E L S E V I E R Automation in Construction 2 (1994) 281-289

Driving forces and status of automation and robotics in construction in Europe ***

W o l f g a n g P o p p y

Construction Machinery /Design and Engineering Department, Berlin University of Technology, Jebensstrasse 1, D-10623 Berlin, Germany

Abstract

Automation and robotics in Europe are concentrated on concrete and asphalt mixing, concrete block and pipe making, precast concrete units and masonry prefabrication, control of mobile construction machinery, tunnelling, and renewing of buildings and sewers. The development has been going at a slow pace, because not all prerequisites to the introduction of these new technologies are fulfilled in the construction industry. Limited need for construction works on one hand, and shortage of skilled workers as well as new demands and tasks on the other hand stimulate the development--performed by manufacturers, construction companies, universities and institutes--in different ways. However, a survey around a lot of European specialists allows to draw a uniform picture of the driving forces and the current status of research, development, and usage of automation and robotics in construction (ARC).

Key words: Automation and robotics in construction; Development of construction in Europe; Need for research in construction; Working conditions in construction

1. Introduction

The construction technique in Europe i s - - a s in all industrial countries of the wor ld - - cha r - acterised by a wide range of mechanisation. The transition from manual working methods to me- chanical work went off very differently in the

* Presented at 10th International Symposium on Automation and Robotics in Construction (ISARC), Houston, Texas, USA, May 24-26, 1993. ** Discussion is open until October 1994 (please submit your discussion paper to the Editor on Construction Technologies, T.M. Knasel).

individual construction areas so that the prereq- uisites for automation and use of robots vary considerably, too. While important advance with the automation of concrete and asphalt mixing was already achieved in the sixties, the develop- ment of the necessary prerequisites for mobile construction machinery first began with the intro- duction of microelectronics in the beginning of the eighties.

Most of the countries of Western Europe are members of the European Community. January 1, 1993, a new age began for these countries: the Common Marke t - -wi thou t economic borders be- tween the twelve members Belgium, Denmark,

0926-5805/94/$07.00 © 1994 Elsevier Science B.V. All rights reserved SSDI 0926-5805(93)E0024-3

282 W. Poppy~Automation in Construction 2 (1994) 281-289

France, Germany, Greece, Ireland, Italy, Luxem- bourg, The Netherlands, United Kingdom, Portu- gal, and Spain.

In reality the borders are not eliminated com- pletely. So the economical and technical develop- ment will be different also in the next years, because the current situation in the various coun- tries is very different.

On one hand, there are similar requirements to be fulfilled in all countries. On the other hand, the historical growth of the economic and the climatic conditions, especially concerning all in- terests of the construction industry and the use of automation and robotics in plants and on sites, are to take into account.

In the following, I will make the attempt to analyse the "Driving Forces and the Status of Automation and Robotics in Construction in Eu- rope". It is the result of a survey around a lot of specialists--mainly scientists and researchers--in the field of automation and robotics in construc- t i o n - n o t only in the European Community but also in Austria, Switzerland, Finland, and Swe- den. The specialists were asked to mark the in their opinion most important points in a ques- tionnaire of 100 issues.

The current status of automation and robotics in Europe can not be quantified exactly on this basis--neither for every country nor for the con- tinent altogether. But independently from eco- nomic and technical conditions one can draw a rather uniform picture of the situation in West- ern Europe.

To characterise the summarised answers of the asked specialists and the situation in Europe the following scale is used: (+ + ) very important, ( + ) important, (o) less important, ( - ) not impor- tant, ( - - ) totally unimportant.

Assessment: ++ very important + important

o less important

not important - - totally unimportant

slide 1

After these (ISARC) symposia had begun in 1984, we agreed every year on basic arguments for need and benefit of automation and robotics

in construction. Most of them seemed to be clear and obvious. But there is a difference between theory and practice.

Scientists and researchers in all countries have many good ideas how to increase construction techniques by using automation and robots. But often they do not have enough money to translate their ideas into action, and therefore they are often protected from bad experiences. They play their games on abstract playgrounds, for example on computer monitors. One main aim of a couple of scientists is to realise a complete change of the basic design and construction rules and methods. In my opinion this way does not exist. There is no alternative to a development of small steps. We can go only this long way--step by step.

