Automation and Robotics for the Precision Manufacturing of Precast Elements using Sustainable Concrete Mixes

Abstract

The precast concrete industry stands at a pivotal juncture, driven by the dual imperatives of enhancing sustainability and embracing digitalization. The utilization of industrial and agricultural waste by-products, such as marble dust, rice husk ash, sugarcane bagasse ash, and waste paper sludge ash, in concrete mixes presents a significant opportunity for reducing the environmental footprint of construction. However, the inherent variability in the chemical and physical properties of these supplementary cementitious materials (SCMs) introduces significant challenges in ensuring consistent workability, strength, and durability of the final precast elements. This review paper posits that the synergistic integration of robotic automation and artificial intelligence (AI) is the key to unlocking the full potential of these sustainable, yet non-standard, concrete mixes. We explore the state-of-the-art in robotic systems for precise handling, casting, and finishing of precast elements, which can mitigate the variability introduced by novel mix designs. Furthermore, we delve into the critical role of AI and machine learning (ML) for real-time quality control, predicting final mechanical properties, and optimizing mix proportions. The paper proposes a novel framework that leverages advanced ML techniques including Computer Vision for defect detection, and predictive models like Artificial Neural Networks (ANNs) and Logistic Regression to create a closed-loop, intelligent manufacturing system. By reviewing and synthesizing contemporary research, this paper outlines a pathway towards a resilient, data-driven, and environmentally responsible precast concrete industry.

Country : India

1 Er. Manpreet Singh2 Dr. Jagdeep Kaur3 Er. Simran

  1. Assistant Professor, Department of Computer Science & Engineering, Sant Baba Bhag Singh University, Jalandhar, Punjab, India
  2. Professor, Department of Computer Science & Engineering, Sant Baba Bhag Singh University, Jalandhar, Punjab, India
  3. Research Scholar, Department of Computer Science & Engineering, GNA University, Phagwara, Punjab, India

