Human-robot collaborative construction system for shotcrete digitization and automation through advanced perception, cognition, mobility and additive manufacturing skills

Project Information

RobetArme

Grant agreement ID: 101058731

DOI

10.3030/101058731

Project closed

EC signature date 24 May 2022

Start date 1 June 2022

End date 28 February 2026

Funded under

• Digital, Industry and Space

Total cost

€ 8 959 275,00

EU contribution

€ 8 959 275,00

Coordinated by

ETHNIKO KENTRO EREVNAS KAI TECHNOLOGIKIS ANAPTYXIS
Greece

Periodic Reporting for period 2 - RobetArme (Human-robot collaborative construction system for shotcrete digitization and automation through advanced perception, cognition, mobility and additive manufacturing skills)

Reporting period: 2023-12-01 to 2025-05-31

Summary of the context and overall objectives of the project

The continuous increase of the demand for construction applications, such as tunnels due to rapid urbanization in emerging economies, and the growth in construction repairs in developed countries impose excessive automation of concrete placement. Shotcrete (i.e. sprayed concrete) is the best method for construction of curved surfaces; it is also used in buildings’ façade restoration after fire or earthquakes as well as on bridges. Shotcrete is a typical example in the construction domain, where even though it is a highly mechanized procedure at present, most of construction companies mainly adopt manual shotcrete operation since there are multiple issues that hinder its automation. However, manual operation renders shotcreting time consuming, less accurate and hazardous for the operators.

The RoBétArmé project is developing a collaborative construction system for shotcrete digitization and automation with advanced perception, cognition, mobility and additive manufacturing skills. Through the introduction of new robotic and digital solutions, the project aims towards a step change in the Construction 4.0 by automating particularly laborious construction tasks in all phases of shotcrete application. RoBétArmé will firstly focus towards the digitalization of the construction site by introducing new BIMs accompanied with real-time Digital Twin and simulation environments setting the prerequisites for highly automation. RoBétArmé will deliver two collaborative construction mobile robots, consisting of an (I) Inspection-Reconnaissance mobile manipulator (IRR) to address fast, high precision modelling and rebar reinforcement through metal additive manufacturing and laser-based cleaning in the preparatory phase and (II) a Shotcrete and Finishing mobile manipulator (SFR) to address autonomous shotcrete application and surface finishing during the construction and finishing phase, respectively. New material mix-design for shotcrete will ensure CO2 reduction during this construction application. The project will demonstrate and validate the integrated solution through real diverse construction sites across different countries in Europe covering shotcreting for (1) ground support (retaining) walls, (2) tunnels and/or culverts, (3) beams & piles of buildings, and (4) the posttensioned boxes of bridges, provided by the project end-users.

For more information on RoBétArmé project, please visit: https://www.robetarme-project.eu/

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

The main results achieved by the RoBétArmé project so far can be summarized in the following points:
Construction Requirements: A comprehensive analysis of technological applications in construction was performed. Use cases, user requirements, and the system’s technical specifications and architecture were defined and refined through workshops (Copenhagen, Paris), system tests, and the January 2025 General Assembly.
Digitalization Tools: A BIM model enriched with shotcrete parameters was created, supporting planning, monitoring, and simulations. Core elements of the Digital Twin, IoT sensors, and a construction Decision Support System (DSS) with Human-Machine Interfaces (HMI) were implemented for real-time data and operator interaction.
Robot Perception: Semantic segmentation with 3D reconstruction enabled accurate surface geometry extraction. Volumetric models, stereo vision for turbid conditions, and monitoring methods were developed. Sensor fusion strategies and an orchestration engine based on Behaviour Trees were designed.
Robot Hardware: Mobile platforms for IRR and SFR were built and tested. The IRR was integrated with robotic arm and laser. An initial SFR arm was prototyped; the second version is under production, expected by August 2025. A new CO2-reducing shotcrete mix design was introduced.
Robotic Skills: Shotcrete data collection supported trajectory planning models. A coupled dynamical system for robot manipulation was tested in real and lab environments. Vision-based closed-loop control for shotcreting and navigation strategies for hybrid indoor/outdoor environments were realized.
Integration and Testing: An integration plan and Git-based software infrastructure were set. IRR integration with planner/controller was completed; SFR integration is ongoing with milestones in June–September 2025. Testbed designs were initiated.
Dissemination: The consortium engaged stakeholders via major events (Hannover Messe 2025, ERF workshop), online presence, and scientific publications. The TECH4EUConstruction cluster was launched for cross-project collaboration.
Technological Sovereignty: A VR training course is being developed to upskill construction workers. A Standardization Toolkit mapping 200+ EN/ISO standards was created and made publicly accessible. Safety risks were assessed by a senior expert. A CEN Workshop Agreement was approved, initiating new pre-standardization activities.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

The key innovation results achieved so far, which advance the state-of-the-art in construction robotics and automation are summarized below:
• A comprehensive literature survey on digitalization technologies in construction, particularly shotcrete applications, was completed. The results refined the technical specifications and overall architecture of the RoBétArmé solution.
• A novel Building Information Model (BIM) including shotcrete parameters was developed, alongside a simulation tool for spray patterns, concentration, and rebound.
• The first set of IoT sensors (temperature, humidity, vibration, crack detection) was integrated with the Digital Twin dashboard for real-time monitoring.
• An AI-based semantic segmentation method was implemented to detect exposed rebar and surface defects. A 3D reconstruction approach combining SLAM and volumetric modeling was also developed.
• A trajectory generation algorithm for shotcrete application was finalized, together with a monitoring algorithm for depth evolution.
• Navigation strategies for shotcrete were defined, including the first tractor-trailer path planning and navigation system based on predictive control.
• A heavy-duty mobile platform was developed for the SFR.
• A combined mobile platform plus trolley with safety measures was manufactured for the IRR.
• The second prototype of the SFR robot is under production.
• An analysis of standards and safety regulations relevant to shotcrete applications was completed to ensure compliance with industry frameworks.
A Standardization Toolkit was delivered, compiling key data on EN, ISO, and national standards. Publicly available on the project website, it supports adoption of best practices in construction.
A CEN Workshop Agreement (CWA) Project Plan was developed and approved, leading to a dedicated working group of partners and experts. This initiative transfers RoBétArmé’s results into a pre-standardization document, ensuring impact beyond the project and paving the way for a potential new European Standard.

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