Cooperation between KUKA and KLEUSBERG: Automated Manufacturing in Modular Construction

Automation for modern homebuilding: KUKA, an internationally active automation group, and KLEUSBERG, a leading specialist in modular construction and mobile space systems, have announced their cooperation. The goal of the collaboration is to modernize production at the KLEUSBERG plant near Halle (Saale) and automate it using KUKA robots.

23 October, 2025

Starting in 2027, floor and ceiling frames for modular construction will be manufactured using a highly flexible, robot-based welding system. This turnkey system, supplied by KUKA, uses state-of-the-art automation technology to enable nearly fully automated production.

Five KUKA robots weld more than two thousand meters of floor and ceiling frames

The heart of the system consists of five robots that are programmed independently of the product, allowing for customized frame production. The more than 1,000 square meter production area enables efficient manufacturing. Each week, over 2,000 meters of 2D frames are expected to be welded together.
“In addition to increasing efficiency, improving working conditions played a significant role in the decision to automate, aiming to reduce health risks for employees caused by physically demanding postures. Furthermore, new technically oriented job roles are being created,” says Oliver Hartmann, Managing Director of Modular Construction at KLEUSBERG.

Precision and quality:Robots like these weld the floor and ceiling elements together in the system. (Symbolicimage, source: KUKA Group)

Digital and automated – for flexible and efficient production

Thanks to automatic collision checks before production starts and barrier-free data handling with other factory systems, a smooth process is ensured. “Maximum precision is always the focus in robot-based automation. The system can position components exactly and visually inspect the weld seams for quality,” says Andre Zander, Key Account Manager at KUKA Systems Assembly & Test.

About Modular Construction

Modular construction is a modern building method using industrially prefabricated room modules based on a modular principle. This type of construction, also known as system construction or serial construction, typically uses steel frame structures but can also be realized with wooden modules. Serial and industrial prefabrication in the factory, combined with digital processes, not only offers cost and planning reliability but also enables significantly faster completion of construction projects compared to conventional methods.