AR glasses for precast concrete elements and formwork construction

Digitalisation is increasingly reaching areas of the construction industry that were long considered to be heavily craft-based. In the manufacture of precast concrete components in particular, digital models, automated production processes and virtual assistance systems are now transforming day-to-day work.

At the bauma in Munich, Weckenmann is therefore showcasing AR glasses that project virtual planning data directly onto real formwork, thereby simplifying assembly and production processes. The focus is on an augmented reality application for the production of large-format precast concrete elements. The technology superimposes digital information directly into the employee’s field of vision. Instead of working exclusively with traditional drawings or dimensional specifications, reinforcement and embedded components can be displayed virtually within the formwork. This form of visual support is becoming increasingly important, particularly in the precast concrete industry. This is because components are becoming more complex, whilst at the same time the pressure for precision, speed and error prevention is mounting.

Weckenmann combines formwork construction with augmented reality

The solution presented is based on AR glasses that combine virtual component data with real production environments. This allows employees to view digital models directly at their future installation position within the formwork. Among other things, the system displays reinforcement, built-in components and other structural elements of a reinforced concrete component. The virtual information serves not only for visualisation but is also intended to support specific work steps. The placement of the embedded parts is particularly interesting. The real component is directly compared with the virtual model. If both positions match, the element is automatically placed in the intended location.

This also changes the workflow within production. Instead of manually transferring dimensions from drawings or laboriously measuring positions, orientation is carried out directly via the digital model in the employee’s field of vision. In formwork construction in particular, such processes are considered prone to errors. Even minor deviations can later lead to problems with fit, structural integrity or assembly. Digital assistance systems are therefore designed to help reduce error rates and improve quality assurance.

Virtual reinforcement facilitates production

A key focus of the application is the visualisation of reinforcement within reinforced concrete components. The complex steel structures are visualised virtually and superimposed directly onto the real formwork. This creates a kind of digital assembly aid for production. Staff can see where individual elements need to be positioned without having to constantly switch between drawings, dimension tables and the actual component.

Key features of the system:

• AR glasses for precast concrete production
• virtual representation of reinforcement and embedded parts
• direct overlay of digital data onto real formwork
• simplified positioning of structural components
• support for less experienced staff

Precast concrete plants are increasingly relying on digital processes

This development reflects a major shift within the precast concrete industry. Production facilities are increasingly being digitally networked, whilst at the same time BIM data, 3D models and automated manufacturing processes are becoming more closely integrated. Large-format precast concrete elements in particular require a high degree of precision. Errors in the formwork or incorrectly positioned embedded parts can quickly lead to costly rework or production losses. Digital assistance systems are therefore designed to bridge the gap between planning and actual production. Virtual models are moving beyond traditional screen displays and are being integrated directly into the production environment. There is a further advantage: the visual representation of complex components facilitates communication within the production process. Staff can more quickly recognise how individual components fit together and what their intended position is. Another interesting aspect is the similarity of such systems to gaming and consumer technology. The intuitive use of AR applications is deliberately reminiscent of digital user interfaces from other sectors. It is precisely this that often lowers the barrier to entry for users.

Augmented Reality is transforming construction production

The solution presented illustrates just how significantly the construction industry is currently changing technologically. Augmented Reality is increasingly evolving from a demonstration technology into a concrete tool for industrial production processes. Weckenmann is thus positioning itself in an area that is likely to become significantly more important for precast plants in the future. For the more complex components and production processes become, the greater the need for visual process support. At the same time, the demands on production staff are changing. Alongside traditional craftsmanship, digital skills and the ability to work with virtual data models are becoming increasingly important. The AR glasses on display make it clear that digitalisation in the construction industry has long since ceased to be confined to office software or machine control. It is increasingly reaching the workplace in the production hall – where formwork is prepared, reinforcement is installed and precast concrete elements are produced.