Supporting sustainable construction

While the operation of buildings is one of the biggest sources of greenhouse gases, embodied carbon that arises from their construction – before they are operational – represents a huge opportunity to address the climate impacts of the built environment. Robotics, smart automation and software are now becoming key tools in the sector's toolbox and how it approaches sustainability. Construction vehicles, including excavators, loaders, bulldozers, backhoes, dump trucks and forklifts, are big consumers of diesel, so are ripe for the energy transition.

Robotics

Traditional construction methods are wasteful and energy intensive. Construction sites generate a significant amount of debris, and reliance on conventional materials like steel and concrete creates a substantial carbon footprint. These factors also contribute to air and water pollution, as well as depletion of natural resources.

Construction robots can perform a variety of tasks with exceptional precision and efficiency. Remotely controlled robots can handle hazardous materials and maneuver supplies (e.g., lumber, bricks, prefabricated components) at building sites. They can demolish structures with minimal environmental impact and automate repetitive or dangerous assignments, freeing up human workers for more specialized roles – a key consideration given the perennial labor challenges facing the sector.

ABB has partnered with UK-based start-up Automated Architecture (AUAR) to create robot-powered microfactories that build low-cost, sustainable homes that can help address the housing affordability crisis confronting many cities. The partnership automates the manufacture of energy-efficient housing from sheet timber.

The process involves robots cutting timber sheets into components and assembling them to create modular units. These units are then transported to construction sites. This automation addresses skills shortages in the construction industry, improves sustainability and enhances worker health and safety. The collaboration will establish a global network of local microfactories, each powered by robots, with the aim of making the construction of affordable, sustainable, low-energy modular timber homes more efficient.

Another innovative application of robotics in construction is in creating new, more sustainable building materials. Researchers at Germany’s University of Kassel have developed a method for creating high-strength, stable and extremely lightweight building components from 0.5-millimeter-thick veneer wood. ABB robots are used to wind and glue the veneer wood, resulting in a significant weight reduction compared to conventional building materials. This method not only uses renewable resources, but also offers flexibility in design through 3D algorithms, and ensures millimeter-accurate fabrication by robots.

3D printing and smart automation

3D printing, also known as additive manufacturing, allows for the creation of structures layer by layer using a computer-controlled system. This method uses only the necessary amount of material, dramatically reducing construction waste. Furthermore, 3D printing enables the use of recycled materials in construction, promoting a circular economy within the industry. For example, researchers are developing concrete mixes specifically designed for 3D printing that incorporate recycled construction and demolition debris. ABB supports 3D printing applications with a range of offerings, including RobotStudio® 3D Printing PowerPac.

One example of 3D printing in action is ABB’s partnership with French start-up XtreeE, makers of industrial solutions that equip construction firms with the technology to produce 3D-printed buildings. The partnership involves using ABB’s six-axis robots and RobotStudio® software as part of XtreeE’s industrialized 3D printing solutions. These solutions allow construction companies to produce unique, design-led building elements and components that cannot be achieved using conventional construction methods.

Automation encompasses a wide range of technologies that streamline construction processes. This includes Building Information Modeling (BIM) software that creates digital twins of buildings, allowing for optimized design, prefabrication of components off-site and improved on-site logistics.

Electrifying construction vehicles and machines

By developing electric drivetrains and power electronics specifically designed for the demanding conditions of construction sites, ABB is helping to reduce the construction industry's reliance on fossil fuels. ABB's electric drivetrains for construction vehicles offer high efficiency and performance, enabling these machines to operate with minimal environmental impact.

ABB's electric drivetrains for construction vehicles are designed to be modular and scalable, making them suitable for a wide range of applications. For example, ABB's electric drivetrains can be used to power excavators, wheel loaders and other heavy construction equipment. By offering a comprehensive range of electric drivetrain solutions, ABB is helping to accelerate the adoption of electric construction vehicles and reduce the carbon footprint of the construction industry. ABB also offers a range of other products and services for the construction industry, including charging infrastructure, energy storage solutions and digital solutions for fleet management and energy optimization.

Norwegian company Nasta AS, in collaboration with ABB, is converting its fleet of diesel-powered heavy machinery to electric powertrains. This initiative aligns with Norway’s commitment to the Paris Agreement, aiming for a 55 percent reduction in CO₂ emissions by 2030. The conversion process involves replacing diesel engines with electric motors, energy management systems and battery solutions, resulting in emission-free operation. This shift not only triples the lifespan of construction machinery but also significantly reduces environmental impact by cutting carbon dioxide and sulfur dioxide emissions.

The benefits of electrification are substantial, particularly in terms of efficiency and sustainability. Diesel engines typically run at around 45 percent efficiency, whereas electric motors can achieve up to 95 percent efficiency. This improvement translates to considerable cost savings and a reduction in greenhouse gas emissions. For instance, a 24-ton Nasta diesel excavator, which consumes approximately 18,000 liters of fuel annually, produces around 48 tons of CO₂ emissions in a year. By converting to electric power, these emissions are eliminated entirely.

Footnotes

¹ https://worldgbc.org/article/bringing-embodied-carbon-upfront

Select region & language

Robotics

3D printing and smart automation

Electrifying construction vehicles and machines