THOREAQ, the testbed for construction and energy innovation

In THOREAQ we test, validate and demonstrate in a real-life environment:

• smart renovation solutions
• techniques that improve indoor air quality
• energy systems and their integration in buildings
• innovations in industrially fabricated envelope components
• breakthroughs in automated construction methods

The strength of THOREAQ lies in three unique and mutually reinforcing test environments. Two identical lab houses, the robotics lab and the outdoor construction lab together lift research and innovation in the construction and energy sector to a higher level. This leading combination of test facilities makes it possible to carry out every step – from experiment to field trial – in one location.

Double lab houses: testing ground for residential construction innovation

The Socio-economic policytwo identical lab houses at Thor Park form a unique test environment for innovation in the residential construction sector. Here, companies and researchers can test, validate and demonstrate new solutions for the building envelope (new build and renovation), indoor air quality, HVAC installations, energy systems and energy management in real life.

Comparative tests under identical conditions

Because both houses are built identically – with the same construction, orientation, solar exposure and shading – precise A/B tests are possible. By changing one parameter in one house, the effect can be measured directly and reliably. Each house is equipped for this with an extensive network of sensors and controllable components.

Virtual occupants and usage simulations

To mimic real user behaviour, the houses are equipped with virtual occupants. These devices emit heat, moisture and CO₂, just like people do. Windows, interior doors, screens, heating, cooling, ventilation and shower are also fully controllable to simulate occupancy. With software, user profiles of up to five people per house can be set.

Flexible building envelope and plug-and-play technologies

The houses have a modular exterior envelope. Three of the four façades can be easily replaced by other façade assemblies (lightweight, curtain wall or heavyweight façades). In adapted set-ups, the positions of windows and doors can be changed. The pitched sections of the roofs are demountable, so alternative roof assemblies can be tested without impacting stability. Thanks to the available plug-and-play technologies, diverse combinations can be installed quickly.

Advanced energy infrastructure

Both houses are connected to the CollecThor network, an innovative 5th-generation thermal network at Thor Park that provides both heating and cooling. In the basements of the houses there is space for alternative generation systems, which can be easily connected to the free connection points of the collectors. Every room is equipped with underfloor heating, radiators and fan coil units, and prepared for the installation of air conditioning. For ventilation, both system C and D are possible.

Smart control and data collection

Each room has its own electrical panel with a PLC system for controlling actuators and devices, and for reading out data. Cable ducts make it easy to adjust or expand electrical installations and sensors. This keeps the research environment flexible and future-proof.

Open to companies and research partners

The lab houses are accessible to companies that want to test, optimise and demonstrate their products and services full-scale in a safe, controlled and practice-oriented environment. Collaboration between different partners stimulates cross-fertilisation and enables integrated total solutions in which systems and services reinforce each other.

Robotics lab for sustainable and automated construction innovation

The construction sector is under pressure. Stricter environmental regulations, higher requirements for energy efficiency, labour shortages and the need for circular and climate-resilient solutions call for change. At the same time, breakthroughs in materials science, robotics, AI and smart construction technologies are creating new opportunities.

In that context, the robotics lab develops innovative building-envelope systems and automated construction methods that stimulate both product and process innovation.

The lab supports research into:

• sustainable and circular construction processes
• robust and multifunctional performance
• affordability and broad applicability
• more efficiency and safety on site thanks to automation

With its active role in European and Flemish research projects and strategic collaborations with industrial partners, the robotics lab helps build a future-oriented, climate-neutral construction sector.

Top technology

The robotics lab has an advanced robotic installation to test innovative construction methods, both off-site and on-site. The infrastructure consists of:

• a modular linear motion system as a seventh axis for the robot arm, with high speed, accuracy and flexibility – enabling tools and components to be moved across a large work area
• a multifunctional industrial robot arm (payload 150 kg), suitable for complex operations
• an optical tracking system with 10 cameras, for real-time tracking of robot and objects, accurate positioning, quality control and safe human-machine interaction

This infrastructure forms a powerful environment to develop and demonstrate tomorrow’s construction technologies, with a focus on sustainability, automation and innovation.

Outdoor construction lab for testing and validating construction solutions

The outdoor construction lab is a unique test and demonstration environment that simulates real construction-site conditions. The enclosed outdoor area of 18 by 23 meters is large enough for the use of hoists, boom lifts and scissor lifts. In the centre of the test zone, there will be a concrete core on which structures can be built and realistic scenarios can be simulated. More details about the equipment of the construction lab will follow soon.

Extensive testing possibilities

The lab offers extensive possibilities for testing, for both robotics and other research. Among other things:

• assembling and testing temporary structures up to 11 meters high, in various materials
• evaluating building-envelope systems and their performance, such as airtightness, thermal behaviour and watertightness
• testing automated and traditional construction methods, including robot-assisted applications
• monitoring and measurement with drones, scanners and sensors
• lifting and transport activities with cranes, forklifts and other machines

Complement to the robotics lab

Although the construction outdoor lab can be used independently, it is a strong complement to the robotics lab. Innovations developed there can be further tested and validated here under real-life conditions.

A concrete example is the RENOMIZE project, in which the outdoor lab is used to test a self-positioning system with tool heads (such as gripper, drill head or other tool) for the installation of anchors and prefab panels, developed by VITO.

Interested?

Interested in testing your products within the THOREAQ environment? Or would you like an exploratory conversation about the possibilities of the THOREAQ facilities? Feel free to contact Margo Colson, THOREAQ project manager, or Kris Boonen, THOREAQ Business Developer.

The role of VITO

THOREAQ was realised by VITO at EnergyVille and is part of the Open Thor Living Lab infrastructure at Thor Park in Genk, a science and business park where the energy transition, smart manufacturing and smart city applications take centre stage.

THOREAQ was made possible with the support of the European Regional Development Fund (ERDF) REACT-EU and the Flemish Fund for Innovation and Entrepreneurship.