Designers in the construction industry and civil engineers in the construction industry with tasks for practical use eat the hard bread of reality. They must find solutions not for academical ideas but for practical problems that cannot be man- aged differently. The final solution must be good for practical use and for all requirements of ef- fective work and high economy. These people have to fight against new enemies every day. Again and again they learn the proverb: the devil is in the detail!

Fact is that overall automation and robotics in construction do not play a very important role in most of the Western European countries. Main activities are pursued in universities and insti- tutes and neither in the construction machinery industry nor in the construction industry. Experi- ences of the last years show that Finland, Ger- many, Sweden, and United Kingdom are the most active countries in Europe.

Activities are not a question of need for au- tomation and robotics in the construction indus- try or of innovative ideas but first of all they are a question of the availability of money. The world- wide recession reduces research and development in most of the European countries.

Only in Germany extensive need for construc- tion work marks the situation since the unifica- tion in 1990. Nevertheless, most of that need is not satisfied with automation and robotics but with conventional construction methods and ma- chinery.

W. Poppy/Automation in Construction 2 (1994) 281-289 283

2. Major driving forces and barriers

2.1. Major driving forces

Further general demands are higher quality of the work execution and the optimisation of work processes.

The first point I will look at are the major driving forces for automation and robotics in con- struction.

For years the personnel, technological and economic conditions for the automation of con- struction machinery and plants in Europe were characterised by - an extensive lack of skilled workers and a

growing average age of the staff, - demands for effective humanisation of nearly

all construction works, - increased requirements on the quality of the

work execution, - a need for works in dangerous and inaccessible

areas of operations, - an increase in performance and reduction of

costs for improvement in economy, - the competition on international markets of

construction machinery. First of all there are three major driving forces

in Europe: increase in performance, reduction of costs, and improvement in economy.

Driving forces: ++ Increase in performance ++ Reduction of costs ++ Improvement in economy

slide 2

Driving forces: slide 4 + Higher quality of the work execution + Optimisation of work processes

Humanisation of construction works and relief and protection of the operators as well as safe machine operation and simplification of the ma- chines' operation do not belong to the major aims.

II Driving forces: slide 5 I + Humanisation of construction works o Relief and protection of the operators

Driving forces: slide 6 + Safe machine operation o Simplification of the machines' operation

In face of the general recession in the Euro- pean construction industry the shortage of skilled workers is at present not one of the major driving forces for automation and robotics in construc- tion.

Special fields are the avoidance of work in inaccessible areas, e.g. micro tunnel, and the avoidance of work in uncomfortable, unreason- able, and dangerous areas, e.g., in case of haz- ardous influence of temperatures, dusts, steams, gases, liquids or radioactivity as well as in case of danger of falling or collapsing. For these prob- lems no alternative solutions exist.

i

Driving forces: slide 3 + Avoidance of work in inaccessible areas,

e.g. micro tunnel ++ Avoidance of work in uncomfortable, unreasonable, and

dangerous areas, e.g., in case of hazardous influence of temperatures, dusts, steams, gases, liquids or radioactivity as well as in case of danger of falling or collapsing

Driving forces: slide 7 - - Shortage of workers in the construction industry + Shortage of skilled workers in the construction industry

Lack of young people in the construction industry Growing average age of the staff

Only in Germany we have to consider a grow- ing average age of the staff and lack of young people in the construction industry. Also for years to come the German construction industry will not succeed in covering the need for qualified junior members of the staff for machines opera- tion and maintenance. In the next decades we will have further increase of employees over fifty and a remarkable decrease of employees under thirty.

284 W. Poppy/Automation in Construction 2 (1994) 281-289

slide 8

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The European specialists see the following is- sues without actual importance for research and development: bet ter use of the machines ' effi- ciency, minimisation of power consumption, de- termination of optimal combinations of machines, just-in-time supply of the machines for the con- struction site, extensive need for construction work (only in Germany) and the competit ion on international markets of construction machinery.

