R2
ZeroLabor R2
The workhorse. Compact, with room for different sheet sizes and types, and tongue-and-groove assembly.
Two robots · one workstation
Products & systems / ZeroLabor
ROBOTICS INSIDE THE LINES
ZeroLabor
The robots that build the building.
50+
ZeroLabor cells installed
7
countries, four continents
Randek saw early how few industrial robots the construction industry used, and how much heavy, repetitive work that left to people. In 2016 we set out to change that, and in 2017 we introduced the first ZeroLabor cell, running industrial robots at scale in an off-site factory. The cells take the physical strain out of the heaviest stations and cut the manpower they need.
A family of robotic cells that each automate one process, such as sheathing, sub-assembly or insulation. There is no ZeroLabor line of its own: you add the cells to a Randek line, or to a line you already run.
ROBOTISE THE LINE
Robotise the line you are planning, or the one you have
We can robotise almost every step of element production, from sub-assembly to sheathing and insulation. Each process gets its own cell, so you add the ones your line needs, one at a time, on a Randek line or on a line you already run.
Upgrade a line you already run
A cell is customisable and fits into an existing production line, including one you already own. Start with a single cell on the station that costs you the most, a compact sheathing cell for example, and add more as volumes and confidence grow.
One process at a time
Because each ZeroLabor is a cell and not a line, you buy only the automation you need: one process now, another later, without replacing the line around it. Cells for noggin placement and gluing are available on request.
Read the brochure →
INSIDE THE CELL
How a ZeroLabor cell is built
One cell, many tools
Every ZeroLabor cell is built the same way: industrial robots, a tool changer and the tools the process needs. What changes from cell to cell is the tooling, so the same robot platform sheathes a wall, fills it with insulation or builds its sub-components.
- Robots on railsTwo to five industrial six-axis robots move along the element. More robots, more capacity.
- Tool changerThe robots switch tools on their own, element by element, so one cell handles a wide mix of elements.
- Tools per processSheet handling, milling and fastening for sheathing, blow-in plates for insulation, worktables for sub-assembly. Each process is described below.
- Driven from CADEvery move comes from the element’s CAD data, so nobody programs the robots element by element.
- Timber or light gauge steelZeroLabor is integrated into an AutoWall for timber or an AutoWall for light gauge steel, never one line for both: each has its own framing station, and the cell’s tools and settings match the material. The insulation cell fills either.
- SoftwareOur own PLC, robot programming and HMI, on the same data as the rest of the line.
ROBOTIC SHEATHING
Sheathing: lay, fasten and format the sheets
The most proven ZeroLabor cell. Robots lay the boards on the frame, fasten them and mill the openings, on one or both faces of the element, in one flow.
The sheathing cell
Several layers and sheet types go on in one pass. Recycle bins keep materials such as OSB and plasterboard apart, and a “next bigger sheet” function keeps waste down.
- Sheet handling toolVacuum cups pick each sheet and place it on the frame.
- Recycling toolVacuum cups and suction pads lift away the offcuts milled out of the sheets.
- Milling toolsEach robot has its own milling tool, optionally with a four-position cutter changer, to format the sheets and mill openings for doors, windows, electrical boxes and ventilation. A saw tool is available as well.
- Fastening toolsStaples, screws or nails.
- Tongue and grooveAssembles tongue-and-groove sheets.
- Robot working tableSquares the frame as it enters the cell.
- Stud correctorStraightens the incoming studs, so the robots work on a true frame.
| Sheathing cell | |
|---|---|
| Robots | Industrial 6-axis robots on rails (2–5 depending on configuration) |
| Board types | Set up for the customer’s boards: tools and grippers are specialised per material (OSB, gypsum, gypsum fibre and more) |
CONFIGURATIONS
How many robots does the sheathing cell need?
Once the cell fits your factory, this is where you size it: two to five robots. Every size has the same tools, for sheathing, sawing, milling, screwing and stapling. What grows is capacity, sheet storage and the number of workstations.
R3
ZeroLabor R3
One more robot for more capacity and multiple layers, with extended sheet storage.
Three robots · one workstation
R4
ZeroLabor R4
High single-layer capacity, with sheathing, fastening and CNC removal of recyclable material.
Four robots · two workstations
R5
ZeroLabor R5
Two workstations split the work between them, for sheathing multiple layers.
Five robots · two workstations
| R2 | R3 | R4 | R5 | |
|---|---|---|---|---|
| Robots | Two | Three | Four | Five |
| Workstations | One | One | Two | Two, sharing the work |
| Tongue and groove | Yes | Yes | Yes | Yes |
| Sheet storage | Different sizes and types | Extended | Different sizes and types | Different sizes and types |
| Built for | A compact start, integrated into a larger line | More capacity and multiple layers | High single-layer throughput | Multiple layers |
| Example layout | Two R2 for open elements, single or double sheathing | Two R3 with Robotic Insulation for closed, insulated elements | R4 with robotic sub-assembly for open elements | With an R3 for closed elements, on AutoWall |
ROBOTIC INSULATION
Insulation: blown in, cavity by cavity
Two robots fill closed elements with blown-in insulation, to the volume and density the design data sets.
The insulation cell
Each robot positions its blow-in plate over a cavity and fills it completely before moving on. Every fill is logged, and cavities too small to fill are flagged for manual finishing downstream. Timber and light gauge steel elements are filled alike.
- Blow-in platesOne per robot, with five nozzles, each fed from its own supply.
- Insulation materialsWood fibre, glass wool or cellulose, through the ISOFLOC easyfloc blow-in system.
