ReAcTIVE: A Real-Time Monitoring Platform for TBM Operations

At Systra Italy, innovation is at the core of how we approach complex underground projects. One of the tools we developed to support smarter tunnelling operations is ReAcTIVE – Real-time Acquisition of Tunnel Information and Visualization Engine.

What is REactive?

ReAcTIVE is a digital platform designed to collect, process, and visualize Tunnel Boring Machine (TBM) data in real time. By transforming raw operational data into clear dashboards and reports, the platform helps engineers and project teams better understand what is happening on site and make faster, more informed decisions.

It is built to acquire TBM sensor data and convert it into meaningful information through customized dashboards and automated reporting tools.
The platform allows users to monitor excavation parameters in real time and quickly identify critical conditions through alerts and notifications.med decisions.

Key capabilities include:

• Real-time visualization of TBM operational data through interactive dashboards
• Automated report generation based on the visualized data
• Custom alert systems that notify users when parameters exceed defined thresholds
• Remote accessibility, allowing project teams to monitor operations from any device

Technically, ReAcTIVE is built using a modern digital architecture. Data is uploaded through an Uploader system, either automatically or manually. The data is then stored in a central Timescale database, where all TBM sensor information is organized and processed. Visualization is powered by Grafana, which provides dynamic dashboards and graphs for real-time analysis.

Where did the idea come from?

Systra Italy frequently works on Design & Build contracts, where close coordination between design teams and construction operations is essential.

In these projects, having clear and reliable information from the construction site is critical. ReAcTIVE was developed to give contractors, engineers, and designers a precise and continuous understanding of what is happening during excavation.

Through real-time monitoring and automated alerts, the platform supports rapid decision-making and effective risk mitigation, ensuring potential issues can be addressed before they escalate.

Because the system is accessible on mobile phones, tablets, and computers, project stakeholders can access the latest data wherever they are.

Another important advantage is the centralized data structure, which allows engineers to build and continuously improve artificial intelligence models capable of anticipating risks and supporting predictive analysis.

Applications and current use

ReAcTIVE is already being used in real projects.

For example, the platform supports construction management activities for the Catania Metro project in Italy, where it helps monitor excavation performance and operational parameters.

It has also been applied to the Łódź railway underpass project in Poland, supporting tunnelling operations with real-time data monitoring.

Beyond active construction sites, ReAcTIVE has also proven valuable for back-analysis of completed tunnels, both in dense urban environments and in deep rock conditions. These analyses help engineers better understand excavation behavior and improve future tunnel designs.

Future developments

The long-term vision for ReAcTIVE goes beyond TBM monitoring alone.

One of the next development steps is integrating TBM data with other sources of construction site information, such as surface settlement monitoring systems. Combining these datasets will provide a much more comprehensive view of excavation activities and ground response.

This integrated approach will enable engineers to better understand the interaction between tunnelling operations and the surrounding environment, further improving safety, risk management, and project performance.

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