I Driving forces: - - Better use of the machines' efficiency - - Minimisation of power consumption

slide 9

Driving forces: slide 10 - - Determination of optimal combinations of machines . . Just-in-time supply of the machines for the construction

site + Continual and high use of capacity during the whole

operation time

Driving forces: slide 11 Extensive need for construction work (only in Germany)

o Competition on international markets of construction machinery

2. 2. Major barriers

The next point are the major barriers for au- tomation and robotics in construction.

The fact that the development to a higher degree of automation in the construction industry of Europe has been going at a slow pace so far has to be attributed to high costs and shortage of

public money for research and development ( R & D).

Barriers: + High costs for R&D + Shortage of public money for R&D ++ High costs for ARC

slide 12

Lack of interest in the construction industry, unsolved technical problems, and the special con- ditions of use in construction plants and sites lead to problems of acceptance in the construction industry.

Barriers: slide 13 - - No need in the construction industry + Lack of interest in the construction industry ++ Problems of acceptance in the construction industry o Not enough improvement in economy

A problem of former years has been solved: the lack of electronic components and systems and of confidence in the life expectancy of elec- tronic components and systems.

Barriers: slide 14 - - Lack of electronic components and systems - - No confidence in the life expectancy of electronic

components and systems

Remarkable self-confidence of the European scientists can be noticed concerning the availabil- ity of scientific institutes and their capability in basic scientific knowledge, e.g. modelling and simulation.

Barriers: slide 15 - - No or not enough scientific institutes o No experience with automation and robotics technology

Lack of basic scientific knowledge No domestic fabrication of construction machinery

In several countries a research infrastructure has grown up, independently from the existence of a large domestic fabrication of construction ma- chinery.

3. S t a t u s o f r e s e a r c h a n d development

What is the status of research and develop- ment in European countries?

IV.. Poppy/Automation in Construction 2 (1994) 281-289 285

To find out the current status of research and development (R&D) concerning automation and robotics in construction (ARC) in Europe three question were asked to the European specialists: How many institutions are working in ARC-R& D? How many manufacturers of construction ma- chinery and equipment are working in ARC-R& D? and How many companies of the construction industry are working in ARC-R&D?

Status of ARC-R&D: slide 16 171 How many Institutions are working in ARC-R&D? D How many manufacturers of construction machinery

[I and equipment are working in ARC-R&D? H O How many companies of the construction industry are II working in ARC-R&D?

No specialist was able to supply an exact infor- mation. The scope of answers reached from com- plete helplessness to unsure estimations. It will be an important task for the International Associ- ation for Automation and Robotics in Construc- tion (IAARC) and their national subsidiaries re- spectively to collect exact information about these questions. Identifying a growing number of com- panies, which are working in research and devel- opment on automation and robotics in construc- tion, and establishing fruitful connections be- tween active partners can help stimulate the de- velopment for more and faster progress.

We have general fields of research and devel- opment on automation and robotics in construc- tion in Europe.

The main general field of research and devel- opment is the growing use of electronic systems in construction machinery and equipment.

General fields of ARC-R&D: slide 17 ++ Electronic components and systems, e.g., sensors,

actuators, microprocessors, micro controllers, bus systems + 3D-measuring devices

A daily task of R & D is to choose and test suitable electronic components as a prerequisite for the configuration of reliable control systems.

So far electronic controls are mainly brought in selectively in addition to and as a modification of the conventional technology. Fundamental prerequisites for the creation of from top to bot- tom new conceived flexibly automated machines and systems are not fulfilled yet.

The necessity for 3D-measuring devices is a special task. Application of robots or manipula- tors on the site demands 3D-measuring devices and 3D-modelling of the building to be built. This 3D thinking and connection of the 3D-model and 3D-measuring is in its infancy at the moment. Control and autonomous navigation of robots in unstructured environment also need 3D-devices.

General fields of ARC-R&D: ++ Control systems o Drive control o Remote control systems + Autonomous navigation in unknown terrain

Maintenance systems

slide 18

A general impression is the neglecting of con- struction engineering and management in all Eu- ropean countries.

