The tunnel boring machine (TBM) has become established as the safest excavation method, supported by ongoing technological advances in geotechnics, improved working conditions inside tunnels, and the implementation of increasingly efficient ventilation systems, among other developments.

It is the most advanced procedure currently available, but also one of the most complex, due to the scale of the machinery involved and the sophisticated operational management it requires. Its application therefore demands a high level of planning, technical coordination, and specialized control throughout all phases of the process.

A significant portion of the technical and economic risks in TBM-driven tunnels is linked to geological uncertainty. Unexpected ground variations can lead to cost overruns, schedule delays, or unplanned stoppages, affecting factors such as safety and project profitability. Despite progress in the use of geotechnical instrumentation and traditional monitoring systems, the ability to anticipate ground behavior ahead of the excavation face remains limited.

In this context, ACCIONA’s I’MNOVATION Startups 2024 program promoted a pilot project with the startup GEPRODE, aimed at developing a real-time geological prediction system for TBM tunnel projects. The solution is based on integrating excavation data with surface and subsurface instrumentation, combined with artificial intelligence techniques, to anticipate settlements and ground behavior before the TBM reaches specific critical areas.

The initiative resulted in the development of the geoRISCO platform, designed from scratch to synchronize data every 30 minutes and for each excavated ring—from the moment instruments enter the pre-excavation zone through to stabilization. This approach enables continuous correlation of TBM progress with the ground response measured at the surface, improving early detection of geotechnical risks.

The pilot was carried out in a real operating environment on Line 6 of the São Paulo Metro, with defined impact objectives: reducing downtime, lowering monitoring costs, and mitigating surface impacts. From a business perspective, the solution makes it possible to estimate meaningful cost savings and an associated reduction in CO₂ emissions, linked to greater efficiency in the construction process.

ACCIONA continues to explore technological solutions that strengthen digitalization, advanced prediction, and risk management in major infrastructure projects, integrating applied innovation and specialized technical capabilities in real operating environments.