When TUM researcher Julia Fleckenstein works with apprentices from the Munich-Ebersberg Construction Guild to erect a wall, a robot is always on hand. Without it, it would be impossible to lay the bricks for the outer layer of the wall. Of the 1,700 bricks used, more than 200 are not positioned exactly above each other. “They are rotated out from the wall at different angles,” says the architect, who holds the TUM Professorship of Digital Fabrication. The reason for this is that the wall is climate-optimised. A digital design configurator knows how shaded or sunny the location is where the wall of a house is to be built and calculates precise, climate-optimized positions for the individual bricks.

The robot stores a digital twin of the wall. As a result, the logic of robot assembly is directly integrated into the design process. “The robot is like a new colleague,” says Fleckenstein. The robot arm is equipped with a gripper and mounted on a mobile base to move left and right as needed. This allows it to reach any point on the approximately 4 x 2.50 metre wall.

Robot included for the first time

The robot was developed at TUM to work on construction sites alongside humans. “It makes sense to build this way,” says Markus Bruckner, a trainer for bricklayers and plasterers at the Guild: “The robot provides precision where humans reach their limits.”

Rather than replacing skilled craftsmen and craftswomen, it complements their skills. Three of Bruckner’s apprentice bricklayers worked on the wall. “It took some getting used to at first when a robot arm suddenly started working alongside us,” says bricklayer apprentice Dragan Stanojevic, who will complete his training next year: “Now it’s easy to imagine it.”

Simulated in advance on the computer

The project, which is funded by the Bavarian transformation and research foundation “Climate Active Envelopes”, is also based on the idea of simpler construction, for example, using only bricks. Instead of complex wall structures with different materials, the trainees lay bricks in several layers one behind the other. The wall is now “four heads deep,” in Bruckner’s words – a total of 55 cm. That is 20 to 25 cm more than usual.

“Weather-resistant clinker bricks or impregnated bricks are used on the outside, while insulating bricks should be used on the inside, initially shown here with perforated bricks,” says Fleckenstein. Master mason and construction technician Bruckner adds: “Bricks allow for simple and sustainable construction – and with monomaterial constructions, we are also thinking about easier dismantling and reusability.”

Robots on the construction site of the future

“The workshop makes it clear that collaborative robotics does not mean replacing craftsmanship, but rather expanding it in a targeted manner,” says Kathrin Dörfer, Professor of Digital Fabrication at TUM, who initiated the workshop together with Laura Lammel, Master Craftsman at the Munich-Ebersberg Construction Guild: “It is precisely the interplay of digital planning, robotic execution and craftsmanship that creates new possibilities in the construction process.”

This opens up prospects for trainees in a future-proof craft which, far from being displaced by new technologies, will actually be strengthened.

A working prototype is expected in early 2026, marking a significant leap forward in the evolution of robotic construction.

Unlike humanoid robots designed to mimic humans, Zyrex is purpose-built for construction – capable of performing heavy-duty tasks such as material handling and delicate trades, including welding, assembling, trimming, carpentry, 3D printing, exterior finishing, and more.

With 26 degrees of freedom, an interchangeable tool module, battery powered with self-changing battery packs, Zyrex is designed to have complete mobility. Leveraging LiDAR (Light Detection and Ranging) and visual sensors and powered by VLA (Vision-Language-Action) AI models, it will be deployed in dynamic job site environments with human monitoring.

Zyrex addresses two urgent industry challenges: the global construction labour shortage and the dangers of high-risk job sites. According to the Associated Builders and Contractors (ABC), the U.S. will need to attract over 439,000 skilled construction workers in 2025 to meet industry demand and avoid further escalation in labour costs. Meanwhile, the construction industry had the most fatal injuries among all industry sectors in 2023 with 1,075 fatalities.

“We’re not just building another robot – we’re engineering the future of construction,” said Ziyou Xu, founder of RIC Robotics. “With Zyrexl, we’re addressing the industry’s labour shortages with powerful robotics capable of performing skilled work at scale,” Ziyou continues, “If Tesla’s Optimus is the Ironman of the Avengers, then Zyrex is the Hulk – only this Hulk is orange and built to construct, not to smash buildings.”

Despite its size and capabilities, Zyrex will be surprisingly affordable. While previous attempts of giant robot builds can cost over $2 million, RIC estimates Zyrex will be priced at under $1 million, with monthly leasing options starting below $20,000.