General fields of ARC-R&D: - - Construction management

Expert Systems for planning and controlling Kinematics

o Modelling and simulation

slide 19

Low interest in the study and analysis of kine- matics and in modelling and simulation shows serious deficit of basic research. More interest is expanded to Expert Systems and Artificial Intelli- gence.

General fields of ARC-R&D: + Expert Systems + Artificial Intelligence - - Fuzzy Logic

Neural Networks

slide 20

Minor interest in Fuzzy Logic and Neural Net- works indicates a shortage of basic scientific knowledge. The importance of research and de- velopment on robotics as a basement of au- tonomous robot control systems will soon grow rapidly.

Overall research and development for automa- tion is concentrated on fabrication of precast concrete units, bricklaying machines (especially in the United Kingdom and Germany), control and monitoring of mobile construction machinery, computer controlled equipment, and tunnelling and for robotics to mobile construction machin- ery, distribution booms of concrete pumps

286 IV.. Poppy~Automation in Construction 2 (1994) 281-289

(Germany), excavators (United Kingdom), renew- ing of buildings, and micro tunnelling (United Kingdom and Germany) and others with no im- portant weight.

R&D for Automation: slide 21 + Fabrication of precast concrete units ++ Bricklaying machines

(especially in the UK and Germany) ++ Control and monitoring of mobile construction machinery ++ Computer controlled equipment + Tunnelling

R&D for Robotics: slide 22 ++ Mobile construction machinery ++ Distribution booms of concrete pumps (Germany) ++ Excavators (UK) ++ Renewing of buildings + Renewing of sewers (Germany) + Micro tunnelling (UK and Germany) o Cranes

4. Status of usage in practice

What is the status of usage of automation and robotics in practice?

In terms of automation and robotization, sta- tionary machines and plants on the one hand and mobile machines for the construction-site on the other hand have attained a very different state of the art in Europe.

The status of usage in practice is marked by monitoring, diagnosis, and maintenance, safety aspects as well as operator information and guid- ance, independently from the kind and type of the machines, but predominantly in the large sizes.

Status of usage in practice: + Monitoring, diagnosis, and maintenance + Safety aspects + Operator information and guidance o Quality control

Measuring and recording of machine data

slide 23

Quality control, and measuring and recording of machine data are not so important until now.

4.1. Fabrication of precast concrete units

A high degree of automation is attained at stationary concrete and asphalt mixing plants and

at the series production of standardised concrete blocks and pipes.

Automation in practice: slide 24 + Fabrication of precast concrete units + Bricklaying machines (UK and Germany) ++ Control and monitoring of mobile construction machinery

Expert Systems for planning and controlling ++ Computer controlled equipment ++ Tunnelling

The prefabrication of large concrete units went through a changing development in Europe. Af- ter a gradual increase of automation up to the early seventies a beginning recession caused a general return to conventional construction tech- niques. Prefabrication plants with a higher degree of automation had to be closed. Some years ago a new development began and has in individual cases already resulted in computer aided manu- facturing (CAM) and in initial stages in computer integrated manufacturing (CIM) of precast con- crete units.

4.2. Bricklaying machines

Besides the fabrication of precast concrete units the prefabrication of masonry elements in stationary plants gains growing importance in the United Kingdom and in Germany. The people's preference to bricked residential buildings and the high dependence on weather of this construc- tion method have lead to the development of a number of bricklaying machines. Some of them are already in practical use. In other cases nei- ther a systematic market analysis has been done nor a ripened design principle has been devel- oped. Therefore, they are not marketable yet. With bricklaying machines a higher output can be achieved. They facilitate great lightening of work and the saving of workers.

4.3. Control and monitoring of mobile construction machinery

So far mobile machines are characterised less by automation and robotization than by a growing penetration with microelectronic components and systems. The machines of some manufacturers

W. Poppy/Automation in Construction 2 (1994) 281-289 287

are already equipped with large systems which inform the operator constantly about the state of the machine, which signal inadmissible changes optically and acoustically and which are able to give instructions to clear faults. Such systems contain control devices to optimise the use of the machines and to suit them to the conditions of use.

