In the 1980s, the use of construction robots began in Japan to improve working conditions and enhance the appeal of a profession often overlooked. Over the years, a range of applications have been suggested, including large facility decommissioning, demolition, and dismantling, building and road construction, heavy/civil construction, and maintenance operations.
However, while the initial expectations were high, progress in the field of construction robotics has been slower and less technologically radical than anticipated. Nevertheless, recent developments, such as customization, additive manufacturing processes, networked manufacturing equipment, and data integration, have led to an increase in the use of construction robots in industrial activity and public appearance.
Automated building construction involves several key functional operations, including materials handling (by bulk and unit load), materials shaping (cutting, breaking, compacting, bricklaying, and machining, sometimes in collaboration between worker and robot), structural joining (assembly), cable robot prototypes for 3D concrete printing, and planning and monitoring.
Robots designed for material handling include programmable cranes and mobile robots, as well as those for concrete panel handling and bricklaying at construction sites. Structural joining by robots is particularly useful for high-rise steel buildings, as industrial robot technology can be easily adapted to this task. Typically, construction automation involves a divided approach, with robots prefabricating building elements offsite in factories, which are then shipped to construction sites for manual structural joining.
In the construction industry, on-site applications are the focus of use for service robotics. These robots are involved in steel welding, reinforcement manufacturing, positioning, concrete distribution, customized construction (masonry), interior finishing, on-site logistics, and facade operation. For general or civil construction tasks, radio-controlled or partly autonomous robotic devices are increasingly considered, with some device types being shared with the mining industry.
Earthmoving equipment
In the mid-1990s, Fujita Corporation, a Tokyo-based construction company, created an innovative solution to improve worker safety on construction sites located in hazardous zones. They developed an unmanned system called the "Tele-Earthwork System" which integrated commercially available wireless communication systems into construction vehicles. This remote-controlled system allowed operators to control conventional backhoes from a control room, without needing to see the machinery directly. Monitoring cameras and wireless image communication systems installed on the construction vehicles and at various locations around the site facilitated remote operation of the vehicles. This system was used to construct a series of check-dams at Mount Fugen, Japan. The teleoperated construction method allowed for workers' safety to be ensured, particularly in areas around active volcano sites.
Recently, in September 2019, the start-up company Built Robotics raised USD 33m for its autonomy stack. This technology retrofits existing construction vehicles with different sensor types and equipment, turning them into autonomous robots. The autonomous fleets can be remotely operated by uploading blueprint metrics into heavy machinery like dozers and excavators, thereby reducing the need for direct human intervention. Built Robotics' autonomy stack provides a safer and more efficient construction process, ultimately leading to a decrease in on-site accidents and faster project completion.
Drilling and fore poling play an important role in various construction activities such as laying telephone cables or electricity wires beneath riverbeds. To ensure precision and efficiency, companies like nLink from Norway utilize industrial robot arms to drill on construction sites. With the help of an app and laser, the drilling process is closely monitored and guided to ensure accuracy.
Trenchless drilling, also known as "micro-tunneling," involves drilling along a predetermined path, widening the tunnel with a reamer, and fitting the product tube, such as a gas or water tube, into the cavity. This method is eco-friendly, causing less damage to underground objects like tree roots, and requires less operating space while producing less dust, dirt, and noise. The use of drilling robots improves cost-effectiveness and is ideal for new drilling tasks, although repairing and maintaining pipelines may require traditional machines.
Tracto-Technik produces trenchless drilling robots that use robotic technology to provide improved maneuverability and precision. Other manufacturers, like Casagrande s.p.a., produce heavy-duty tunnel digging machines with hydraulically powered robotic arms, allowing for fast and precise positioning.
Automated offshore drilling became the focus of attention for oil companies after the Gulf of Mexico disaster in 2010, leading to the development of safer exploration rigs by companies like Nabors Industries. Schindler AG and the Council of Tall Buildings and Urban Habitat (CTBUH) have partnered to develop autonomous drilling in elevator shafts, while Scaled Robotics uses mobile robots equipped with sensors to create 3D maps to detect mistakes and verify the construction process. Strabag, an Austrian construction company, has even started using Boston Dynamics' four-legged robots Spot for their construction site documentation.
In the 1980s and 1990s, Japan invested heavily in developing robots to address the shortage of construction labor and improve quality. However, the excitement surrounding automation in construction waned as it affected various aspects of construction materials, processes, logistics, and operations. Consequently, a slower evolution began, focusing on the development of specialized equipment for specific high-performance applications like tunneling, wheel loaders for on-site transport, and semi-automatic cranes for local material transfer.
