Learn about some of the innovative digital tools we are using on the Align project

Robotics used in our Tunnel Precast Factory

First project in the UK to achieve protection level 3 (PL3) of a post-tensioned concrete structure the size of the Colne Valley Viaduct. PL3 allows active monitoring of the integrity and strength of the tendons thread through the segments that make up the deck of the viaduct, ensuring the durability and safety of a post-tensioned structure.

Transparent noise barriers - through extensive modelling and understanding of noise receptors, Align developed a noise barrier using a mix of materials to respond to specific noise receptors on the viaduct route, mitigating noise pollution whilst reducing visual impact in the local area and preventing bird/bat strikes wherever practical. 

Semi-continuous and continuous boring developed and trialled and implemented on the C1 project. Using Continuous Boring, segment lining installation activities are done simultaneously without the need to stop the TBM. As-built chrono-analysis shows a 10% productivity gain

Installation of robotics onboard improving safety and efficiency. Krokodyl robot removes the wooden spacers between segments delivered to the TBM. DoByDo robot: used to insert dowels into tunnel segments to connect to the adjacent ring, the introduction of these robots removes the need for an operative to work in a potentially hazardous environment.

The Mobydic monitoring system which involves monoblock discs mounted on the cutterhead measuring force, temperature and rotation speed. Enables accurate picture of ground conditions, identifies obstructions and monitors cutter disc wear and maintenance needs.

PIG

Is designed to avoid slurry spillage in the tunnel and improve safety while maintaining a high level of control. This innovation is translated from the oil & gas industry and adapted to tunnelling by BYTP. It was deployed/improved on HS2 C1 with great success. The technology has been used for ⅔ of the tunnel drive (descending profile). Benefits include a 40% gain in productivity (time only) for the task of pipe extension.

Auto Slurry

Moving away from individual pump management to an automatic system, providing pressure and rpm control throughout the entire line. As well as improved safety, this system removed the need for 18 manual Potentiometers to just one and reduced operator tool-time.

Polymer replacement for lime/acid

The project team were keen to reduce the carbon impact of using lime to treat slurry,  which makes it easier to filter and place. A polymer alternative was successfully trialled and is now in use for the duration of the project. This innovation had led to an overall reduction of approximately 10,650 tCO2e and significantly reduced associated vehicle deliveries for lime and acid.

Trialling new ways of working, we partnered with ALICE (Artificial Intelligence Construction Engineering) Technologies, to test a software that helps teams explore large numbers of planning scenarios to ensure the schedule chosen is the best fit for the desired project outcomes.

Earthworks

Align trialled and then implemented an equipment management platform to optimise use of plant/equipment. The platform enabled improved productivity, reduced idle time by 13% (Q3, 22 vs Q2, 23) and reduced fuel consumption/distance travelled.

GRASSLANDS

Align is proposing to create a low management, rare, calcareous grassland habitat consisting of 127 hectares of wildflower and invertebrate-rich calcareous grassland and wood pasture, utilising 3 million m3 of chalk excavated from the Chiltern Tunnels. Expected to generate an estimate saving of 49,000 tonnes of CO2 through Carbon sequestration (absorption) and a further saving of 12,675 tonnes from lorry movements no longer required to transport the chalk off-site.

Align are working with Cranfield University and Tim O’Hare Associates on lab trials and site tests to achieve optimal growing conditions. 

Weather forecasting

Each year, weather delays 45% of construction projects worldwide. Align conducted a 12-month trial of a site-specific AI weather forecasting tool. The tool enabled our Production teams to better plan daily/weekly operational activities in specific areas more heavily impacted by weather conditions such as rainfall and wind speed.

SELF SERVICE STORE

To optimise ordering equipment, Align collaborated with VJ Technology and developed an onsite self-service store for fixings and tools accessories. This has lowered Operatives frustrations regarding having the right tools available when they need them. In addition, has simplified the procurement process and reduced carbon footprint by optimising site deliveries.

Our carbon reduction efforts

• Powering tower cranes being used on the Colne Valley Viaduct with a Battery Energy Storage System (BESS)

• Using automation and AI software to re-route power at the point of demand

• Trialling hybrid plant featuring a 100% electric swing system

• Low carbon concrete trials

• Conducted HVO trial = seven of our 14 sites are diesel-free