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Robotics

Rise of the Machine:


Robots Show Promise to Take Over High-rise Construction
Chaitanya Raj Goyal

he Indian subcontinent is often considered a region where most types of automation have been introduced slowly. Thus, the history of construction automation in India is relatively short as compared to that of developed countries which go back over 25-30 years in construction automation. Today, as buildings become higher, larger and more complex, building con-

struction needs more accurate technology and more skilled workers on site than ever before. However, the number of skilled workers is decreasing in many countries, because the younger generation does not prefer labor work, and many skilled workers are aging. Not only does this increase labor costs but also the overall construction costs, and also raises the possibility of acci-

dents, poor-quality work, and delays in construction schedules. One of the proposed solutions for these issues is the automation and robotization of the construction processes. In addition to the above potential reasons to introduce more technology in the construction sector, a contractor and equipment dealer in India is also pointing to safe work practices as an

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Robotics

These advances in technology, especially in robotic fabrication, promise high precision and differentiation in build production without necessarily implicating greater expenditure of labor and materials. Despite these potentials, very few automated building processes have been realized till date. Against this background, we need to identify the aptitudes of robotic fabrication on a conceptual and technical level and investigate possible impacts on contemporary design of high rise buildings. This should be done in the urban context of metro cities, which are characterized by the extensive demand for high rise housing, while paying special attention to the local sites and specific constructional parameters in which these techniques are to be deployed. The goal is not to automate the complete building process. Rather the module should carefully develop specific design logics and constructional processes in high rise housing programme, and identify the points at which a robotic intervention makes sense. This will allow us to develop new high rise building typologies, offer insights into the production of formal variety and differentiation in generic urban conditions, and test the integration of robotic technologies into design and fabrication of key aspects of high rise housing projects in developing Indian metros. Assembling elaborate environments: Robots on the move The use of robots, combined with digital design tools, means a new aesthetic becomes possible, with novel shapes and patterns that would be nearly impossible to achieve without the automated machines: industrial manipulators that are extremely precise and good at repetition. Currently tech savvy nations like Japan claim to have developed 89 - single task construction robots and 11 different automated construction systems. Using robots, researchers in Singapore, have fabricated intricate building parts out of wood, concrete, bricks, and foam, and have used these parts

important reason to spur a revolution in how construction work is performed. Synchronizing high rise construction with robotics: Analyzing the scope Recent developments in the fields of computer-aided architectural design and robotic fabrication have opened the potential for a seamless connection between design and fabrication data.

to build complex, beautiful installations in Zurich, London, Barcelona, New York, and other locations. Though such creations thus far are limited in size, the architects are currently exploring the idea of applying robotic fabrication to the design and construction of highrise buildings. The results thus far have been impressive. In one of their projects, Swiss architects fitted a manipulator robot in a modified freight container - a mobile fabrication unit that could travel anywhere in the world. They took it to Manhattan a few years ago in 2007, where the robot built a 22-meter-long (72 feet) brick structure. In another project, they used the robot as a milling machine, to create parts that could shape the acoustics of a room. Some of their most interesting creations, though, are the ones that use robots to assemble elaborate environments. Newly developed fabrication robots, called ROB Units, build structures by placing modular pieces of building materials such as brick or wood in preprogrammed patterns. Algorithms and parameters written by the architects feed the design of the structures. The results are intricately detailed and beautiful installations. The advantages of employing robots in construction are precision and consistency, conditions normally vulnerable to the element of human error in construction. Combined with digital design programs, automated robots can manipulate materials into shapes and patterns that rely on exact replication and repetition. Until recently the robots have been used to prefabricate the structures in controlled environments. In order to operate the robots directly in the construction sites, researchers are developing units to cognitively adapt to construction tolerances and variations, and to correct course. Flying high: Counting on airborne robots If you're a young engineer looking for a job with a future, you might con-

www.masterbuilder.co.in The Masterbuilder - October 2012

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Robotics

Bolt Feeding Device

Gripper

Tool Charger
Bolting End-Effector Robot

sider learning as much as you can about flying robotics. Underlining the importance of robotics in construction, flying quadrocopters recently built a 20-foot-tall tower at a museum in France. Made of 1,500 polystyrene blocks, the tower represents a model of a futuristic 2,000-foot tall "vertical village" capable of housing as many as 30,000 people. Each 'quadrocopter' was equipped with custom electronics and onboard sensors, which made it easy to precisely control each copter. This allowed for pre-programmed flight paths, such as arcs and spirals, and it prevented the copters from flying into each other.

The same technology is also used for automating routine take-offs, landings and vehicle calibration and charging. Rapid flights kept things on schedule and cut down on construction delays. The flying constructor robots provide a glimpse in the future of building construction. They've already essentially taken over the building of automobiles in factories around the world. Why not the next-generation of skyscrapers? Once architects finish a blueprint for a building (on CAD systems), computers and robots will take over, interpreting the designs and activating robotic copters to finish construction.

