By N S (Satya Narayana) Rao, Group CFO, Ramky Group
Throughout history, construction has been associated with a huge workforce. Gazing at the Great Pyramid of Giza in Egypt, one wonders how many workers would have laboured to build this grand monument that has stood tall for over 4500 years. The Greek historian, Herodotus, writes that the pyramids were built by 100,000 workers and took 20 years to construct. However, modern Egyptologists put the figure closer to 20,000-30,000 workers. Closer home, we have the Taj Mahal, completed in 1653, employing some 20,000 artisans. This continued till the 1970s and 1980s when Japanese companies such as Shimizu, Obayashi, and Takenaka Corporation first innovated construction automation and robotics.
Today, the construction industry worldwide has not gone untouched by the wave of automation sweeping businesses and is undergoing a significant transformation. Automation technologies, including robotics, drones, and autonomous machinery, are revolutionising traditional construction processes and bringing major developments that enhance efficiency, increase safety for workers, and allow for precision in planning even in large-scale projects. The change is timely as it has come about when the global construction industry is grappling with labour shortages, rising costs, demand for higher productivity, and the need to focus on sustainability.
The Promise of Automation in Construction
Simply put, automation in construction involves using technology to perform tasks that were traditionally labour-intensive and performed by human hands. Today, automation encompasses processes from prefabrication to on-site operations. It streamlines activities, reduces errors, and enhances quality. Robots, for instance, can lay bricks with precision. Drones can be used for site inspections and monitoring project progress. These advances allow for speedier project completion while maintaining high-quality standards.
A report by McKinsey & Company highlights that up to 49% of construction tasks can be automated using current technologies. Concerns about job losses are misplaced as automation in construction is more likely to complement human labour than replace it entirely. However, workers will increasingly need to learn new skills to operate and manage automated systems.
Robotics in Construction
Like in other industries, robots can be deployed for repetitive and hazardous tasks. These include pouring concrete, bricklaying, and rebar tying. For example, a robotic arm can lay bricks with greater accuracy and speed compared to manual labour. In Wyoming, robotic earthmovers are preparing wind farm sites, demonstrating the efficiency of automation in large-scale projects. Lift-assist equipment are designed and built to handle and place heavy material on construction sites, improving the safety and efficiency of your whole team.
Drones for Site Management
Drones provide aerial views of construction sites, helping in surveying for site topography and monitoring and inspecting areas that are otherwise difficult to access. They are particularly useful in ensuring safety and efficiency in infrastructure projects such as highways and bridges. They can survey extensive areas much faster than ground crews, with high-precision mapping drones doing the work 50% faster than a walking survey.
Autonomous Vehicles in Construction
Autonomous excavators, bulldozers and cranes perform construction tasks that are risky but critical to the process, maximising efficiency across various projects. In mining operations, autonomous trucks have lowered load and haul unit costs by around 15 per cent.
Autonomous excavators are streamlining the excavation process. Equipped with computer vision and GPS technology, they can navigate job sites, dig trenches, remove debris, and load materials with minimal human intervention. Similarly, autonomous bulldozers and graders are taking over grading and levelling tasks by using laser and GPS systems to create flat, even surfaces with remarkable accuracy. Autonomous cranes with sophisticated sensors and computer algorithms can perform heavy lifting operations and move loads with precision and safety.
Automated Factories for Prefab and Modular Construction
Factories equipped with automated machinery are producing prefabricated components that are assembled on-site. This method reduces waste and speeds up construction. Companies like Katerra are leveraging automation to produce entire modules, such as hotel rooms, with design, engineering, component supply and off-site manufacturing all integrated to deliver ready for on-site installation.
3D Printing in Construction
One of the fastest growing technologies in construction which cannot be ignored is the 3D printing. It is a revolutionising technology, powerful enough to build structures in astonishingly shorter timeframes. A best example of this would be the two-story administrative building of Dubai municipality, which hold the record for being the largest 3D-printed building in the world.
Besides shorter construction (printing) period, the 3D-printing technology also champions for sustainability as it uses new age materials like Geopolymers, Recycled Plastics & Earth-based materials. Dubai is leading the way in adopting this technology, with an ambitious goal to integrate it into 25% of all buildings by 2030.
Advantages of Automation
Automated systems can work continuously, leading to shorter project timelines. But the real benefit is allowing machines to perform dangerous roles that otherwise put human lives at risk, such as working at heights or handling hazardous materials. According to the Occupational Safety and Health Administration (OSHA), one in five worker deaths in the U.S. occurs in construction. The other benefits include financial savings. Although the initial investment in automation may be high, it results in long-term savings through reduced labour costs and minimised material wastage. And of course, automation can optimise material use, reducing waste and the carbon footprint of construction projects.
Challenges to Adoption
Despite the many benefits, adopting automation in construction faces some challenges. Apart from the costs, the need for skilled personnel to operate and maintain advanced machinery is a significant barrier. Moreover, many construction companies, especially in developing countries, are hesitant to adopt new technologies due to budget constraints and lack of awareness of the benefits. Regulatory hurdles due to outdated laws are another factor that must be addressed.
As the industry evolves, collaboration between stakeholders will be crucial in overcoming these challenges. Automation is no longer a futuristic concept in construction but a present reality with immense potential. As the construction sector adopts automation, it is poised to redefine itself, ensuring it meets the demands of the 21st century.