IRJIET, Volume 9, Issue 9, September 2025 pp. 142-148

doi.org/10.47001/IRJIET/2025.909020

References

  1. Chagger, Jeevanjot & Anil, Er. (2025). A REVIEW STUDY: ELECTRICAL WORK ON CONSTRUCTION SITE. Industrial Engineering Journal, ISSN: 0970-2555, Volume: 53, Issue 6, No.5, June: 2024. https://www.researchgate.net/publication/396053644_A_REVIEW_STUDY_ELECTRICAL_WORK_ON_CONSTRUCTION_SITE
  2. Chagger, Jeevanjot & chedda, Er & Wuntah, Er. (2025). Review study: Waste glass powder (WGP) with replacement of cement. International Journal of Structural Design and Engineering. 6. 01-06. 10.22271/27078280.2025.v6.i2a.43. https://www.researchgate.net/publication/394245448_Review_study_Waste_glass_powder_WGP_with_replacement_of_cement
  3. Sharma, H., Singh, J., Kumar, A., Bala, M., & Kumar, S. (2025, June). Review on the utilization of the Geogrids in road construction. In AIP Conference Proceedings (Vol. 3261, No. 1, p. 120002). AIP Publishing LLC. https://www.researchgate.net/publication/392428380_Review_on_the_utilization_of_the_Geogrids_in_road_construction
  4. Suri, Navleen & Chagger, Jeevanjot & Sharma, Er. Harish & Chandel, Dr. (2025). INVESTIGATION ON THE TENSILE STRENGTH WITH USE OF ScBA AND WPSA WITH PARTIAL REPLACEMENT OF CEMENT IN CONCRETE. Industrial Engineering Journal. 54. 678-704. https://www.researchgate.net/publication/391643779_INVESTIGATION_ON_THE_TENSILE_STRENGTH_WITH_USE_OF_ScBA_AND_WPSA_WITH_PARTIAL_REPLACEMENT_OF_CEMENT_IN_CONCRETE
  5. Jeevanjot Singh, Simran, Pema Chheda, Prince Wuni Wuntah. A review study on machine learning to investigate the issue of plastic pollution in oceans. Int J Hydropower Civ Eng 2025;6(1):48-51.DOI: 10.22271/27078302.2025.v6.i1a.62, https://www.researchgate.net/publication/396213967_A_review_study_on_machine_learning_to_investigate_the_issue_of_plastic_pollution_in_oceans
  6. Chagger, Jeevanjot & Sharma, Er. Harish & Bala, Er. (2024). PARTIAL REPLACEMENT OF CEMENT WITH RICE HUSK ASH & SUGARCANE BAGASSE ASH: REVIEW PAPER. Industrial Engineering Journal ISSN: 0970-2555 Volume: 53, Issue 6, June: 2024. https://www.researchgate.net/publircation/387567151_PARTIAL_REPLACEMENT_OF_CEMENT_WITH_RICE_HUSK_ASH_SUGARCANE_BAGASSE_ASH_REVIEW_PAPER
  7. Suri, Navleen & Chagger, Jeevanjot & Sharma, Er. Harish & Chandel, Dr. (2025). INVESTIGATION ON THE COMPRESSIVE STRENGTH WITH USE OF ScBA AND WPSA WITH PARTIAL REPLACEMENT OF CEMENT IN CONCRETE. Industrial Engineering Journal. Industrial Engineering Journal ISSN: 0970-2555 Volume: 54, Issue 4, April: 2025. https://www.researchgate.net/publication/391643772_INVESTIGATION_ON_THE_COMPRESSIVE_STRENGTH_WITH_USE_OF_ScBA_AND_WPSA_WITH_PARTIAL_REPLACEMENT_OF_CEMENT_IN_CONCRETE
  8. Chagger, Jeevanjot & Bala, Er & Sharma, Er. Harish. (2024). INVESTIGATE THE COMPRESSIVE STRENGTH OF CONCRETE USING FLY ASH ON M30 CONCRETE GRADE. Industrial Engineering Journal ISSN: 0970-2555 Volume: 53, Issue 6, No.5, June: 2024. https://www.researchgate.net/publication/387566115_INVESTIGATE_THE_COMPRESSIVE_STRENGTH_OF_CONCRETE_USING_FLY_ASH_ON_M30_CONCRETE_GRADE
  9. Singh, Er & Chagger, Jeevanjot. (2024). Review Study: Robotics and Automation in Construction, IRJIET, Volume 8, Issue 11, November 2024 pp. 260-264. 10.47001/IRJIET/2024.811033. https://www.researchgate.net/publication/396051331_Review_Study_Robotics_and_Automation_in_Construction
