The construction industry is no stranger to technological evolution. From the days of blueprints and tape measures to today’s digital environments, the tools and methods used to bring projects to life have continuously evolved. One critical innovation shaping modern workflows is the use of robotic total stations. These advanced digital layout tools are streamlining operations, improving precision, and reimagining how construction projects are executed.
David Mueller, VDC Manager at Stellar, offered valuable insights into this transformation in a recent Tech Insider interview. His firsthand experiences illuminate how technologies like robotic total stations are helping construction professionals solve problems and achieve unprecedented efficiency. “We have about a dozen items that we will lay out or verify in the field, depending on whether we’re self-performing the work or verifying what our trade partners have done,” he says. “We’re looking to grow that out exponentially here in the future. The technology is providing substantial efficiency gains.”
From Tape Measures to Total Stations
Before robotic total stations, construction teams relied heavily on manual tools and processes to execute layouts. These included 2D plans and tape measures. While reliable, these methods were time-consuming and prone to human error, particularly on large-scale projects like foundations and structural layouts.
“Teams would use 2D plans, either a PDF or a hard copy out on site, and pull tape measures from a known point to another point,” Mueller explains. He notes the inefficiency of these methods, especially for tasks like anchoring bolts in massive facilities. “It’d be very time-consuming to go out and verify that everything had been put in place before concrete arrives on site.”
This workflow, while tried and true, often introduced unnecessary delays, risks, and inaccuracies—an outcome that the industry could simply no longer afford.
The Role of Robotic Total Stations
Robotic total stations have revolutionized how contractors approach project layouts. These devices connect digital design models with real-world sites for precise measurements and layout verification. Stellar, for instance, uses the Leica iCON robotic total stations to integrate their physical and digital workflows.
“Leica is such a name brand in this industry with technology. There are competitors out there that do things very similarly, but the support that I’ve gotten over the years from Leica—not just at Stellar, but at previous jobs using Leica equipment—the technical support and the speed that support comes to us and helps us resolve problems is unmatched.”
The ability to quickly correlate what’s in the field to the design model significantly reduces the time needed for layout and eliminates many of the inconsistencies seen with manual methods.
A prime example is the verification of anchor bolts before pouring concrete. Rather than pulling tape manually over a 100,000-square-foot area, total stations make it possible to complete this task with remarkable efficiency and accuracy. “You’ve got your form set up, pouring foundations… it really is a massive time saver to verify,” says Mueller.
“Leica is such a name brand in this industry with technology. … The support that I’ve gotten over the years from Leica—not just at Stellar, but at previous jobs using Leica equipment—the technical support and the speed that support comes to us and helps us resolve problems is unmatched.”
—David Mueller, VDC Manager, Stellar
Benefits and ROI
The benefits of total stations go beyond just saving time. They enhance accuracy, reduce errors, and provide peace of mind by ensuring correct implementation. “You also have accuracy improvements because you have much better accuracy than you would with a tape measure,” notes Mueller.
More importantly, the sense of assurance they provide can be invaluable. “Having the peace of mind knowing that we went out and verified all of this work is where it’s supposed to be … has a benefit all on its own.”
Mueller notes there is a clear return on investment when technology identifies construction issues early, such as misaligned anchor bolts or clashes between ductwork and piping. He explains, “You can look at that and say you just saved 15 grand of having to tear concrete out and do it over.” By catching these problems digitally, significant savings are realized compared to addressing them in the field.
However, when technology verifies that everything is correctly placed, the focus shifts to efficiency gains, such as how much faster verification and construction can occur.
A commitment to innovation and technology makes advocating for these advancements easier. “I’m very thankful to have the opportunity at Stellar to be able to push technology forward,” he says.
The Importance of Employee Buy-In
For any new technology to succeed, cultural adoption is key—and robotic total stations are no exception. Mueller stresses the importance of training and employee buy-in to fully realize the benefits of advanced tools. “You have to make sure your model is correct. You have to make sure you have adequate site control,” he explains, highlighting that there are no shortcuts when adopting new processes.
Implementing technology also requires strong leadership support. At Stellar, their top-down approach to encouraging innovation plays a pivotal role in building employee trust and enthusiasm. “From the very top of the company down, we’ve got the support to research technology, [and] identify what might work,” says Mueller.
With proper training and organizational backing, teams can overcome the learning curves and fully integrate these tools into their workflows, setting the stage for long-term efficiencies.
Essential Technology Questions
Transitioning from traditional methods to digital layout with robotic total stations is a game-changer for the construction industry. Beyond reducing costs and improving project timelines, these technologies foster collaboration, enhance accuracy, and elevate client satisfaction.
Adopting tools like robotic total stations isn’t just about keeping up with modern trends—it’s about solving problems, creating value, and enabling seamless workflows for construction teams.
For professionals searching for ways to stay competitive, leveraging digital layout technology is a step toward maximizing project potential and entering the future of construction with confidence.
Mueller provides some parting guidance for overcoming internal technology investment hurdles. “Does the technology increase efficiency? Does it make you faster at what you’re doing as a company? Does it make you more accurate? Is it something that your client wants or is requesting? Does it fit your company and the projects that you’re working on?” he says. “Understand those things, and then make a case for it.”
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