ABSTRACT
Precast concrete segment production is a critical activity for contractors involved in tunnel construction using Tunnel Boring Machine (TBM) technology. However, the global shortage of skilled production personnel poses a growing challenge, making it increasingly difficult to maintain adequate production capacity and ensure high product quality.
Robofactory addresses this issue by introducing an innovative precast plant where robots and automated systems collaborate with operators to enhance efficiency in a modernised working environment. This approach significantly reduces the risk of injuries while optimising production workflows. Over the past two years, Robofactory plants have been successfully commissioned in Italy, the UK and France, establishing a new paradigm for precast production. Robots handle tasks such as mould opening and closing, cleaning, and oiling, with the potential to expand robot functionality to additional stages of the segment production cycle. By transferring workers from physically demanding tasks to supervisory and control roles, these automated plants improve working conditions while at the same time significantly boosting efficiency. Current production data indicates a 30% increase in daily output, along with a substantial reduction in segment defects and workplace injuries, thereby enhancing overall production effectiveness and safety. Digital integration of the precast plant is achieved through tracking software that monitors production schedules, product quality, component stock levels, and logistics management, from initial storage to segment installation in tunnels.