- Material handlingA bunker system of about 20 m³ feeds the cell.
- Cell tableSets its width to each element automatically, for elements up to about 3,000 kg.
- Traceable qualityA weighing protocol logs the material used in every element.
ROBOTIC SUB-ASSEMBLY
Sub-assembly: the components before the frame
Robots build the rough openings and multi-studs that are slow to make by hand, on their own or feeding a line.
The sub-assembly cell
U-studs, L-studs, doubles, triples, noggings, and window and door rough openings, built the same way every time. The cell adapts to different construction standards.
- Sub-assembly worktableWhere the components are built.
- Reload stationFeeds material into the cell.
- Pallet bufferingBuffers finished components for the line downstream.
IN THE LINES
ZeroLabor in each Randek line
The same cells robotise different lines. Which stations they take, and how many robots, we plan with you in a pre-study.
AutoWall
In production. On the wall line the cells take sheathing, insulation and sub-assembly, from open panels through to closed, insulated elements, whatever the mix of elements. See AutoWall →
AutoFloor
On the standard AutoFloor line two robots take the place of the portal: they place, fasten, saw and mill the sheets on floor cassettes and ceiling elements. See AutoFloor →
AutoEye
In development. Robotic assembly puts roof trusses together, joining a line that already presses nail plates in nine seconds. See AutoEye →
HOW IT STARTS
Every cell starts with a pre-study
The pre-study is a service, not a sales meeting. It works out which stations are worth robotising in your factory, and how many robots they need.
Pre-study
A Randek project leader defines your products, KPIs, factory constraints and layout, and sets a lead time. Existing equipment is reused where it fits. Before anything is ordered.
Engineer and prove
The cell is built and verified through Factory Acceptance Testing before it ships.
Install and start
Our own installation staff commission the cell, train your operators and supervise the production start. MyRandek tracks the KPIs from then on.
SEE IT RUN
ZeroLabor in production
In production
Customers running ZeroLabor
British Offsite
AutoWall · LGS framing · ZeroLabor
“They didn’t just provide automation; they co-developed a process that works in a real-world, high-volume factory.”
Shaun WestonManaging Director
Read the full story →
Modscape + Modbotics
AutoWall · Robotic production cell
“We’ve been operating the robot line now for two years, but it’s been a seven-year journey. We’re still improving, but every day of the week and every week of the year we’re getting more efficient.”
Jan GyrnCEO and Co-Founder
Read the full story →
Arcabo
AutoWall · ZeroLabor R2
At our state-of-the-art factory, we construct our modular recreation homes with efficiency in mind. This not only minimizes transportation needs but also ensures a superior working…
Read the full story →
BoKlok
AutoWall · ZeroLabor
“Randek is an important supplier for us. Our new production line will enable us to double the production rate and we will be able to produce our new multifamily type of houses faster.”
Sacha Pardon, Press Officer, BoKlok
Read the full story →
Trivselhus
AutoWall · ZeroLabor
Randek has been very responsive to our expectations and we received a final tender that was within the technical specifications and our budget. At Trivselhus we work in project groups. All…
Read the full story →
Riverbend Building Supply
AutoWall · ZeroLabor
“As Canada’s first supplier of components to the housing industry, Riverbend chose a ZeroLabor robotic wall manufacturing system — reaching a higher level of productivity and precision.”
Riverbend Building Supply, Canada
Read the full story →
Donaldson Timber Systems
AutoWall · ZeroLabor
“Our original site in Westhill, Scotland, has had Randek framers for over 30 years. We were probably one of the earliest Randek customers in the UK.”
Frank O’ReillyManufacturing Director
Read the full story →
Timbertruss
AutoWall with ZeroLabor and Robotic Framing · AutoEye · Stud cut saw
“We’re always looking for ways to do better. And Randek’s been a big part of that journey.”
Mark McDonald, CEO, Timbertruss
Read the full story →
QUESTIONS
What buyers ask first
How many robots are in a cell?
Between two and five. R2 is the compact workhorse, R3 adds one robot and extended sheet storage, R4 is built for single-layer capacity, and R5 has five robots across two workstations for multiple layers.
Can a cell be added to a line we already have?
Yes. The cells are customisable and fit into existing production lines, or they can operate independently.
Does ZeroLabor handle light gauge steel as well as timber?
Yes. ZeroLabor is integrated into an AutoWall built for one material: an AutoWall for light gauge steel with an LGS framing station, or an AutoWall for timber with a timber framing station. No AutoWall runs both. On a steel line the robots lay and fasten the sheets just as they do on timber, with tools set up for the material.
How long has ZeroLabor been in production?
Randek set out to bring industrial robots into construction in 2016 and introduced the first ZeroLabor cell in 2017.
Where do we start?
With a pre-study. A Randek project leader works out which stations in your factory are worth robotising, how many robots they need and what lead time to plan against, before anything is ordered.
Is the cell tested before it arrives?
Yes. It is verified through Factory Acceptance Testing before it ships, and our own installation staff commission it, train your operators and supervise the production start.
What happens if something goes wrong?
Our support staff troubleshoot over remote connection, and in most cases software can be updated and equipment monitored remotely. A Service Level Agreement adds scheduled maintenance.
Does the cell work with our CAD software?
The cells run on CAD data, and Randek integrates with the leading CAD vendors in the market.
Terms explained
Key terms around ZeroLabor
Your next factory starts here
Talk to Randek
Tell us what you build today and where the bottleneck is. We will point you to the right team: locally where we have one, from Sweden where we do not.