Some existing automated systems: Striving for acceptance Japan has already applied automation systems to the manufacturing industry a long time ago, and obtained outstanding accomplishments regarding safety and productivity. With core technologies obtained from the manufacturing industry, major construction companies led construction automation projects. The major results are as follows: total automated building construction systems (the roof push-up, SMART, ABCS, the T-up system, the liftup method, etc.), concrete floor surface finishing robots, and a shield machine for constructing underground expressways. These systems were initially called Construction Factories (CFs) because they were developed to make the entire construction process fully automated and free from the effects of outdoor weather conditions, just like factories. The goals were as follows: 1) improvement of safety and environment on construction sites; 2) low affects from the weather; 3) productivity increments; and 4) reduction of material waste. But, the developed systems were too heavy and expensive. Due to these reasons, although the systems were very successful in terms of productivity gains, they could not be popularized. The Automated Building Construction System (ABCS) is a new construction system developed to solve

The elements were constructed by a digitally controlled robot that cut and precisely placed the slats according to an algorithmic pattern

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Robotics

22m long brick structure built by 'Manipulator Robot'

these problems and at the same time increase productivity. ABCS employs an erection system by which to install steel members, external panels, etc., which differs from a typical conventional tower crane system, provides a working space protected from the elements by a shell. ABCS also incorporates various integrated automation and information technologies. In 1993, the ABCS was used for the first time to build a high-rise building (10 floors above ground). Shimizu Manufacturing system by Advanced Robotics Technology-

SMART represents more recent attempts at computer integrated construction (CIC) that claims to reduce by 30% the number of man-hours required to complete a multi-storey building. System set-up takes about six weeks, after which the building's top floor and roof are erected on top of four jacking towers: the effect is to resemble a top-hat. The jacking towers are used to push up the 1,323 ton top floor assembly - the main work platform - as well as lifting their own bases from floor to floor in a cycle time of around two and a half hours. The heart of the system is com-

posed of lifting mechanisms and automatic conveying equipment which is installed on the work platform. This later becomes the roof of the building. Overhead gantry cranes are connected to the underside of the roof structure in a way that resembles a factory production facility. Trolley hoists are used to lift and position components which are introduced at ground level. The whole process is computercontrolled, though workers are still involved in overseeing operations at least for the time being. Simplified connections between components facilitate rapid erection times: self-centering column connections require only finetuning with a torque wrench and a laser-guided gauge. A clamp-on welding robot - one of a few task-specific devices is used afterwards to effect the final mating of the column ends. Floors emerge from under the top-hat preclad - again from the inside - allowing work in fitting out to begin immediately. Weather is excluded from the job-site by a mesh fabric hung around the work area. Racks of pre-assembled pipe work are a further example of an entire approach to rationalizing design and production, the aim of which is to drive down the man-hours required for production. SMART thus automates a range of production processes including: Erection and welding of steel frames; Place-

Milling machine Robot creating parts to shape the acoustics of a room

Quadrocopters being used to build a tower model in France

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Robotics

SMART system for High Rise Buildings

High-Rise Building inspection robots - NDT

ment of precast concrete floor planks; Exterior and interior wall panels; Installation of various prefabricated units. Inevitably, with the first run of anything, costs are higher than normal: it would be unusual if it were not so. However, further improvements to the systems will enable them to have wider application and, hence, lower costs because of economies of scale and familiarity with the technology. Likewise, lower costs will make the system more attractive.

Future R&D continues: Flesh vs. metal Who will build the next generation of skyscrapers? Will construction crews rise to the challenge and take materials into lofty stratospheric heights? Or will robots answer the call to streamline the task-as they have with such precision in the automotive industry. Automation of construction processes has potential significant effects on construction of buildings. Since 2006 architects & engineers worldwide

Robotic cleaning systems for windows and faades on high-rise buildings

have explored various manufacturing techniques, including both subtractive and additive fabrication, as well as a wide range of materials, to create astonishing structures entirely built by robots. Despite the global initiative for research and application in this field, the Indian construction industry still remains unreceptive to these technologies and continues as a craft-oriented and laborintensive industry with minimal automation of tasks. By the next decade, it looks like robots will take over some of the work of building high-rise towers. This new building technology is expected to bring down the number of injuries at high-rise construction sites and also cut down on the time spent on building them. It may only be a matter of years before robots take over such deathdefying work. Not surprisingly, the robotled systems are expected to cut labor costs by up to one-third and start-to-finish project time by around 20 percent. Add it all up and experts say it will boost overall productivity by an impressive 25 percent. Although the fully automated construction site is still a dream of many civil engineers, research developments have shown the promise of robotics and automation in high rise and other construction.

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