ALIGN JV: Automating the Manufacturing of Concrete Segments for the HS2 Rail Project
ALIGN JV: Automating the Manufacturing of Concrete Segments for the HS2 Rail Project
How Equans Digital Automated the Preparation and Finishing of Concrete Segments for One of Europe’s Largest Infrastructure Projects
As part of the construction of the HS2 high-speed rail line in the United Kingdom, ALIGN JV faced a major industrial challenge: producing tens of thousands of concrete segments while maintaining high standards of quality, safety, and productivity.
To support this ramp-up, Equans Digital designed and integrated an innovative robotic solution based on four ABB industrial robots dedicated to mold preparation and the finishing of concrete segments.
Thanks to this automation, ALIGN JV has been able to reduce the most physically demanding tasks for operators, improve safety on the production lines, and ensure a consistent level of quality across all segments intended for the construction of the HS2 tunnels.
Building the rail infrastructure of tomorrow requires new industrial approaches
The HS2 project is one of the largest rail infrastructure projects currently underway in Europe. To construct the route’s tunnels, tens of thousands of prefabricated segments must be produced with impeccable precision before being assembled on-site.
In this context, ALIGN JV was seeking a solution capable of automating certain critical stages of the manufacturing process to improve working conditions for the teams while ensuring consistent production performance.
The Challenges of the Align JV Robotics Project
Automating physical, repetitive, and quality-critical operations
As part of the manufacturing of segments for the HS2 rail project, ALIGN JV had to produce tens of thousands of concrete segments while ensuring extremely high quality standards. The operations involving mold preparation and segment finishing were essential steps in the production process but still relied heavily on manual labor. The challenge, therefore, was to automate these tasks without compromising the precision, quality, and industrial performance expected for a project of this scale.
The mold preparation phases—including blowing, brushing, cleaning, and applying release oil—as well as the troweling of concrete segments placed a heavy burden on the operators. Performed repeatedly throughout the day, these tasks required physically demanding movements and constant attention. ALIGN JV was looking for a solution that could relieve the teams of these low-value-added operations while improving working conditions at the production site.
Beyond ergonomic concerns, certain tasks were performed near industrial equipment and in a high-volume production environment. ALIGN JV sought to reduce operators’ exposure to the most demanding work areas and limit the risks associated with repetitive movements. Automation emerged as a key strategy for ensuring operational safety while maintaining the efficiency of the production line.
The success of the HS2 project depended on the continuous production of a very large volume of concrete segments for tunnel construction. To meet the project’s scheduling objectives, ALIGN JV needed a reliable production process capable of maintaining sustained and consistent output over the long term. Any variation in processing times or in the availability of workstations could have a direct impact on the plant’s overall performance.
Each precast segment had to meet strict quality and finish requirements before being installed in the tunnel rings. The preparation of the molds directly determined the quality of the poured concrete, while the troweling operations had to ensure a uniform and consistent finish on each segment. ALIGN JV therefore sought to standardise these steps to guarantee consistent quality throughout the project, regardless of the production volumes.
Equans Digital's expertise serving industry and infrastructure
As a specialist in robotic integration and industrial automation, Equans Digital supports companies in the manufacturing, logistics, and construction sectors in modernising their production facilities.
From design to commissioning, our teams develop customized solutions to improve safety, operational performance, and competitiveness at industrial sites.
Equans Digital's solution: a robotic cell dedicated to precast concrete
To address these challenges, experts at Equans Digital designed, developed, and commissioned a comprehensive solution combining industrial robotics, automation, and monitoring.
The teams deployed two ABB industrial robots capable of automatically performing the following operations:
- blowing;
- brushing;
- cleaning;
- oiling the molds.
This automation ensures consistent preparation before each concrete pour while reducing manual intervention.
Cycle time: 7 minutes 30 seconds per mold.
Two other robots perform the finishing and troweling operations on the upper surface of the concrete segments before they are sent to the curing chamber.
Automating this step ensures a consistent finish while improving the overall performance of the production line.
Cycle time: 4 minutes 30 seconds per segment.
The teams handled the entire project:
- solution analysis and design;
- robot programming;
- integration of automation systems;
- commissioning;
- testing and performance validation;
- support for operations teams.
Inside the factory: the preparation and finishing robots supporting the HS2 project
Tangible Benefits for ALIGN JV
Beyond automating two key steps in the manufacturing process, the solution deployed by Equans Digital has enabled ALIGN JV to achieve several strategic objectives: improving working conditions for teams, enhancing operational safety, maintaining a high level of quality, and ensuring the production performance required for an extraordinary infrastructure project. The robots are now fully integrated into the industrial process and contribute daily to the manufacture of concrete segments for the HS2 project’s tunnels.
By automating the processes of preparing molds and finishing concrete segments, ALIGN JV has been able to relieve operators of the most repetitive and physically demanding tasks. Operations such as blowing, brushing, oiling, and troweling are now performed by robots with consistent precision. This automation allows teams to focus on higher-value-added supervisory and monitoring tasks, while reducing exposure to daily physical strain.
The introduction of industrial robots helps limit manual intervention in the most demanding production areas. By reducing the presence of operators near equipment and during certain repetitive tasks, ALIGN JV improves the overall safety of its manufacturing process and helps reduce the risk of accidents or musculoskeletal disorders. Robotics thus becomes a concrete tool for preventing workplace hazards.
The robots perform each operation according to precisely defined parameters, ensuring perfect repeatability of movements and results. The consistent preparation of the molds prior to casting, along with the consistent quality of the troweling of the segments, help ensure a high level of finish across all the voussoirs produced. This standardisation of the process is a major advantage in meeting the particularly strict technical requirements of the HS2 project.
By automating key process operations, ALIGN JV ensures consistent production rates while minimising variations caused by manual intervention. The robots perform tasks with controlled and consistent cycle times, enabling the production pace required to manufacture tens of thousands of concrete segments. This operational reliability directly contributes to the successful execution of one of Europe’s most ambitious infrastructure projects.
Beyond immediate productivity gains, this project illustrates the ability of industrial robotics technologies to address the challenges of transformation in the construction sector. By combining improved working conditions, safer operations, consistent quality, and industrial performance, ALIGN JV demonstrates that it is possible to successfully integrate robotic solutions into large-scale precast concrete manufacturing environments. This landmark achievement paves the way for new Industry 4.0 applications in the construction and infrastructure sectors.
Key Figures on the Project's Results at Align JV
Accelerate Your Industrial Automation Projects with Robotics
Are you looking to automate repetitive tasks, improve safety for your teams, or optimise your production performance? The experts at Equans Digital can help you design and implement robotic solutions tailored to your business needs. Let’s discuss your project.Accelerate Your Industrial Automation Projects with Robotics
Are you looking to automate repetitive tasks, improve safety for your teams, or optimise your production performance? The experts at Equans Digital can help you design and implement robotic solutions tailored to your business needs. Let’s discuss your project.