The goal is well within reach, as RIC’s current 3D construction robot, RIC-PRIMUS, already shares many of Zyrex’s capabilities, including high-speed, automation, and battery powered mobile platform with a large-scale reach up to 32 ft. More importantly, RIC has demonstrated the commercial viability of large-scale construction robots: its earlier model, RIC-M1 Pro, successfully 3D-printed two Walmart warehouse extensions – one in Tennessee and another in Alabama – with 200 more planned nationwide.

Measured at 5,000-square-foot, 16.5-foot-tall, the warehouse in Alabama was completed in 7 days, 3 weeks ahead of schedule, saving 75% time and 80% skilled labour.

Zyrex builds on that proven performance, now expanding beyond 3D printing to become a multi-functional, general-purpose construction labour solution.

While robotics continues to transform the industrial and automotive sectors, there’s one industry within which it’s yet to make widespread progress: construction. But making use of robotics and automation could be the solution to many of the challenges currently faced by the sector.

Overcoming staffing shortages

Filling in skills gaps is one example of how robotics might be used to benefit construction companies. Consultancy firm Pagabo found that some 92 per cent of construction firms are struggling to recruit the right talent. Specialist skills like welding are in dwindling supply, and as more employees begin to reach retirement age, there’s concern that there isn’t enough fresh talent entering the industry to meet future demands.

Here, robots could step in to make up for some of the worker shortfall. Monotonous and repetitive jobs, such as simple welding tasks, could be automated to free up valuable time for employees. This way, there’s still the opportunity for human workers to use their skills for more complex tasks, but without having to do so on top of their normal workload.

But technology could even help drive recruitment to the sector. A Deconstruction report carried out with YouGov in 2023 found that 69 per cent of UK adults would not consider a career in construction. And that percentage increases to 77 when the same question was asked to full-time students between the age of 18 and 24. When asked to select words and phrases that they associated with the construction industry, 70 per cent selected ‘strenuous’, 52 per cent selected ‘dirty’ and a quarter selected ‘unsafe’.

Evidently, it’s clear that the sector needs a makeover if it’s to change wider perceptions and encourage more people to pursue a career in construction. Removing some of these concerns around physical stress and safety could be possible with a wider implementation of technology, including robotics and drones. Not only will this boost recruitment, but it can also help to retain employees.

Improving worker safety

Closely linked to improving retention and recruitment is safety. And here, robotics offer further advantages. Hazardous environments, such as those with harmful chemicals like asbestos, are ideal for robot deployment.

To protect against asbestos dust, workers will typically need to wear protective suits and masks. But these can restrict movement and be uncomfortable to wear for long periods. Furthermore, exposure rules dictating how long employees can work with asbestos per day can mean that for large-scale projects, asbestos removal is a costly and time-consuming process.

Instead, asbestos experts could look to utilise robotics technology. Opting for a remotely operated solution means that the health risk posed to employees is averted, while still making use of their expertise to control and manipulate the robot to remove asbestos panelling safely.

Mitigation against fall risks is also possible with these robots. Out of all fatal falls reported across industry, more than half of these are attributed to the construction sector. And the risk is amplified when working offshore in the oil and gas industries, where ladders and walkways can be greasy, icy or wet. Implementing robots instead of humans is far safer in these high-risk environments.

Driving sustainable buildings

Robotics could also be beneficial for construction waste recycling. It’s estimated that 32 per cent of our landfill waste comes from building construction and demolition. Sorting through waste manually is a time-consuming and arduous process, often putting workers at risk of contaminated or otherwise hazardous objects, such as extremely sharp materials. Automating the process can help construction companies cut the amount of waste they send to landfill while increasing their recycling for more sustainable business operations.

While there are use cases for robotics within a construction setting, there’s still clearly a lag in adoption. Data presented in 2022 at the Big 5 Global, one of the largest events in construction industry, estimated that 98.8 per cent of work carried out in the industry was performed solely by humans.

It might be surprising that, given the challenges faced by the construction industry, there’s been little progress in successfully implementing alternative, autonomous methods. But it’s the construction processes themselves that are often a huge barrier to robotic adoption.

Manufacturing plants, for example, are often very standardised. They will typically work on very specific tasks and are either fixed in position or only move within a limited space.

