Reinforcing Iron and Rebar Workers

In some parts of their job, rebar workers are already getting robotic help. For example, TyBOT is a machine that moves along road or bridge forms and ties steel bars to each other – it can tie over 1,200 connections per hour, far faster than a person ^[1]. Researchers at Hong Kong University also built a robot that “swiftly” travels along steel rods and automatically ties them at each intersection ^[2].

Another company (ACR) has made an “IronBOT” that places and positions rebar on bridge decks for workers ^[3]. These machines use cameras or sensors and make repetitive tying or placing tasks much faster and safer.

Most other tasks are still done by people. Workers today measure, cut, bend, and weld rods by hand (using tools and bending machines), and they read blueprints to decide where each rod goes. AI and robots haven’t replaced that on-the-spot judgment work.

In fact, builders train ironworkers to use the new machines. ACR’s CEO says ironworkers call these robots “tools of the trade” – they take courses to operate TyBOT or IronBOT so the workers can get more work done safely ^[3]. In short, machines are starting to do the hurting, tedious part (tying and moving steel), while people still handle the planning, cutting, welding, and final fit.

Whether companies use these robots quickly or slowly depends on several things. One big factor is cost. A TyBOT robot costs on the order of $425,000 (including training) for a wide system ^[3], which is like many years of one worker’s salary.

That high price makes firms careful. But the payoff can be large: in practice, contractors report TyBOT cuts rebar labor by about 25% ^[3]. To manage costs, some firms rent the robot as a service instead of buying it outright ^[3].

Industry studies note that high upfront costs and the chaotic nature of construction sites are major hurdles for automation ^{[4] [4]}.

Another factor is labor conditions. Some people believe there really isn’t a worker shortage but rather not enough steady jobs ^[5]. If lots of trained ironworkers are available, a builder might not rush to invest in robots.

On the other hand, when jobs are risky or hard to fill, companies are more eager for automation. Social acceptance also matters: here, unions see robots as helpers. ACR works with the Ironworkers union to train members on the bots ^[3].

By learning to use new tools, workers keep their jobs and stay safe under heavy rebar cages. In the end, AI and robots are likely to be tools that skilled ironworkers use to speed up tough tasks and reduce injury, rather than replacing people. This way, human skill – in reading plans, solving problems, and fine work – will still be very valuable on the job.