Design for machines and the productivity will come

The dividing trench between UK earthworks PLC and the rest of the construction industry is set to be filled in by three simple words' Design for Machines'. They may be simple words, but they are fundamental to a change in approach and mindset that is accelerating through the sector, from large customers like National Highways and HS2 to Tier 1 contractors like Skanska. 

It's thanks to people like Mark Lawton, the Plant & Earthworks Community representative to Highways England and Head of Engineering surveying and GIS at Skanska, that this and other messages are finally getting through. 

To find out more, I recently caught up with Mark at the Highways UK show, some two years after we first met at the same show in 2019. At this first event, we discussed his future vision for the 'Connected Worksite' and why he had become an active and vocal member of the Continuous Automated Plant (CAP) Community. 

This is a collaborative group of industry leaders and influencers formed to investigate the current technology, future possibilities, and ways to overcome hurdles to an autonomous future. 

The industry has definitely moved forward at a pace in the last two years. Still, Mark's passion for accelerating further change in work practices, safety and the adoption of innovation, has continued to grow, as he explained: 

Mark: "Our work is focused on changing the industry and all the things we aim to do are driven to improve safety onsite. Two years ago, the industry took a major step forward as 3D machine control was mandated on National Highways projects. Since then, the adoption of machine control has grown so rapidly that it's like a 'Herd of Elephants coming over the hill'. In other words, we are now faced with feeding all of these data hungry machines, and in order to keep them full, busy, productive and efficient, we need to design models that they can consume. After all, machines are like robots. They just need simple instructions to operate. This is why we now need to 'Design for Machines' not just for projects. But what does that mean?

"In simple terms, client surveyors and engineers have been using 3D modelling now for some time, creating whole project models that reflect the complete site delivery elements. So whether it's the construction of motorways or railways, which include structures like bridges, tunnels and viaducts or a housebuilding site with plots, roads and utilities, a full site model is now commonplace.

“However, the problem with these models and simpler 2D models supplied by clients for less complex projects is that the data can simply be translated into a file needed to support machine control. Inevitably this leads to a new model having to be created for the earthworks element of a project. Feeding the 'as built' data from the earthworks side of the project then becomes disconnected from the main model and software used to control the whole programme of works. 

“We lose all of the benefits real-time data capture, processing, and analysis can deliver to a project when this happens. When we look at machine control adoption and the challenges being tackled in its roll-out, we see the industry coming together to create solutions. 

“For example, leading players like Flannery Plant Hire, Plantforce and Lynch Plant Hire have all recognised the need for training and upskilling. All three businesses have invested in training centres, people and technology like simulators to help operators use new technologies like machine control.” 

A14 success has accelerated change

“We only have to look at the successful delivery of the A14, under budget and opened early thanks in part to the use of 3D machine control. This was managed effectively due to the creation of an Integrated Delivery Team (IDT), a joint venture between Balfour Beatty, Costain and Skanska, design consultants Atkins and CH2M and client National Highways.

The IDT brought together six management teams, each responsible for an individual section of the scheme, into a single, highly effective delivery model. Thanks to a 12-month early contractor involvement programme, which I was involved with, we determined how to create and manage effective earthworks models before equipment came onto site.  

It was a real testbed for collaboration from client to contractor to earthworks specialist. What the A14 did highlight was the need to get the right skillsets together for a project and understand the investment challenges needed to purchase new equipment and technology for the full life of the job.

The experience gained and shared from this project has given confidence for greater collaboration in the industry and the acceleration of technology adoption across the board.  

Remote control and semi-autonomous machines have arrived  

This year I have also witnessed impressive advances in 'Site Ready' technology. The first is the arrival of the Caterpillar Command Station for Construction, which can remotely operate several different types of equipment used for construction jobs, from wheel loaders to excavators. 

The operator sits in a 'cab-like' station connected remotely to the individual machines, which can be anywhere in the world and on multiple different sites. I believe this technology is going to be a true game-changer. 

Similarly, this year's introduction of the first Semi-Automatics machine onsite by Plantforce Rentals shows just how far down the autonomy road we have already travelled. The machine itself is a Kobelko SK210 excavator, fitted with an SMP tiltrotator connected to the new Leica Geosystems semi-automatics MC1 3D machine control solution and the Xwatch safety system. It has been working on projects across the country, proving this new technology's productivity and fuel efficiency benefits.

Machines will become surveyors. 

When we talk about 'as built' data in the future, the machine is not only going to tell us when it has dug the trench to the right depth and length. It will also survey the area around it because the advancement in sensor technology will allow the machine to become the surveyor, cutting out any latency in data transmission. This will remove the need to bring another device or sensor into the equation. 

For example, in construction, we will soon be able to backhaul data, instantly pushing data back from the machine's tracks. There's nothing quicker than that, and it's already happening in the mining sector.

We will be travelling virtually to the job site with a digital twin. 

With the pandemic, we have had to look at different ways of working, which has challenged traditional norms. For example, we now use “Microsoft Teams” to walk through digital twin models of projects discussing construction challenges without going to the site. This digitally enhanced approach allows teams to connect virtually to the site and go through digital rehearsals before a machine arrives. A whole project can be modelled, sequenced and rehearsed in this way, saving a huge amount of time whilst bringing experts from across the country and world together. 

The knock-on effects of reducing travel downtime and cost also greatly impact our journey to net zero, whilst increasing productivity. It's also a great way to show our industry to the next generation. I recently took part in some STEM work where we took some students to a project in Cambridge virtually to explore the challenges of a bridge build. There was no safety traffic management required, and the 14 to 15 year old students didn't realise we were capable of working in that way. It certainly opened their eyes to a future career in our industry. 

In conclusion, we are definitely on a transformative journey in the construction and earthworks sectors, and it's not ended yet…