However, on-site construction doesn’t meet these attributes. There’s little task or environmental standardisation across different building projects. And with sites often playing host to a number of staff and heavy machinery, a robot with no set path could easily get in the way. As a result, construction managers are left with a range of questions: How will they transport the robot to the site? Can it manoeuvre across varying terrains? Will it fit onto lifts? How will it interact with other workers on the plant?

Dedicated design

So, what can robot manufacturers do to address these questions? It’s clear that advancements will need to be made in more than one area to deliver intelligent, dexterous robots.

This includes more sophisticated sensing capabilities. For a robot to successfully navigate around the construction site on its own and avoid surrounding objects, robots must have more sophisticated object recognition powered by onboard sensors to safely move around. These may be visual sensors using regular cameras and image processing technology, or Light Detection and Ranging (LiDAR), using near-infrared light.

A team at Monash University in Australia is attempting to build more sophisticated image recognition robots, using images to train AI to recognise different materials in construction site waste. Its AI system is now able to categorise materials more quickly than humans, allowing for recyclables such as wood and glass to be collected safely.

DC motor technology

As projects are ongoing to improve the ‘thinking’ capabilities of the robot, what can be done about the physical? To improve the functionality of the robot, we need to take a closer look at the underlying motor technology. A robot may contain any number of small DC motors, depending on the extent and range of movement required.

Since the range of tasks on any construction site can vary widely, it’s imperative that the robot is designed to accommodate for these. For example, a robot tasked with picking up and placing objects will need a strong enough grip to hold it securely without damaging the material. In contrast, a robot tasked with hole-drilling or screwing won’t need as much dexterity, but needs more precision to ensure the work is carried out accurately.

But there are some attributes that will be universally required across construction robotics, including robustness. With dirt, dust and debris common across working sites, the motor must have the appropriate sealing to protect itself from harm.

Therefore, it’s important that construction robot manufacturers select their drive system components wisely. Advancements in motor technology mean that DC motors are lighter and more powerful than ever before. But for the optimum performance, motor selection must be done with consideration to the end application.

For example, tasks like welding will benefit from a high precision motor technology. Stepper motors are an ideal choice here. Rather than a classic DC motor, which rotates continuously, stepper motors move in tiny increments of a full rotation. These small increments are referred to as ‘steps’ and are what give stepper motors their name. The benefit of this step-by-step movement is that it allows for extremely high positional accuracy, ideal for intricate work.

Where speed takes priority, a standard brushless DC motor might be preferred. These motors can produce a stable torque at low, medium, and high speeds, providing enough power to lift and transport heavy objects.

It’s clear that the construction sector is ready for a change. If it’s to attract the talent needed to keep the industry running smoothly, it must look to follow other sectors with embracing technology. Robotics driven by DC motors will be central to modernising the sector, reimagining construction for the public and helping construction companies build more in less time with no compromise to quality.

AUAR’s transformative approach to integrating robotic automation into the building process will tackle skills shortages, boost sustainability, and improve health and safety by deploying robots in a global network of local micro-factories. These micro-factories will construct energy-efficient, affordable buildings from sheet timber.

AUAR reports that it has completed a £2.6m seed round led by deep-tech and AI fund Miles Ahead, alongside ABB Robotics and Automation Ventures and several other investors.

“The increasing capabilities of robots enabled by vision and AI, coupled with their inherent speed, flexibility and consistency, makes them the ideal solution for meeting the growing need for affordable, high quality, sustainable housing,” said Craig McDonnell, managing director for the industries business line at ABB Robotics.

“With 95 percent of building firms in our recent market survey describing sustainability as ‘important’ or ‘very important’ to their businesses, and 38 percent seeing robots as a way of reducing waste, our collaboration with AUAR opens new possibilities for homebuilders to deliver affordable sustainable homes at scale.”

ABB is already heavily involved in helping construction companies automate their processes. ABB robots are widely used in a range of modular assembly and 3D printing building projects worldwide, as well as academic projects researching new ways to integrate robotic automation into construction.

The collaboration with AUAR follows the announcement by ABB working with German management consulting firm, Porsche Consulting, to develop innovative new practices in modular housing manufacture.

AUAR is the brainchild of two architects, Mollie Claypool (CEO) and Gilles Retsin (CTO/chief architect) who have worked for over 10 years on robotics, automation, construction, and architecture. During that time, they have relied extensively on support from ABB Robotics to realize their vision.

