The construction industry is on the edge of a big change due to new automation and robotics technology. In 2021, the global construction robot market was valued at $420 million and is predicted to reach $765 million by 2026.
Despite this potential, the construction industry has been slow to adopt robotics and automation. Only 55% of construction companies across the U.S., Europe and China say they use robotics, compared to 84% of automotive companies and 79% of manufacturing companies, according to a survey commissioned by ABB Robotics.
Some companies have started using software like Building Information Modeling (BIM) to improve their operations, but many have been hesitant to fully embrace automation. This hesitation is often due to a resistance to change and past negative experiences with new technology.
Today, we'll explore these challenges and understand how construction can move past these barriers to improve projects with robots. Are construction robots here to stay? The answer depends on how well we address these issues and advance the necessary technology.
UPDATED AT: July 25, 2024
In the 1960s and 1970s, simple machines were developed to help with tasks like bricklaying and concrete placement, reducing the physical strain on workers. In the 1970s and 1980s, Japan became a leader in construction robotics due to labor shortages and the need for more productivity. Companies like Shimizu Corporation and Kajima Corporation created early robotic systems for tasks like concrete finishing and automated welding.
The 1990s saw big improvements in robotics thanks to better computers, sensors, and materials. Japan continued to lead in this field, developing robots for tasks like automated rebar tying and welding. Europe also began exploring robotic systems for tasks like demolition and handling hazardous materials.
In the early 2000s, advanced robotics became more common in construction. Innovations in artificial intelligence and sensors allowed for more complex and versatile robots. Companies like KUKA Robotics and Fujita Corporation developed robots for tasks like automated bricklaying and steel structure assembly. By the mid to late 2000s, robots were used for tasks like 3D printing building components and automated surveying, led by companies like Contour Crafting Corporation.
The 2010s saw a lot of growth and innovation in construction robotics. Companies worldwide invested in robotic solutions to address labor shortages, improve safety, and increase efficiency. Collaborative robots (cobots) that worked alongside human workers became popular, helping with tasks like lifting heavy materials and precision drilling. Companies like Boston Dynamics and Built Robotics developed versatile robots for site inspection and material handling.
© Aaron Hargreaves / Foster + Partners
In the 2020s, the role of robotics in construction continues to grow. AI and machine learning have led to smarter and more adaptable robots. Drones are commonly used for site surveying and inspection, improving safety and accuracy.
Companies like Autonomous Solutions Inc. and Naska.AI are developing autonomous construction equipment and mobile robots for site management. The goal is to create fully autonomous construction sites where robots handle everything from excavation to finishing work, making construction safer, more efficient, and more sustainable.
In the early days of construction robotics, several companies emerged with promising technologies but ultimately failed to sustain operations due to multiple reasons we will cover later in the article such as high costs and slow adoption rates.
The early 2010s saw numerous startups entering the market, but many could not overcome the financial and technical challenges.
One example is Rovenso, a Switzerland-based company. They developed autonomous robots for security and safety monitoring of industrial sites. Founded in 2016, Rovenso raised $2.8 million in funding. However, the company shut down, significantly impacted by the effects of the COVID-19 pandemic.
Formwork Labs tried to automate the creation of formwork for concrete construction. High development costs and scaling difficulties forced them to shut down. OKIBO created autonomous plastering robots to work alongside human workers. Despite its innovative idea, the company couldn't sustain operations and shut down.
Katerra aimed to revolutionize construction with prefabricated building components and robotics. Despite the investment of around $2 billion by SoftBank, operational challenges, rapid expansion and supply chain issues led to Katerra’s bankruptcy in 2021.
Rethink Robotics made collaborative robots (cobots) like Baxter and Sawyer, which had potential uses in construction. However, market adoption and competition issues led to its closure in 2018.
3D Robotics was known for its drones and software for construction site surveying and mapping. Facing stiff competition and market saturation, the company eventually shut down its hardware operations. Skycatch, another drone technology company, aimed to provide high-precision aerial data for construction site management. Financial difficulties forced Skycatch to close its operations.
Integrating robotic machines within construction has a number of benefits, but it has certain drawbacks, as well. Some of the most worth mentioning disadvantages are the following:
The initial costs for purchasing, deploying, and maintaining robotic systems can be high, making it a significant challenge, especially for smaller companies. Construction robots prices typically range from $25,000 to $400,000 depending on functionality and sophistication.
