A shortage of skilled labour in Canada’s construction sector is intensifying pressure on efforts to deliver new housing at scale. With demand for housing continuing to outpace supply, the gap between workforce availability and construction requirements has become increasingly pronounced.
Amid growing pressure to expand housing supply, Horizon Legacy, a Canadian real estate developer, has been exploring automation as a way to address labour constraints in housing delivery. The company has partnered with ABB Robotics, an industrial robotics company, to deploy on-site robotic systems for residential construction.
An estimated 500,000 additional workers may be required to support the construction of 4.8 million affordable homes needed by 2035, according to the Royal Bank of Canada, reflecting the scale of the workforce challenge.
The development reflects a broader push in the construction industry to test automation-led approaches to address workforce constraints and delivery pressures in housing projects.
On-site robotic system used for 3D concrete construction in Ontario
The collaboration has led to the deployment of an on-site robotic system in Gananoque, Ontario, where a housing project comprising 26 townhouse units was constructed.
The system is based on a modified six-axis robot from ABB Robotics, adapted for 3D concrete printing and operated under the name VAL 2.0. The setup enabled construction activities to take place directly on site, rather than in a controlled factory setting.
While presented as a single housing project, the deployment signals how robotic systems are being tested in real-world, on-site construction environments rather than controlled industrial settings.
Horizon Legacy integrated the robotic system with ABB Robotics’ RobotStudio® programming and simulation software, allowing adjustments during the build process and enabling testing of different construction approaches in real time.
The project used an all-electric, low-waste construction method, with material applied in precise quantities during the printing process. This approach resulted in substantially less waste compared with traditional building techniques.
The use of on-site robotics also reduced labour requirements, while enabling the creation of complex structural forms that would be difficult to achieve through conventional construction methods.
However, the project remains within a controlled pilot environment, where performance outcomes and scalability to larger, more complex developments are yet to be established.
Engineering support and field performance in challenging conditions
ABB Robotics engineers supported the project throughout development and deployment, assisting with technical challenges related to calibration and system performance. This included managing vibration at the tool centre point and optimising the robot’s movement across multiple positions required during construction.
The robotic system operated in outdoor, dusty construction-site conditions, maintaining stable performance that allowed work to continue with limited disruption.
ABB Robotics also provided additional technical support during the project, including assistance with sourcing critical hardware when supply chain delays posed risks to the timeline.
Nicolas Durand, former General Manager of ABB Robotics Canada, said the collaboration demonstrated the potential to extend robotics applications beyond manufacturing into construction environments, where systems must handle repetitive, demanding tasks under variable conditions.
The collaboration also highlights how robotics providers are being integrated into construction workflows not just as equipment suppliers, but as technical partners during deployment in non-standard environments.
The project is described as a proof of concept, with Horizon Legacy assessing additional opportunities to integrate automation into other stages of the construction process. It points to ongoing experimentation with robotic construction methods as developers explore pathways towards more automated housing delivery models.
The company is moving towards a phase of commercial rollout and wider deployment of robotic construction systems aimed at supporting future housing delivery.