One such development is Taisei Corporation's robot for asbestos removal from elevator shafts, commissioned by the New Energy and Industrial Technology Development Organization (NEDO) in Japan. This remotely controlled robot can remove and collect dry-sprayed asbestos on beams, ceilings, columns, and walls of buildings, with the operator controlling it via video monitor from a separate room. Similarly, an automated asbestos removal robot is used for blasting off the asbestos-infested layer of stucco on building facades.
Innovative start-ups like Baubot are designing multi-purpose robots that can handle various construction tasks, from concrete 3D printing and welding to milling and painting. While prototypes of robotic road rollers and paving machines exist, only a few products are commercially available.
Several robotic designs for road maintenance have been evaluated as prototypes, including intelligent highway safety markers that can replace traditional safety barrels. Mobile robots equipped with 2D or 3D navigation modules are central components of these construction machines, which can be interfaced with specific devices. Despite the potential benefits of robotic technology in construction, it has yet to revolutionize the industry, and progress has been slower than anticipated.
Robotic Cranes and booms
Robotic cranes and booms are revolutionizing the construction industry by providing more efficient and safer ways of lifting and moving heavy objects. These robots are typically equipped with hydraulic-powered arms that can be precisely controlled and programmed using computer software.
The Brokk 900R is an example of a teleoperated robotic boom that is widely used in construction applications. Its one-arm manipulator can be equipped with various tools, making it a versatile solution for many different types of tasks.
Another example of computer-controlled cranes is the Ergonic 2.0 system developed by Putzmeister Concrete Pumps. This system allows for precise control of a multi-jointed hydraulic arm, which can be programmed to move in a variety of ways to optimize efficiency and minimize damage to surrounding structures. The result is faster and more precise delivery of concrete, leading to significant returns on investment for construction companies.
In addition to improved efficiency and safety, robotic cranes and booms also offer the potential for cost savings over traditional methods. By reducing the need for manual labor and minimizing damage to structures and equipment, these robots can help construction companies complete projects more quickly and with fewer expenses.
Overall, the development and implementation of robotic cranes and booms are leading the way for innovation in the construction industry. As technology continues to advance, we can expect to see even more sophisticated and capable robots being used in construction applications, further increasing safety, efficiency, and cost-effectiveness.
Robotic manipulators for bricklaying and fabricating
The Meyco ME5 Logica, now Epiroc (Sweden), utilizes advanced laser scanner sensors to automatically control the standoff distance and angle of the spraying jet, ensuring precise and consistent results every time.
Although bricklaying robots are still in the prototype stage, there are promising developments in pre-manufacturing and mobile fabrication units. Construction Robotics employs conventional industrial robots for pre-manufacturing brick walls and other structures, while mobile fabrication units combine the benefits of prefabrication with just-in-time production on-site.
Innovative designs utilizing robotics are transforming the construction industry, enabling complex and one-of-a-kind architectural designs. Examples include a segmented shell-like structure based on the anatomy of a sea urchin robot and a web-like pavilion inspired by the lightweight shell of a beetle. The DFAB House is the world's first house to be designed and built using predominantly digital processes, and a fleet of drones programmed to lift and stack polystyrene bricks created a series of towers in France.
While the construction industry has been slower to adopt robotics due to perceived risks and the challenging environment of construction sites, there is great potential in heavy and civil engineering. CAT offers autonomous earthmoving equipment ranging from assistive task execution to fully autonomous vehicles, making construction sites safer and more efficient.
Revolutionizing construction with robotics: Advantages and Challenges
The construction industry is ripe for a technological overhaul, and robots are leading the charge. By eliminating the need for cranes, construction robots can reduce building time by up to 30%. Plus, they can operate indoors, making it less disruptive to neighboring areas.
However, robotic construction requires some changes to traditional building methods. Hydraulic cylinders must be installed in the foundation to enable the transport unit to move up and down. Therefore, it's important that there's enough demand for this kind of construction to make it financially viable.
The benefits of robotic construction are numerous. Robots can improve working conditions, collect valuable data on construction sites, and increase accuracy, ultimately driving innovation in the industry. Additionally, semi-automated or remotely controlled unmanned construction equipment can take on dangerous tasks, making construction work safer for human workers.
The cost-benefit considerations and marketing challenges must be carefully evaluated before implementing robotics in construction. But the benefits of reducing manual labor and increasing safety make it an attractive prospect for companies looking to improve their bottom line while taking care of their workforce.