The relationship has already seen ABB Robotics win the prize for ‘Best Use of Robotics or Automation in Construction’ at the 2023 Robotics and Automation Awards.

AUAR’s automated micro-factory approach provides a solution to many of the challenges facing building companies, including supply chain issues, project delivery and quality and skills shortages.

Conventional buildings consist of thousands of different components shipped from around the world, making it almost impossible to automate construction. In contrast, AUAR’s goal is to work with one type of material and one type of machine to dramatically simplify the supply chain.

The production process uses standard sheets of timber. A robot cuts the sheets into components and assembles them into units that are transported to site, enabling complete customized homes to be built in a matter of weeks.

While many of the assembly tasks are automated, AUAR’s approach supports local jobs by promoting the use of micro-factories close to construction sites, where local contractors and suppliers can coordinate delivery.

The micro-factory approach is flexible enough to meet whatever each market demands. Each facility can be scaled to reflect local needs, with the ability to ramp up production by adding modular robot cells.

“With the focus on the dual needs of building more affordable homes and minimizing the environmental footprint of buildings throughout their lifetime, automated modular construction presents a great opportunity to rethink the way that the buildings are constructed,” added McDonnell. “Our collaborations with AUAR and Porsche Consulting mark an exciting step in our efforts to accelerate the use of robotic automation in the construction industry to help address its challenges and deliver the sustainable buildings of the future.”

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The collaboration will help to meet the need for more affordable and sustainable buildings and reduce the environmental impact of construction, amidst widespread labour and skills shortages.

“The construction industry is facing numerous challenges. Highly automated factories for buildings can deliver higher quality and more affordable housing. In combining ABB’s leading robotic solutions and Porsche Consulting’s knowledge in planning and running state-of-the-art factories, we want to help transform this important industry,” said Eberhard Weiblen, chairman of the executive board at Porsche Consulting.

“We think there is a clear opportunity to transform this sector and the way homes are built by automating the process of manufacturing modular components,” added Marc Segura, president of the ABB Robotics Division. “Greater, more intelligent automation is the answer to widespread labour shortages and this collaboration will boost productivity, allow greater customization and enable more sustainable and efficient construction practices.”

Construction-related occupations typically dominate the list of labour shortages, a contributing factor to the shortage of housing in many countries. In the United States, labour shortages are contributing to a housing shortfall of nearly four million homes, while Germany is forecast to have housing supply shortages in 35 of its cities by 2030.

The traditional construction sector is struggling to meet the demand for new homes, while the environmental performance and efficiency of buildings needs to improve, along with the adoption of more sustainable construction methods. These include reducing the transportation of raw materials to construction sites and eliminating the corresponding costs and impact of removing unwanted materials and waste. This is estimated to account for up to 25 percent of the material transported to a building site.

Modular construction will yield efficiencies through the reduction in material wastage and the number of days lost to adverse weather conditions. Factories also provide a safer and more hospitable working environment, as construction workers account for around 30 percent of workplace injuries and are four times more likely to be involved in a fatal accident versus other sectors.

Construction lags behind other industries in adoption of automation and robotics. In a global sur-vey commissioned by ABB of 1,900 large and small construction businesses in Europe, the US and China, only 55 percent of construction companies say they use robots, compared with 84 percent in automotive and 79 percent in manufacturing. The survey also shows 81 percent of construction businesses plan to introduce or increase the use of robotics and automation in the next decade.

“We understand the importance of sustainable housing and believe the transfer of technology and expertise to the construction sector will deliver the positive impact we have seen in other industries,” added Porsche Consulting’s Eberhard Weiblen.

“We will bring our blueprint to life and demonstrate how robotic modular construction can help support the changes our society is demanding. The joint approach will take modular construction to a new level in terms of quality, efficiency, design, and sustainability,” concluded ABB’s Marc Segura.

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GS-MR is armed with more than 35 years of engineering excellence, with 16 years of global high-end machinery experience in the glass processing industry. “The only robots we use are from Kawasaki,” says GS-MR director Robert Owen. “The wide range of models available and their durability is matched by the technical competence of their sales and integration teams. That back-up and knowledge has always proved pivotal and has given us a significant advantage when we’re in project discussions with our customers.”

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