CONCERT Modular Robot: The Future of Flexible Construction

While the construction industry has always faced challenges such as labor shortages, safety issues, and operational complexity, emerging robotic technologies are playing a pivotal role. At the heart of these technologies is the CONCERT project from the Italian Institute of Technology (IIT), a fully reconfigurable modular robot designed for complex construction environments.

What is a Reconfigurable Modular Robot?

A "reconfigurable modular robot" (MRR) is a system made up of mechanical and electronic blocks or modules that can be connected and disconnected, allowing the robot’s structure, degrees of freedom (DoF), and functionality to change based on the work needs at the site. The fundamental idea is to have a single platform that, instead of using several single-purpose robots (e.g., one for drilling, one for sanding, one for transporting), can be adapted for a wide range of tasks by swapping modules and tools. This approach is particularly important in construction, where sites are dynamic, irregular, and variable—and the cost/time of changing traditional equipment is high.

What is CONCERT? (Technical Summary and Project Status)

CONCERT is a modular robotic platform developed by a group of researchers at the Istituto Italiano di Tecnologia (IIT) as part of the European CONCERT project. The robot is designed to operate as a cobot (collaborative robot) on construction sites, performing tasks such as precision drilling, sanding, plastering/insulation spraying, and heavy lifting while avoiding collisions with obstacles. Key technical features include the use of "high power density" motors, quick-connect modular mechanisms, interchangeable tool holders, and a software chain that automatically updates kinematic and dynamic parameters after module installation/removal, enabling the system to be reassembled and operational in under 10 minutes. This system has also been tested in real-world sites.

Field Evidence and Initial Results

The CONCERT project has been tested not only in the laboratory but also on real construction sites. This real-world application demonstrates the practical potential of the robot for challenging and variable construction environments. For example, in a hospital construction project in Krakow (field sample), the robot successfully performed a variety of tasks under real conditions (precision drilling, sanding, spraying, cargo handling). CONCERT also has the capability to carry multi-hundred-kilogram loads and perform multi-purpose tasks, with capacity varying based on configuration. This shows that the platform is scalable and deployable for operational use, not just as a laboratory prototype.

Advantages and Strategic Outlook

• Increased Safety and Reduced Human Vulnerability: CONCERT offers a safer alternative for tasks like insulation spraying or heavy lifting, replacing human workers in these high-risk jobs.

• Industrial Flexibility: The robot can quickly adapt to different tasks, eliminating the need for single-purpose models.

• Cost and Time Reduction: By replacing multiple dedicated robots with a single multi-purpose robot, capital and maintenance costs are reduced.

• Addressing the Labor Crisis: This technology can help fill the gap caused by the shortage of skilled labor.

• Integration with Digital Workflow (BIM/Digital Twin): Executed outputs are directly fed back into the model, simplifying the quality control cycle.

Limitations and Practical Challenges

Despite its achievements, there are challenges:

• Environmental Sustainability and Robustness: Harsh weather conditions (rain, dust, extreme temperatures) and site-induced vibrations/impacts need to be addressed; this issue has been mentioned in field reports.

• Standardization and Work Safety: Standards, risk assessment methods, and safety certifications for site work are necessary.

• Initial Cost and ROI Analysis: Although the modular platform saves costs in the long term, a total cost of ownership (TCO) and ROI analysis is crucial for companies.

• Workforce Adjustment and Training: New operators, maintenance teams, and project managers must become familiar with the modular logic and new software.

• Supply Chain and Module Maintenance: Fast distribution of modules, spare parts, and on-site maintenance is an issue.

The Outlook for Modular Robots in the Construction Industry

Modular robots or configurable robots are robotic systems that can quickly change their mechanical structure, work tools, and even control software to adapt to the required operations on a construction site. This flexibility, demonstrated in projects like CONCERT, marks a shift from single-purpose robots to the era of "multi-capable and self-configuring robots."

The potential of this technology in the construction industry goes beyond merely mechanizing a few processes. It represents a systematic transformation in the management of human and technical resources for projects. In the next 5 to 10 years, these robots could transform construction into a data-driven, flexible process that is resilient to fluctuations in the labor force. Given the current labor shortages, increasing project costs, and pressure to meet safety and sustainability standards, the use of this technology is not just an option—it is a necessity.