4. 4. Expert systems for planning and controlling

An exact choice of construction machinery and planning of work is necessary for their use on sites. Due to many exogenous conditions on con- struction sites the execution of work is mostly of stochastic nature. To take these conditions com- pletely into account, planning systems have been developed, which make it possible - t o determine optimal combinations of ma-

chines, - to ensure just-in-time machine preparation on

the construction site, - to gain continual and high use of capacity

during the whole operation time. By the aid of Expert Systems the organisation of the construction site can permanently be adapted to changing conditions.

4.5. Computer controlled equipment

So far the working processes of mobile ma- chines have to be controlled by operators. An important decision in every development is to split control tasks between men and technology, especially in case of machines, whose movements of working equipment have to be adapted to a permanently changing working process, e.g. hy- draulic excavators, drilling machines, and con- crete pumps with distributor boom.

II Robotics in practice: slide 25 ++ Mobile construction machinery, e.g.: drilling in tunnelling + Distribution booms of concrete pumps (Germany) + Micro tunnelling (Germany) + Renewing of sewers (Germany)

4. 6. Tunnelling

For years underground construction methods have been of growing importance in Europe. The

shotcrete technology for the lining of tunnels imposes tremendous requirements on the opera- tors. Shotcrete robots have been developed to improve the working conditions, the shotcrete technology, and the quality of work.

In many centres of population it is not possible to do service works with open trenches. There- fore, the number of trenchless working laser-con- trolled machines for micro tunnelling with small cross sections has increased considerably.

4. 7. Renewing of buildings and sewers

The sewerage systems represent a special problem in many German towns. Already in World War II they have suffered excessive dam- ages and now they reach the end of their normal lifetime, too. Urgent need exists both for robots to inspect the sewers and for renewing the dam- ages with trenchless methods. Several robots to coat old pipes, to renew pipes and to point bricked sewers have been developed.

5. A g u e s s a t f u t u r e u s a g e

Finally I will make a guess at future usage of automation and robotics in construction in Eu- rope.

General aims and tasks of future development and usage are--in the opinion of European spe- cial ists- the improvement of working conditions and safety in construction, the increase of perfor- mance and quality, and the reduction of costs of construction work. These tasks are abstract and self-evident.

Aims and tasks of future development: slide 26 ++ Improvement of working conditions and safety in

construction ++ Increase of performance and quality ++ Reduction of costs of construction work

"'In addressing automation and robots applica- tions, consideration must be given to the whole subject of "Computer Integrated Construction". Automation of the construction process will be slow unless we consider the use of "robotics" in the

288 IV.. Poppy/Automat ion in Construction 2 (1994) 281-289

design process and as an integral part of complete Information Technology (IT)systems.

Robotics application will be selective and be influenced by economic and practical considera- tions and, of course, the type and nature of con- struction. However, in selective operations, such as excavation, the wider application of robotics will be feasible. Equally, Inspection Robots will have a very useful and wide application to many types of structures. On the other hand, the universal intro- duction of "heavy robot plant to site", will be difficult indeed.

To accelerate the introduction of automation and robotics in the construction process, there is a need for a number of test beds where the integra- tion process of IT machines and human resources may be demonstrated." (Dr. Fikry K. Garas, Tay- lor Woodrow UK).

Future development and usage: ++ More use of information technology + Computer-support of design, planning,

cost-calculation etc. + 3D-modelling of buildings

slide 27

For a lot of people in the European construc- tion industry robotics is not a "hot issue". The main issue in automation in the construction in- dustry is not the automation of the construction process itself ("replacing labour"), but the com- puter-support of design, planning, cost-calcula- tion etc.

A main task of automation in the construction industry is to increase the possibilities of informa- tion interchange--not only between locations or companies, but also between computer-applica- tions in one system.

The prerequisites to the development of au- tomation and robotics are not alone fulfilled by the availability of new technologies, especially of microelectronics. The suitability of electronic components for construction machinery is signifi- cant. High loads and heavy use of the construc- tion machinery, extreme changes of weather and climate, influence of building materials and dirt as well as poor operating and maintenance re- quire the use of extremely robust automation components, which must be available in low cost/heavy duty versions.

