FLEXRO: FLEXIBLE KIT FOR ROBOTICS HARDWARE AND DIGITAL INTEGRATION FOR EFFICIENT AND SUSTAINABLE CONSTRUCTION PRODUCTION SYSTEMS
FLEXRO is the title of a project proposal that was submitted to EU Horizon call (HORIZON-CL5-2024-D4-02: Robotics and other automated solutions for construction, renovation and maintenance in a sustainable built environment- Built4People Partnership).
FLEXRO project provides a solution by introducing a modular robotic kit aligned with European standards, integrating robots, lean management, digital tools, and prefabrication to reduce emissions by 40%, cut waste by 20% initially (our vision is to achieve wasteless construction with robotics), and shorten project timelines by 40% initially (and by 90 later with wider adoption and integration of robotics and prefabrication). Enhanced safety is ensured through AR/MR tools, ergonomic simulation models, and validated prototypes, with training and open standards supporting SMEs.
FLEXRO’s modular robotic kit enables the creation of use-case-specific solutions from generic modules, such as positioning modules, end-effectors, tooling, and peripheral components. These tailored instances integrate the unique requirements of construction tasks, use cases, and sustainability considerations, leveraging project partners' expertise, techniques, and technologies for maximum efficiency.
The five FLEXRO demonstrators (three use cases and two business pilots) showcase the kit’s versatility and adaptability across diverse construction scenarios, including housing construction, infrastructure, façades, building components, and interior finishing.
FLEXRO’s Objectives are as follows:
1. Overall Robotic Construction Production System: Prefabrication, site factories, and construction robots.
2. Lean Construction for Waste and Environmental Impact: Digital pipelines, construction process management, and robot-oriented design.
3. Human Factors Engineering: Simulation, virtual ergonomics, and human models for robotic construction.
4. FLEXRO Flexible Kit: Modular robotics and safety-oriented peripherals.
5. Test and Validation of Robotic Systems: Across building typologies for new construction and renovation.
6. Market Uptake, Business Models, Regulatory Readiness: Supporting standardization, scalability, and compliance to foster widespread adoption.
Description: Housing renovation and construction are critical for achieving Europe’s sustainability, urbanization, and energy efficiency goals, with renewable wood supporting circular economy and low-carbon initiatives through timber-based solutions. Led by BYCN, the project integrates robotics and BIM workflows, with partners like DT, imk, RWTH, and TMT contributing to system design, integration, and demonstrations. A modular robotic kit will perform tasks such as sealing and screwing or nailing, reducing on-site complexity through partial prefabrication and demonstrating both on a real site and in BYCN’s dedicate testing place, Scale One©, showcasing dual-use efficiency for factory and on-site applications. This aligns with FLEXRO’s objectives of lean construction, modular robotics, and sustainability. Key outcomes include a tailored robotic kit for finishing tasks, reduced on-site workload, enhanced worker safety, and significant reductions in waste and emissions.
Description: Inspection, renovation, and maintenance of Europe’s infrastructure are essential for safety and sustainability, with FLEXRO’s modular robotics addressing key construction challenges. STR provides use cases for bridges and roads, supported by DT, imk, RWTH, Tu/e, OTH, and CLI for development and integration, while Tu/e and TUD focus on prefabrication, GDT on joining solutions, and TMT on BIM-linked simulations, UNIVPM will test the AR/MR safety tool. The modular robotic kit will handle handling, assembly, sealing, and on-site welding, enhancing precision and reducing complexity through prefabrication. This aligns with FLEXRO’s objectives of supporting infrastructure renovation, enabling modular robotics for diverse use cases, and promoting lean construction with BIM integration. Key outcomes include a tailored robotic kit for STR’s use cases, reduced on-site complexity, improved precision, and scalable, efficient solutions for infrastructure projects.
Description: Facades are critical to building performance, increasingly incorporating advanced technologies for sustainability, and FLEXRO tackles the complexities of their construction in sustainable office buildings. BLP defines project requirements, with imk and OTH validating workflows, RWTH and DT developing the robotic solution, Tu/e and TUD providing modular factory setups, GDT designing and printing (metal printing) joining solutions, and TMT simulating BIM-integrated workflows, UNIVPM will test the AR/MR safety tool. The modular robotic kit will manage off-site fabrication of bespoke 3D-printed metal components, ensuring high precision and efficiency. This aligns with FLEXRO’s objectives of promoting sustainability, lean construction, modular robotics, and BIM integration for optimized performance. Key outcomes include a robotic kit tailored for façade tasks with demonstrated capabilities in drilling, positioning, and inspection, offering scalable and efficient solutions.
Description: Concrete and ecological alternatives are pivotal to European construction, with robotic 3D printing offering sustainable solutions to labour shortages. ZHAW and ETH define requirements with local authorities, while DT, RWTH, and OTH develop the robotic system, and imk and TMT simulate BIM-integrated 3D printing workflows. The mobile modular robot supports both off-site and on-site 3D printing, featuring interchangeable tools for tasks like post-processing and surface smoothing to ensure efficiency and versatility. This aligns with FLEXRO’s objectives of sustainability, flexibility, waste reduction, and precision through BIM-integrated workflows. Key outcomes include a scalable mobile robot for 3D printing, demonstrating advanced workflows and potential for global adoption in sustainable construction markets
Description: Building installations are becoming increasingly complex, requiring significant labour in both new construction and renovations, which FLEXRO addresses by automating sequential tasks to enhance efficiency and reduce labour demands. OTH, CLI, RWTH, and DT customize the robotic solution, while imk and TMT manage BIM-integrated simulations, with demonstrations positioning FLEXRO as a scalable export model. The FLEXRO kit performs sequential ceiling tasks such as drilling, bracket placement, assembly, and inspections, showcasing versatility and precision in a complete workflow. This aligns with FLEXRO’s objectives of modular robotics for diverse tasks, lean construction to reduce labour intensity, scalability for export, and BIM-driven task precision. Outcomes include a robotic kit for ceiling installation with end-to-end workflows, improved efficiency, reduced labour, and global scalability.