HP Robotic Solution Accelerates Construction Process

How an end-to-end robotic solution revolutionizes the complex layout process on construction sites, reducing time and costs for construction projects.

In the construction industry, time is a crucial factor: delays usually lead to additional costs for project participants. Numerous prominent examples testify to the unpredictability of construction sites – from Stuttgart 21 train station and the Elbphilharmonie to BER airport or the Pergamon Museum. Only 30 percent of all construction projects are completed on time and within the estimated budget. This is also because construction is a craft, involving many manual activities and therefore sometimes prone to errors.

According to the “State of Construction Productivity 2023” survey by the technology company HP, 60 percent of the construction workers and decision-makers surveyed believe that techniques and processes have hardly changed in the last 20 to 30 years. The demand for digitalization on construction sites is increasing: two out of three respondents, for example, wish to automate layout tasks such as marking floor plans. The survey also revealed that layout errors typically lead to delays of two weeks, resulting in a loss of 19 percent of a project's average profit margin. As a result, HP developed an end-to-end robotic solution called “HP SitePrint” designed to automate the site layout process with pinpoint accuracy, in a fraction of the time it takes manually.

The HP SitePrint was used, for example, by the Spanish construction company Acciona during the construction of the Hospital Central do Alentejo in Évora, Portugal. This largest construction project in the country includes a ten-story building with 400 beds and all necessary functional units. The challenge was to precisely mark almost two kilometers of drywall profiles on an area of about 8,400 square meters. Traditionally, this is done manually by a two-person team using tape measures and chalk lines. This process is time-consuming and error-prone.

To speed up this work, Acciona decided to use the HP SitePrint. The layout robot uses digital CAD drawings to automate the marking process, eliminating the need for manual measurements. The small vehicle was monitored by a single operator, while a technician prepared the documentation. This enabled a productivity rate of 225 m²/h compared to 40 m²/h using manual methods. The entire layout process was completed in 37.4 hours – six times faster than usual. This efficiency improvement allowed workers to start installing the walls earlier, ultimately leading to a faster project completion. In addition to saving time, the printing robot also helped reduce errors, as it offers an accuracy of less than three millimeters. This resulted in fewer reworks and lower overall costs.

The printing robot navigates around obstacles using sensors and LiDAR lasers and is connected to a total station commonly used on construction sites, which performs precise measurements of distances, angles, and heights. CAD plans can be uploaded to the system from the cloud and controlled on-site via tablet; the operator can upload changes to the construction plan back to the cloud in real-time. This way, all stakeholders are always informed about the current status of the process. Additionally, this connectivity allows notifications about the robot's status or ink tank levels to be immediately transmitted to the service team.

Since the system is connected via Telekom's LTE mobile network – WLAN or fixed network are not available in shell constructions – HP can distribute and use its autonomous printing robot internationally. The basis is Telekom's global mobile network, which guarantees reliable and secure connectivity through its own networks, such as in Germany, as well as through roaming agreements with more than 600 partners worldwide. Thus, HP has already supported construction projects worldwide – from Düsseldorf to Badalona in Spain and San Angelo in Texas to the US Virgin Islands in the Caribbean or the remote province of Nunavut in northern Canada. And without having to set up new contracts each time, but with a central contact person providing true global connectivity – a clear efficiency advantage.

HP SitePrint can also be used for other application areas involving layout tasks. The Berlin-based ArtLab Studios, specialized in light design and event technology, had to set up a large booth at the Düsseldorf trade fair. This involved the precise measurement and marking of locations for lighting, sound, and electrical systems on an area of 8,000 square meters. Traditionally, this task requires a large team of specialists working with printed floor plans and tape measures. Especially for temporary events like a trade fair, the available time for setup is often limited, creating additional pressure.

The HP SitePrint also automated this layout process, requiring only one person to operate the printer. ArtLab was able to complete the work in 9 instead of 16 hours, cutting time requirements by nearly half. The higher detail accuracy of the markings also reduced errors and associated reworks. Additionally, short-term changes could be easily integrated without jeopardizing the schedule.

Speaking of trade fairs: HP will demonstrate its printing robot at Digital X 2024 in Cologne on September 18 and 19. Europe's largest digitalization event also offers many other successful best practices from the Connected Business sector for visitors, as well as panel discussions, masterclasses, and the opportunity to network with digital pioneers.