''Drill & Blast'' tunneling and mining method more environmental-friendly, safe, with better quality and high cost-effectiveness. In this innovation, we developed and demonstrated a fully automated shotcrete machine, which ensures in real-time that the thickness of the concrete layer is always correct according to specifications (safety, costs and environmental footprint. The developed system consists of a high-precision 3D vision system consisting of two optical sensors for generating point cloud data and software that perform real real-time concrete thickness measurement during the shotcrete process. This 3D vision system generates also the 3D map of the tunnel wall that are visualized in real-time with thickness information. This 3D vision system is also interfaced with the computerized shotcrete control system for future use in automating the adjustment of the concrete spray where needed. Furthermore, the realized visualization is also easily accessible to operator through on-site industrial PC and screen to enable follow-up the operation, but also to ensure digitalized documentation of the finished process and concrete thickness. In this innovation, we also designed a robotized shotcrete equipment that will be combined with the 3D vision system for fully automatizing the process. The whole system was piloted in real tunnels in Agder and Porsgrunn area to optimize it for a final prototype. The company has received the first order of the system to be commercially delivered in Summer 2023 and therefore, a production and roll-out process is on-going. Moreover, we have had several disseminations activities during the project lifetime (presentations, press release and marketing), from which we expect to follow-up for wide exploitation and commercialization of the system.

For AMV, this innovation has enabled to develop a new product (based on the 3D vision system) with a first commercial order to be delivered in Summer 2023. Also AMV has made a radical innovation in the shotcrete process by adding a robotized system that will give their actual product a leading competitive advantage towards a higher market shares. For Veidekke and LKAB Berg & Betong, they are aiming to deploy the new product to achieve 15% reduction of concrete, which means app. 1000 NOK cost-reduction per meter of tunnel produced - in addition to achieving a better quality. This will also give tremendous benefits for society at large. For NORCE, this innovation has enabled to gain into a new domain knowledge for development and innovation of 3D Vision and allowed novel research methods for achieving real-time high-precision and high-resolution 3D visual mapping.

This innovation has the aim to make the shotcrete operation in the ''Drill & Blast'' tunneling and mining method more environmental friendly, safe, with better quality and high cost-effectiveness. This can be achieved by developing a fully automated shotcrete machine, which ensures in real-time that the thickness of the concrete layer is always correct according to specifications (neither more nor less). The shotcrete operation has severe HSE (Health, Safety and Environment) issues, because of the concrete dust and chemicals in the air. We therefore see a great potential if they could be automated towards less (or no) personnel on site, in addition to more efficient digitalization of the production and documentation of the finished work (e.g. concrete thickness, quality,...etc). To reach this goal, we aim to realize a new system including automated real-time concrete thickness measurement by means of accurate real-time 3D vision in the dusty low-light tunnel environment. This 3D mapping system shall be a part of the shotcrete process, continuously transferring the ''3D map'' of the tunnel ceiling/wall in real-time to the computerized shotcrete control system, which again use this to spray the concrete where needed (according to specified concrete thickness). In addition we aim to realize an interactive visualization system of the 3D mapping for operators/personnel to follow-up the operation (using e.g. tablet or goggles), but also to ensure digitalized documentation of the finished process and concrete thickness. The potential of this technology seems unlimited, as there are no such solutions available in the market today. The participation of Veidekke and LKAB B&B in this project can also be seen as a door opener for realizing this innovation. The demonstration of the new machine in tunneling and mining in Norway and Sweden (Kiruna) can be the gate to marketing and commercialization worldwide.