Sixense, in collaboration with World Sensing, has developed an intelligent tunnel segment datalogging solution that fundamentally changes how tunnel linings are monitored throughout their lifecycle.
Instead of installing instrumentation after construction, the system embeds sensors and autonomous data loggers directly within the precast concrete segments during their manufacture.
These “intelligent segments” are therefore capable of recording structural behaviour from the earliest stages – starting with concrete curing, through to transportation to site and subsequent installation, and continuing throughout the operational life of the tunnel.
At the core of the solution is a robust, multi-channel datalogger connected to sensors such as vibrating wire strain gauges or pressure cells. These components are encased in a protective housing and cast directly into the segment, allowing them to withstand harsh construction conditions while remaining fully operational.
Once installed in the tunnel lining, the datalogger continuously collects measurements related to stress, strain, and overall structural performance. Data is transmitted wirelessly to nearby gateways—initially located on the tunnel boring machine (TBM), and later along the tunnel itself—providing engineers with near real-time insight into the stability of the lining without interrupting construction activities.
The applications of this intelligent datalogging solution are extensive and highly impactful. During construction, it enables continuous verification that tunnel segments are not subjected to excessive loads from handling, assembly, or ground conditions, significantly improving worker safety and reducing the need for risky manual installations.
In the long term, it supports structural health monitoring by tracking how stresses evolve due to environmental changes, ageing, or operational loads. This continuous data stream allows asset owners to adopt a data-driven maintenance strategy, anticipate potential issues before they become critical, and extend the service life of the infrastructure.
By combining embedded sensing with wireless data transmission, Sixense and World Sensing provide a scalable, low-maintenance monitoring system that enhances both efficiency and safety across modern tunnelling projects.