  10. Chagger, Jeevanjot & Sharma, Er. Harish. (2024). Review Study on Partial Replacement of Cement with Sugarcane Bagasse Ash (SCBA), National Conference on “Empowering Sustainability: Bridging Science, Technology and Climate Resilience” (ESBSTCR-2024), 17-19 Jan 2024; SBBS University, Jalandhar, Punjab. https://www.researchgate.net/publication/396270286_Review_Study_on_Partial_Replacement_of_Cement_with_Sugarcane_Bagasse_Ash_SCBA
  11. Chagger, Jeevanjot & Sharma, Er. Harish. (2024). A Review: ScBA& WPSA Used in Concrete as Partial Replacement of Cement, National Conference on “Empowering Sustainability: Bridging Science, Technology and Climate Resilience” (ESBSTCR-2024), 17-19 Jan 2024; SBBS University, Jalandhar, Punjab. https://www.researchgate.net/publication/396270282_A_Review_ScBA_WPSA_Used_in_Concrete_as_Partial_Replacement_of_Cement
  12. Chagger, Jeevanjot & Sharma, Er. Harish. (2024). A Review on Improving Asphalt Mixtures Through the Use of Geosynthetics and Waste Fibers, National Conference on “Empowering Sustainability: Bridging Science, Technology and Climate Resilience” (ESBSTCR-2024), 17-19 Jan 2024; SBBS University, Jalandhar, Punjab. https://www.researchgate.net/publication/387573908_A_Review_on_Improving_Asphalt_Mixtures_Through_the_Use_of_Geosynthetics_and_Waste_Fibers
  13. Mahi, Vishal & Chagger, Jeevanjot & Sharma, Er. Harish & Bala, Er. (2024). Performance Evaluation of Adhession in Recycled & Reused Construction Material in RCC, International Research Journal of Innovations in Engineering and Technology (IRJIET), ISSN (online): 2581-3048, Volume 8, Issue 1, pp 19-37, January-2024 https://doi.org/10.47001/IRJIET/2024.801004, https://www.researchgate.net/publication/387570170_Performance_Evaluation_of_Adhession_in_Recycled_Reused_Construction_Material_in_RCC
  14. Anmol, & Sharma, Er. Harish & Bala, Er & Chagger, Jeevanjot. (2023). An Examination the Use of Waste Glass Powder as Cement Partial Replacement in Concrete. International Research Journal of Innovations in Engineering and Technology (IRJIET) ISSN (online): 2581-3048 Volume 7, Issue 11, pp 343-355, November-2023 https://doi.org/10.47001/IRJIET/2023.711047, https://www.researchgate.net/publication/375826197_An_Examination_the_Use_of_Waste_Glass_Powder_as_Cement_Partial_Replacement_in_Concrete
  15. Chagger, Jeevanjot & Singh, Gurpreet & Mohit, (2023). A Review Study on The Use of Geosynthetics in Road Constructions. International Journal of Research Publication and Reviews, Vol 4, no 7, pp 518-522 July 2023,https://ijrpr.com/uploads/V4ISSUE7/IJRPR15273.pdf, https://www.researchgate.net/publication/396052553_A_Review_Study_on_The_Use_of_Geosynthetics_in_Road_Constructions
  16. Chagger, Jeevanjot. (2023). ASSESSING THE EFFECTIVENESS OF BAMBOO IN ENHANCING THE STRENGTH OF CONCRETE STRUCTURES: A REVIEW STUDY, International Journal of Engineering Technology Research & Management, Vol-07 Issue 07, 68-76, July-2023. https://www.researchgate.net/publication/396052546_ASSESSING_THE_EFFECTIVENESS_OF_BAMBOO_IN_ENHANCING_THE_STRENGTH_OF_CONCRETE_STRUCTURES_A_REVIEW_STUDY
  17. Singh, J.; Chandel, S.K.; Mohit; Singh, G. The Article Explores Improving the Performance of Asphalt Mixtures through the Utilization of Added Fibers. Int. Res. J. Innov. Eng. Technol. 2023, 7, 59–65. https://www.researchgate.net/publication/389533862_The_Article_Explores_Improving_the_Performance_of_Asphalt_Mixtures_through_the_Utilization_of_Added_Fibers
  18. Singh J, Mohit, Gurpreet Singh. Case study on partial replacement of cement with RHA. Int J Res Anal Rev (IJRAR). 2023;10(3):5-10. Available from: http://www.ijrar.org/IJRAR23C1002.pdf, https://www.researchgate.net/publication/389533760_Case_Study_on_Partial_Replacement_of_Cement_with_RHA
