Long, Chism (2023) Development of a low-cost IoT Thermal Work Limit sensor used in construction tunnels. [USQ Project]
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Abstract
The significance of Thermal Work Limit (TWL) monitoring in tunnel environments stems from potential health hazards, particularly heat stress. Despite the enhancements in IoT devices that monitor environmental parameters, there exists a notable deficiency in cost-effective, real-time TWL monitoring systems suitable for tunnel environments. The Project uses the calculation methodology formulated by Derrick Brake and Graham bates and applies the TWL Index with IoT technology in a real-world application, providing a low-cost solution to real-time health and safety monitoring.
Addressing the unique challenges of sensor placement in a construction tunnel was an essential part of this research. The airflow patterns, influenced by the tunnel's shape and the presence of Mechanical and Electrical (M&E) equipment, demanded research into sensor positioning. A systematic, grid-based analysis was adopted, with the aim of identifying locations that offered a consistent representation of wind speeds. From the data gathered, an ideal position for the anemometer was determined at a location 5.0m above the paving surface around the centre of the tunnel.
Hardware choices played a critical role in the development of the prototype. The Arduino Nano 33 IoT emerged as the chosen microcontroller after an evaluation of ten potential candidates. The integration of the Adafruit BME280 sensor and FS7 constant temperature anemometer were critical for acquiring accurate atmospheric and environmental data. The software was a significant part of the foundation of the prototype. The coding ensured seamless operation and interfacing of the sensors and components. The primary emphasis during this process was acquisition and validation of data from the BME280 sensor, and AF7 CTA ensuring accurate measurement data for TWL calculations. The integration with the Arduino IoT Cloud was also important as it handled, processed, and presented data, for the real-time visualisations. This integration aided in immediate data assessment but also highlighted the potential for future enhancements, including remote monitoring, scalability, and interdevice communication.
The implementation of the prototype underwent a 32-hour deployment. The deployment was interrupted by site commissioning activities and had to be removed. Within those 32 hours, the system captured valuable and usable data, however it was 5 ½ days short of the projected test time which would have offered a more comprehensive dataset. Results from calibration, workshop and onsite testing can substantiate the information obtained during the prototype’s short deployment.
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| Item Type: | USQ Project |
|---|---|
| Item Status: | Live Archive |
| Faculty/School / Institute/Centre: | Current – Faculty of Health, Engineering and Sciences - School of Engineering (1 Jan 2022 -) |
| Supervisors: | Alehossein, Habib; Low, Tobias |
| Qualification: | Bachelor of Engineering (Honours) (Electrical) |
| Date Deposited: | 30 Sep 2025 01:30 |
| Last Modified: | 30 Sep 2025 01:30 |
| Uncontrolled Keywords: | Thermal Work Limit (TWL); safety monitoring; tunnels |
| URI: | https://sear.unisq.edu.au/id/eprint/52968 |
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