These components, e.g. sensors, actuators, mi- croprocessors, on-board computers, bus systems, process in- and output units and power modules, must have--considering very different combined machine pools--the feature of machinery compo- nents: standardised, with well-known use and quality characteristics, easy to handle and gener- ally available.

Aims and tasks of future development: slide 28 ++ Development of standardised concepts of measurement,

control, and automation Development of low cost/heavy duty microelectronics components

+ Development of 3D-measuring devices

On this base the manufacturers can use cheaper series products of component suppliers, and the user of construction machinery can or- ganise a simpler storage of replacement parts and maintenance.

Those tasks require theoretical basics, which make a systematic new design of products and construction processes under integral aspects possible, i.e. with tuned fusion of mechanical, hydraulic, electric and electronic components (mechatronic). That fusion cannot be achieved by an empirical development of machines and sys- tems, where an electronic component is grafted on to an existing product. The development must rather start with a complete system analysis, which includes machines, operation, construction meth- ods, building materials and all conditions of use. Such an integral reflection on the system man- machine-construction technology-site-environ- ment and the consideration of all interactions is as a rule possible by modelling and simulation of all important system parameters only.

General aims and tasks of development and usage of automation are--in accordance to the European specialists--safety aspects and quality control.

Aims and tasks of development and usage of Automation: ++ Safety aspects ++ Quality control + Operator information and guidance

[[ + Monitoring, diagnosis, and maintenance

Ii o Measuring and recording of machine data

slide 29

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An often expressed idea concerning the devel- opment of robotics are multi-functional robots to increase the productivity and multi-functional robots for dangerous jobs.

Aims and tasks of development and usage slide 30 of Robotics: + Overall feasibility appraisal including cost benefits + High effectivity with minimum of labour, and good

quality of work + Multi-functional robots to increase the productivity + Multi-functional robots for dangerous jobs

Special tasks of such robots are to be seen in the substitution of interior works, e.g. multidisci- plinary robots to work on interior surfaces of floors and wails (finishing, plastering, and paint- ing), robots for maintenance, inspection, and re- pair of tall buildings, cooling towers, and oil drilling platforms, multi-functional gripping tools for assembly works of different elements (walls, columns, slabs), and block and brick laying robots.

Aims and tasks of development and usage slide 31 of Robotics: + Multi disciplinary robots to work on interior surfaces of

floors and walls, e.g. for finishing, plastering and painting + Robots for maintenance, inspection, and repair of tall

buildings, cooling towers and oil drilling platforms + Multi-functional gripping tools for assembly works of

different elements (walls, columns, slabs) + Block and brick laying robots

6. Conclusions

The European development in the field of automation and robotics in construction is handi- capped by the current recession. Compared with similar branches of the industry the construction technology is characterised by an enormous delay

- - in spite of several encouraging examples of automation and robots. That delay has to be made up to improve working conditions and safety in construction, to increase performance and quality and to reduce costs.

Representatives of the German construction industry look forward to a special way of using robots. They expect the growing of service com- panies, which commission a pool of rental robots including skilled operators and all maintenance tasks. It can be a way to guarantee a full and qualified use of the robots' capacity. A compara- ble example of such service is the combination of ready mixed concrete and mobile concrete pumps.

An important step ahead is the grown confi- dence in the life expectancy of electronic compo- nents and systems, because manufacturers pre- sent solutions with a high standard of quality.

The manufacturing of construction machinery in small series and the machine pools of the construction companies with many different kinds and sizes of machines suggest the development of standardised concepts of measurement, control, and automation for mechanised construction pro- cesses. On the one hand, that will create better conditions for developing a suitable range of components. On the other hand, that will simplify the use and the maintenance of construction ma- chinery in the construction companies.

Large need exists for highly sophisticated re- search in the field of basic knowledge, e.g. Expert Systems, Artificial Intelligence, Fuzzy Logic and Neural Networks. It leads to the needed theoreti- cal basement for practical solutions in the future.

However, actual progress will only be possible in case of commercial interest of the construction industry.