  19. J. Singh, D. S. Chandel, "An Examination and Investigation Compressive Strength the Use of Waste Paper Sludge Ash and Rice Husk Ash as Cement Substitutes in Concrete", International Journal of Innovative Research in Engineering and Management (IJIREM), Vol-10, Issue-3, Page No-60-66, 2023. Available from: https://doi.org/10.55524/ijirem.2023.10.3.11, https://www.researchgate.net/publication/372098556_An_Examination_and_Investigation_Compressive_Strength_the_Use_of_Waste_Paper_Sludge_Ash_and_Rice_Husk_Ash_as_Cement_Substitutes_in_Concrete
  20. Jeevanjot Singh, Mohit, Gurpreet Singh (July2023), “THE EXAMINATION STUDY TO INVESTIGATE THE EFFECTS OF USING A REDUCED AMOUNT OF CEMENT WITH WPSA, ‘International Research Journal of Modernization in Engineering Technology and Science, Volume:05/Issue:07/July-2023 Impact Factor- 7.868 www.irjmets.com, e-ISSN: 2582-5208. https://www.researchgate.net/publication/396052546_ASSESSING_THE_EFFECTIVENESS_OF_BAMBOO_IN_ENHANCING_THE_STRENGTH_OF_CONCRETE_STRUCTURES_A_REVIEW_STUDY
  21. Jeevanjot Singh, Dr. Sandeep Kumar Chandel, Mohit, Gurpreet Singh (2023), “A Study: How Using Waste Paper Sludge Ash and Rice Husk Ash Instead of Cement in Concrete, ‘Quest Journals Journal of Architecture and Civil Engineering, Volume 8 ~ Issue 7, pp: 20-29, ISSN (Online) :2321-8193, www.questjournals.org, https://www.researchgate.net/publication/396052558_A_Study_How_Using_Waste_Paper_Sludge_Ash_and_Rice_Husk_Ash_Instead_of_Cement_in_Concrete
  22. Thakur, Dr & Kumar, Naveen & Kaith, Sangharsh & Rana, Sanchit & Goyal, Pranshu & Tiwary, Aditya & Kumari Thakur, Ratnesh. (2022). A Critical Review on Fiber Reinforced Polymer Composites in Strengthening Reinforced Concrete Structure. 10.55524/ijirem.2022.9.2.88. https://www.researchgate.net/publication/362546639_A_Critical_Review_On_Fiber_Reinforced_Polymer_Composites_In_Strengthening_Reinforced_Concrete_Structure
  23. Thakur, Dr & Kumar, Manish. (2023). Study of mechanical properties of conventional concrete and for fibrous concrete with various volume fractions of micro and macro steel fibers. European Chemical Bulletin. volume 12. 672-685. 10.31838/ecb/2023.12.3.052, https://www.researchgate.net/publication/370204599_Study_of_mechanical_properties_of_conventional_concrete_and_for_fibrous_concrete_with_various_volume_fractions_of_micro_and_macro_steel_fibers
  24. Thakur, Dr. (2023). Enhancing the soils geotechnical properties by using plastic waste: A Review, Journal of Basic Science and Engineering. 23. 168-186. 10.37896/JBSV23.5/2096. https://www.researchgate.net/publication/370528028_Enhancing_the_soils_geotechnical_properties_by_using_plastic_waste_A_Review
  25. Yousuf, Saleem & Thakur, Dr. (2023). A Review Intelligent Transport System. GIS SCIENCE JOURNAL. volume 10. 2017-2045. https://www.researchgate.net/publication/371131269_A_Review_Intelligent_Transport_System
  26. Themisana, Rajkumari & Thakur, Dr &Thaguna, Parwati& Thounaojam, Anuradha &Senagah, Amenjor. (2023). TO DETERMINE THE STRENGTH OF CONCRETE WITH PARTIAL REPLACEMENT OF SAND WITH MARBLE DUST POWDER, Journal of Biomechanical Science and Engineering, Japan Society of Mechanical Engineers, ISSN: 1880-9863, Advances in Mechanical, Civil, Computer Engineering in respect Public Health and Safety, DOI 10.17605/OSF.IO/QD68N, https://www.researchgate.net/publication/372724255_TO_DETERMINE_THE_STRENGTH_OF_CONCRETE_WITH_PARTIAL_REPLACEMENT_OF_SAND_WITH_MARBLE_DUST_POWDER