The way that machines on construction sites operate has been steadily evolving over the past decade, moving further into the realm of automation, geofencing and satellite GPS, as well as BIM software to streamline processes on site. In fact, many large-scale Kiwi construction companies have already adopted this advanced technology to speed up earth work efficiency and productivity, to save costs and deliver ROI.
There’s no doubt that automation and positioning systems are the future of construction, but does it ultimately mean the end of human error in construction - and in a world where machines are ‘self-driven’ and entirely autonomous, is it safe and does it deliver better results?
In this blog, we dive into the finer details of machine automation, covering the Topcon X-53x as an example of automatic control on the construction site.
What is driving the need for automated machines in construction?
A traditional construction approach, also known as ‘brick and mortar” requires designers, engineers, architects, labourers and qualified tradesmen to pool their knowledge and experience together, work cohesively over the period of a project and deliver an outstanding project.
While this (for the most part) ensures a high-quality finished product, there are a few inherent issues:
- The cost for each individually skilled employee or contractor is extremely high, and can quickly rack up costs as the project progresses. Overtime, annual leave, sick leave, statutory working days, improperly scoped work and more hands on deck equals more money.
- Beyond the cost of labour, there are also two other factors that cause companies to go over budget while managing their construction project: time and materials wasted. A director from NZ Strong, Chris Hunter, comments;
“A lot of time can be wasted waiting for equipment to arrive, working out exactly where something should be installed, fixing errors or filling out paperwork. And in any project, delays cost money. While the material waste generated on building sites is a significant issue, inefficiency is just as big a problem.”
Technological advances in machine automation offer an opportunity to tackle the problem of cost by streamlining all areas of construction. Automation utilised in the right way works wonders for margins.
Think about it this way; if you reduce the room for error, time wasted on site, labour costs and material waste, and you were able to maintain quality, would you do it? Most construction directors would answer with a resounding yes - and that’s what’s driving the need for automation and digital transformation in the construction industry.
The Role of Human Error in Construction
One of the key reasons that a connected construction site and advances in machine automation are so key, is the role that human error plays in the workplace. If your workplace (in this instance, a construction site) is 100% operated by workers, you’re guaranteed to encounter human error throughout a project.
In fact, UK statistics showcase this problem astutely:
“Only 5% of employees in the UK work in the construction sector but it accounts for 27% of fatal workplace injuries and 9% of reported major injuries” (Health & Safety GOVT Figures).
It’s not just a safety issue either - when it comes to making best judgement decisions day in and around operations, materials, process and logistics, there are so many factors that contribute on a granular level to whether any given worker will ‘make the right call’ so to speak.'
These might include:
-
The Management System
In a broad sense, policies, procedures, practices, processes, strategies, goals, objectives, metrics, etc. Essentially how things are run within an operation that informs how people interact with one another and how problems are solved when they occur. -
Distractions
In an ideal world, any given worker would be fully engaged in the task at hand, every minute of the day on site. However, actually staying on task is no easy feat. We’re human, and humans are subject to both sensory and emotional distractions every day (ie. what’s happening in our environment vs. reaction to scenarios in our personal lives), so distractions are a reality any workplace has to deal with. -
Error Prone States
If we understand that as humans we’re prone to distraction and the influence that work and home environments have on our performance, and finally, the effect of the structural management system on site, we also have to accept that to a degree, humans operate in an ‘error prone state’.
“In some experiments, it was found that errors occurred anywhere from 25 to 50 percent of the time in many occupational settings. This indicates the pervasiveness of human error and the importance of designing means and methods that accommodate them with minimal adverse effect.” - IRMI
We know that human error occurs on construction sites and that it holds a direct impact on safety, quality of work, time efficiency, waste and of course, the bottom line. We also know that these external and internal factors don’t hold any weight on an automated machine's ability to complete a job, and that’s where the opportunity lies.
If machines are automated, is safety guaranteed?
While in one sense human judgement can be the cause of errors in the workplace, it’s also one of the main concerns that construction companies have when investing in automated machines. If a machine doesn’t have human judgement, how can we ensure safety on site?
The answer is by combining the best parts of human and machine operation.
The benefit of machine safety:
Machines have the inhuman ability to concentrate on a task at hand indefinitely - there is no element of fatigue, judgement, boredom or distraction, which is the cause of most accidents or unsafe scenarios on any construction site. Through automated machine systems, you’re able to guarantee less human error, and therefore less accidents - with the added bonus of productivity, efficiency and accuracy.
Automated machines with human control:
Although automated machines are completing the work on our behalf with zero distractions and 100% accuracy, it’s important to note that humans are still entirely informing when, how and what they work on. This is achieved by creating and importing designs (see our 3D modelling blog) which are executed by trained professionals.
Humans also set the parameters of operation, as an automated system requires several levels of safety to operate. For example:
- geofencing to keep the automated machine in the designated area
- on-machine and wireless emergency stops to halt operations
- sounds and lights to indicate status and action
- sensors and video cameras to detect obstacles such as people
Remotely, project managers or operators are able to choose when and how an automated machine performs it’s work, and pull the plug if need be - the main difference is, they’re able to do this at scale.
The takeaway here is that automated machines reduce human error through their inhuman ability to accurately and efficiently perform a task for hours on end, but they still require the important element that humans bring to the table on a construction site; design, planning and judgement.
The Topcon X-53x: Automation Exemplified
A product which really exemplifies just how much machine automation can reduce human error and produce an extremely high quality product is the Topcon X-53x Auto Excavator.
We caught up with Jamie Nelson, our Synergy Positioning Systems Southern Regional Manager, to get an insight into how the Topcon X-53x reduced human error and increased productivity for CCL Construction at the Cashmere Estates, Christchurch.
“The next step and change for excavators is moving them towards a semi autonomous state… There have been four key enhancements with the X-53x compared to previous generations of equipment. We now have new, high speed IMU sensors, a new GRI33 GNSS multi constellation receiver - which means for the operator that more satellites are tracked. So if you’re working in a valley or closer to structures or around trees, you’ll be able to keep working. There’s also a new version of 3DMC which is more configurable to the end user and brings in 3D views and more complex surfaces on the fly.
What does that look like in practice?
- An operator can load a design onto the onboard computer
- As the operator digs, the system takes control to dig to the designed grade
- Operators are able to dig faster and more accurately than ever, the operator only needing to position the machine, and the machine takes control from there
- In the image below, you can see a grade that would be extremely difficult for even the most experienced operators, but by using automation, an inexperienced operator can achieve the same result.
As Jamie says;
“It’s not about replacing experienced operators, it’s about upskilling less experienced operators and giving them the ability to pull a grade very accurately, and quickly”.
You can check out the full review in the video below.
So, do self-driving machines mean the end of human error in construction?
To a large degree, yes. Machine automation is rapidly becoming the preference on large construction sites because of its ability to considerably reduce human error, and increase productivity and efficiency. If you’d like to learn more about connected construction and the ways that automation can supercharge your business, download our FREE Guide to Connected Construction below.