This often means that only large companies with the financial resources can afford the latest technology. As a result, many small and medium-sized construction companies may struggle to compete and could potentially go out of business.
Demonstrating a clear return on investment (ROI) within the short timelines of construction projects is challenging. Site conditions vary, which complicates the ability to predict ROI accurately.
Construction projects often involve unique and customized tasks that demand flexibility, collaboration, and teamwork among various trades and skilled workers.
Effective communication, coordination, and the ability to make quick adjustments are crucial for a successful project execution. However, robots can lack the necessary flexibility and improvisation required in these complex environments.
Unlike human workers who can adapt on the fly, robots typically follow pre-programmed instructions and may struggle with unexpected changes or nuanced tasks. This rigidity can be a significant drawback, as it may lead to delays or errors when conditions on a construction site change suddenly.
Acquiring the right robotic equipment is one thing, but having skilled workers to operate it is another challenge. Training employees to use new technology takes time and money, creating an initial hurdle for many construction companies.
Without a workforce trained in operating and maintaining robotic systems, companies may struggle to realize the full benefits of their investments. This training requires not only a financial commitment but also a shift in the skill set of the existing workforce, which can be a significant adjustment.
Adding robots to current construction methods, which mostly rely on manual labor, can be tricky. Adapting existing workflows to include new robotic technology requires careful planning and coordination from employers.
The construction industry faces a serious shortage of skilled workers, which is getting worse with changing demands.
While robots can help by automating tasks and supporting the workforce, they won’t replace the need for skilled labor on the job site.
The introduction of robots could also negatively impact existing labor rates. MIT research shows that for every robot added per 1,000 U.S. workers, wages decline by 0.42% and the employment-to-population ratio drops by 0.2 percentage points, equating to approximately 400,000 job losses.
Advances in AI have the potential to tackle several challenges in construction robotics. Large language models can enhance how robots understand and process complex instructions, improving their interaction with construction plans. Reinforcement learning allows robots to adapt and refine their actions based on feedback, making them more effective in dynamic construction environments.
Computer vision technology has also made significant strides, enabling robots to better perceive and interpret their surroundings. This includes recognizing objects, avoiding obstacles, and performing tasks with greater precision.
The integration of AI and machine learning into construction robotics allows for continuous improvement based on data. For instance, machine learning algorithms can optimize construction routes and workflows.
To make an impact on job sites, developments such as enhanced sensors and machine vision are necessary for better site analysis. Additionally, integrating Building Information Modelling (BIM) with construction robots ensures precise execution of tasks, aligning closely with the project's plans.
Robotics has the potential to transform construction processes and methodologies in several ways. One major benefit is increased efficiency. Robots can work around the clock without needing rest, unlike human workers, which means projects can progress continuously.
Precision is another area where robotics can make a difference. Robots are designed to reduce human errors, leading to higher-quality work and fewer mistakes.
For example, Boston-based contractor Suffolk uses Boston Dynamics' Spot, a 2-foot-tall robot equipped with a 360-degree camera, to walk job sites and take photos. Using computer vision, a robot system can evaluate the site with a high degree of accuracy and catch things that might be missed by the human eye.
Safety on construction sites is also expected to improve. According to the National Safety Council, robotics could reduce construction-related accidents by up to 20%. San Francisco-based Canvas has developed a robot to handle the mudding and sanding processes of drywall finishing, reducing the risk of back, arm, and shoulder injuries.
Sarcos Robotics, based in Salt Lake City, offers the Guardian XT, a robotic arm that can be remotely controlled to perform dangerous tasks. Contractors can lease this unit for $5,000 per month.
Additionally, robotics can address labor shortages by performing tasks in challenging environments. This ensures consistent availability, less reliance on human labor and meets project deadlines more effectively.
Large contractors like DPR Construction and Swinerton have seen the benefits of early adoption. DPR uses Dusty Robotics' layout robot, which performs layout work six times faster than traditional methods. Swinerton has utilized both Dusty's layout robot and Canvas' drywall bot, addressing industry-wide productivity and labor shortage issues.
Canvas' drywall bot
The construction industry is a major economic sector, but it faces significant challenges, including inefficiencies and low productivity.
Robotics and automated systems have the potential to address these challenges by increasing efficiency, precision, and safety. Despite these benefits, the adoption of robotics in construction remains low.
Overcoming barriers such as high costs, integration with existing processes, and workforce training will be crucial for broader implementation. Embracing these advanced technologies could revolutionize construction, making it more efficient and sustainable for the f