Storage efficiency for tunnelling segments

Efficient use of storage space is a challenge for factories producing concrete tunnelling segments. The size and shape of these segments take up substantial yard space. As production volumes increase, many producers are looking for smarter and more efficient solutions. A recent project with AFCONS Infrastructure Ltd. — a major construction company and part of the Shapoorji Pallonji Group — shows exactly what’s possible.

The challenge: safe and efficient storage of tunnelling segments

Tunnelling segments are not just heavy—they’re irregularly shaped and space-consuming. Storing them horizontally means using a large surface area. That space could otherwise be used for additional stock, operations or logistics. Moreover, moving and stacking these segments comes with significant safety concerns.

The solution: vertical stacking with vacuum tilting technology

Aerolift 90-degree vacuum tilter provides an innovative yet simple answer. By tilting each tunnelling segment from horizontal to vertical, it becomes possible to stack them upright, creating pyramid-shaped stacks up to four segments high. The vacuum tilter handles lifting and tilting in one smooth movement, with no manual effort. The result is a more compact, organised and safer yard.

The result: Afcons is able to save up to 65% storage space

 Delivered via Aerolift’s local partner Trikausch, 90-degree vacuum tilters were commissioned at one of Afcons’ sites earlier this year.

Since implementation, Afcons has been able to stack segments in pyramid formations, enabling up to a 65% reduction in required storage space. The solution not only optimised their layout but also improved handling safety and efficiency.

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Why vacuum tilting is the future of tunnel segment storage

Storage yards are being challenged to become more compact, more efficient, and safer. Vacuum tilting technology offers a modern, reliable and proven solution to this problem. It removes the need for complex mechanical rigs, reduces manual handling, and significantly increases storage density.

For any tunnelling segment manufacturer dealing with tight yard space or growing output, adopting a vacuum-based tilting and stacking system is more than a smart move — it’s a long-term investment in efficiency, safety and operational productivity.