Robotic Production of EPS Formwork for cost-effective Concrete Stairs

Project Information

SMARTSTAIR

Grant agreement ID: 947471

DOI

10.3030/947471

Project closed

EC signature date 18 February 2020

Start date 1 March 2020

End date 30 June 2023

Funded under

• INDUSTRIAL LEADERSHIP - Innovation In SMEs

Total cost

€ 1 354 245,00

EU contribution

€ 947 971,50

Coordinated by

ODICO A/S
Denmark

Periodic Reporting for period 2 - SMARTSTAIR (Robotic Production of EPS Formwork for cost-effective Concrete Stairs)

Reporting period: 2021-03-01 to 2023-06-30

Summary of the context and overall objectives of the project

The SmartStair project addresses a general problem in the construction industry through a specific optic; production methods fail to develop in tandem with demand for advanced concrete products. Relative to other industries, productivity in the construction industry increases at an exceptionally slow rate. Furthermore, building projects are hugely cost sensitive which inevitably detract from specialized projects, that are highly attractive but have higher expenses and higher risk of costly delays. Thus, a certain degree of conservatism prevails alongside strong demand for better infrastructure and architecture in society. Goals and means diverge.
The SmartStair project aims to bring goals and means to converge, starting with a specific niche which has long been challenge to concrete manufacturers: Staircases. Building customized formwork for staircases is very expensive and although CNC machining of parts for assembly is now an integrated part of the process, staircase formwork continues to be characterized by time and resource intensive craftmanship. Furthermore, current methods of production waste huge amounts of wood material, whereas the SmartStair production cell is based on wire cutting of low-cost EPS (Expanded Polystyrene), most of which can be granulated and reused.
Specialized formwork based on expert knowledge relies on a close understanding between the commissioning party and the formwork producer, where details and unique features must be agreed upon. Contrarily, robots are exceedingly efficient but only insofar as they operate in predictable environments. The SmartStair cell will make use of Odico’s proprietary Sculptor software, which enables easy translation of customized input into complex robotic output. Together with Odico’s wire cutting tool and a range of easily changeable tools, the SmartStair cell is capable of highly flexible operation and will cancel the gap between special and generic. This means that pre-manufacturers can offer sought-after custom elements at a feasible price. The SmartStair cell will thus contribute to a significant increase in productivity in the construction industry and help meet the demand for better infrastructure and architecture.

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 work performed from the beginning of the project has focussed on obtaining a fully functional production cell with end user validated manufacturing capability. The end of RP1 thus marks a transition phase into the TRL8-stage of the project.
In the first reporting period from 01/03/2020 to 28/02/2021, we have achieved the following results:
1. Preparation and assembly of a containerized work platform for housing the industrial robot and an automated tool changing system.
2. Development, integration and testing of a proprietary wire cutting tool
3. System design, integration and testing of a coating system
4. Development, integration and testing of a sanding tool for surface refinement
5. Development and preparation of a milling tool for edge finishing
6. Adaptation and augmentation of the Cloud-based software solution to translate the parametric formwork design input into robotic movement output through the Sculptor® robot control architecture.
7. A graphical user interface (GUI) design
8. System tests and production of formwork with different levels of detailing and end user defined typology constraints
The containerized platform consists of two standard open-sided 20-foot containers. One container houses the industrial manipulator and the associated hardware while the other container is placed parallel to the housing container and functions as a workstation on which to place the work object (i.e. EPS blocks). In this configuration, the system can perform all operations in an automated fashion – i.e. cut the EPS in a sweeping motion, apply a surface treatment, refine the surface, and perform edge-finishing for perfect encasement – based on inputs and prompts from a superintendent via a simple tablet interface.
The work envelope is designed to accommodate the majority of staircases produced by pre-manufacturers. With the motion constraints of the robot and the width of the wire tool, tests have validated that staircase designs of > 4,2 x 1,2 metres can be produced.
Surface quality is paramount to pre-manufacturers since staircases provide use surfaces. For this reason, much testing has been done to develop a custom coating solution with an surface with good release properties and good durability. As of RP1, a coating solution has been implemented and tested with a non-toxic, water-based self-crosslinking material. Since surface treatment is so essential, we have implemented the system in an open-ended way such that adjustments can be made to both application and material composition based on more extensive use case data and end user feedback during RP2.
To achieve perfect levelness, a sanding tool has been implemented and a milling tool which extends the height of the formwork has been designed to ensure perfect evenness of the sides for perfect encasement.
As of RP1, a beta version of the SmartStair production cell has been built and its primary functionality validated.

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)

During RP1, nothing has changed the market analysis on which the project is based. Based on an analysis of the Total Available Market, a market potential valued at €2.13Bn was revealed. The market potential is therefore very significant, not least due to the mentioned state-of-affairs in the construction industry. Advances in state-of-the-art remains dominated by incremental streamlining of an existing method, where CNC machining improves precision and efficiency of what is essentially sophisticated carpentry. SmartStair is attempting to create an entirely new market for digitally customized, low-cost formwork production by applying robotics, which will cut labor costs and enable a step-change in efficiency and flexibility.
With SmartStair, the central shape-giving operation is counted in minutes instead of days. A 4-meter piece of staircase formwork takes 30-40 minutes to cut. Today, lead times can be up to four weeks or longer for specialized formwork. More importantly, the SmartStair method does not differentiate standard from specialized formwork and particularly this no-cost alternating capacity with no need for production line conversion has high breakthrough potential.
The operation of the cell does not require artisan skill since everything is entered on a simple tablet interface after which the Sculptor software translates the input into robotic movement. After that, everything takes place automatically.
The SmartStair project thus changes the benchmark for productivity in concrete staircase manufacturing by making available a user-friendly, automated approach to formwork production that will increase the viability of ambitious architecture and infrastructure by bypassing costly links in the value chain.
The target for the remaining part of the project is to successfully complete pilot testing onsite with our concrete partners and to have a marketable product ready 3 months after the project ends in 2022.

Rendition of the SmartStair cell