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PILOTING · Project

Robots That Inspect and Maintain Ageing Refineries, Bridges, and Tunnels

manufacturingPilotedTRL 7
piloting-project.eu

Imagine sending a drone or a climbing robot into a refinery tank or under a bridge instead of putting a human inspector in a harness. That's what PILOTING built — a fleet of ground robots, aerial drones, and crawlers equipped with AI that can spot cracks, corrosion, and damage in places that are dangerous or hard to reach. They tested the whole system in real refineries, on actual bridges, and inside working tunnels across Europe, comparing the robots' results against traditional human inspections.

By the numbers
3
large-scale pilots in real industrial environments (refineries, bridges/viaducts, tunnels)
14
consortium partners
7
countries represented in consortium
8
industry partners in the consortium
57%
industry ratio in the consortium
21
total project deliverables
The business problem

What needed solving

European refineries, bridges, and tunnels are ageing, but large investments in new infrastructure are not expected. Manual inspection of these structures is slow, expensive, dangerous for workers, and often fails to cover hard-to-reach areas. Companies need faster, safer, and more thorough ways to inspect and maintain critical infrastructure without costly shutdowns or putting people at risk.

The solution

What was built

The project built a fleet of ground robots, aerial drones, and crawlers integrated into a single AI-powered inspection and maintenance platform. Final versions of all robotic vehicles were delivered along with a data management system. The platform was tested in 3 real-world pilots (refineries, bridges/viaducts, tunnels) with full evaluation results and operator training sessions.

Audience

Who needs this

Refinery and petrochemical plant operators needing non-destructive testingNational highway agencies and bridge maintenance contractorsTunnel operators and railway infrastructure managersIndustrial inspection service providers looking to add roboticsInsurance companies assessing infrastructure condition
Business applications

Who can put this to work

Oil & Gas
enterprise
Target: Refinery operators and petrochemical plant owners

If you are a refinery operator dealing with costly shutdowns for manual tank and pipe inspections — this project developed robotic vehicles (ground robots, aerial drones, crawlers) integrated into a single inspection platform, tested in real refinery environments across 3 large-scale pilots. The final pilot experiments included direct comparisons with traditional inspection procedures, showing where robots improve coverage and reduce downtime.

Transport Infrastructure
enterprise
Target: Highway authorities and bridge maintenance contractors

If you are a road authority managing hundreds of ageing bridges and viaducts with limited inspection budgets — this project built and demonstrated robotic inspection systems specifically for bridge and viaduct structures. With 14 consortium partners across 7 countries, the platform was validated in real operational conditions and compared against conventional manual inspection methods.

Civil Engineering & Tunnels
mid-size
Target: Tunnel operators and railway infrastructure managers

If you are a tunnel operator struggling with the safety risks and traffic disruptions of manual inspections — this project deployed AI-equipped robotic platforms inside working tunnels as one of 3 large-scale pilot sites. The system was designed to increase inspection rates, improve coverage, decrease operational costs, and reduce the time human workers spend in hazardous environments.

Frequently asked

Quick answers

What would it cost to deploy this robotic inspection system?

The project data does not include specific pricing or cost-per-inspection figures. However, the project explicitly aimed to demonstrate decreasing costs and time of operations compared to traditional methods. Contact the consortium for commercial licensing or deployment pricing.

Can this work at industrial scale across multiple sites?

Yes — the system was specifically designed for large-scale deployment. It was tested in 3 large-scale pilots in real industrial environments: refineries, bridges/viaducts, and tunnels. The final deliverables include evaluation results with direct comparisons to traditional inspection procedures.

Who owns the IP and how can I license the technology?

The consortium of 14 partners across 7 countries jointly developed the platform. IP is likely shared among partners according to their EU grant agreement. The coordinator, Fundacion Andaluza para el Desarrollo Aeroespacial (Spain), would be the first point of contact for licensing discussions.

What types of robots are included in the platform?

The platform integrates ground robots, aerial robots (drones), and crawlers — each designed for different inspection scenarios. Both first and final versions of the robotic vehicles were delivered, with reports describing configuration and characteristics of each vehicle type.

Has this been tested in real conditions or only in labs?

Real industrial conditions. The project ran 3 large-scale pilots in actual refineries, bridges/viaducts, and tunnels. The final pilot experiments included training sessions for operators and full evaluation against metrics defined during the project, including side-by-side comparisons with traditional inspection methods.

Is this compliant with industrial inspection standards?

The project explicitly aimed to contribute to industrial standards in robotics for inspection and maintenance. Based on available project data, the platform was designed to meet necessary safety levels for ageing European infrastructure. Specific certifications should be confirmed with the consortium.

How long does it take to integrate this into existing operations?

The project included training sessions organized during the final pilot experiments, suggesting the system is designed for practical adoption. The 14-partner consortium includes 8 industry players who shaped the platform for real-world deployment. Integration timelines would depend on the specific infrastructure type and scale.

Consortium

Who built it

The PILOTING consortium is strongly industry-oriented with 8 out of 14 partners (57%) coming from industry, including 4 SMEs. This is a good sign for commercial viability — the technology was shaped by companies that understand market needs, not just academic interests. The consortium spans 7 countries (Switzerland, Czech Republic, Greece, Spain, France, Netherlands, Norway), giving broad geographic coverage across European infrastructure markets. The coordinator is a Spanish aerospace development foundation classified as an SME, which suggests agility and commercial focus. With 2 universities and 4 research organizations providing the scientific backbone, this is a well-balanced team built to move technology from lab to field.

How to reach the team

Fundacion Andaluza para el Desarrollo Aeroespacial (FADA), Spain — contact via project website or SciTransfer introduction

Order a report on this consortiumSee FUNDACION ANDALUZA PARA EL DESARROLLO AEROESPACIAL profile →
Next steps

Talk to the team behind this work.

Want to explore robotic inspection solutions from EU research for your infrastructure? SciTransfer can connect you directly with the PILOTING team and help evaluate fit for your specific use case.

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