How Pilar and Wirtek are transforming sustainable construction through IoT‑driven screw foundation technology, cutting CO₂ emissions by up to 85%

Summary

With sustainability at the forefront and increasing pressure to comply with the EU’s Energy Performance of Buildings Directive (EPBD), the construction industry is embracing innovative solutions to cut CO₂ emissions and drive environmentally conscious progress. Traditional concrete foundations are among the largest contributors to emissions in new buildings, and concrete is the second most‑used substance in the world, only trumped by water. Screw pile foundations provide a groundbreaking, sustainable alternative capable of reducing CO₂ emissions by up to 85% compared to concrete.

Showcase results

• 85% CO₂ reduction compared to traditional concrete foundations.

• Integrated SaaS solution for seamless data capture and compliance monitoring.

• Optimized installation process, minimizing material waste and reducing project costs.

• 98% time reduction in installing foundations with screw piles compared to concrete processes like pouring and curing.

Challenge

The widespread deployment of screw pile foundations faces hurdles. Without precise measurements and correct documentation, regulators and insurers resist the technology due to load‑bearing capacity concerns. Construction companies need a reliable, automated system that ensures alignment with building regulations and eliminates risks of over/under‑dimensioning, incorrect placement or installation failures—all while minimizing documentation to ease the transition from traditional concrete structures to the greener alternative that screw piles offer.

Solution

To address these hurdles, Pilar developed an innovative cloud‑based SaaS solution combined with an advanced IoT measuring and guidance system. The IoT Smarttorq Unit uses high‑precision sensors and advanced algorithms to measure stress, depth and torsion in drilling equipment, utilizing edge computing to give live feedback to the installer and mitigate risks and errors. It fills a critical industry gap: the lack of a precise method for measuring key installation parameters.

Recognizing the need for a technology partner, Pilar partnered with Seluxit (now part of Wirtek) to build a new IoT‑powered solution for the Smarttorq Unit, integrating high‑precision sensor technology and advanced software. Wirtek’s expertise in smart systems, energy software development services, and hardware is key to delivering accurate measurement, real‑time optimization and seamless calibration of drilling equipment. The new IoT Smarttorq Unit is engineered for resilience and high performance in tough environments such as construction sites, and ongoing R&D is creating a sensor‑equipped system capable of detecting the smallest variations in installation measurements, preventing failures and ensuring safe, efficient and scalable installation.

Unlocking Growth in Clean Tech Solutions

Wirtek has become a trusted partner to Pilar, reinforcing its strategic expansion beyond traditional IT services into scalable, high‑impact solutions. Wirtek’s acquisition of Seluxit and Pragmasoft accelerates its growth in IoT, automation and subscription‑based revenue models. By collaborating with Pilar, Wirtek strengthens its commitment to Clean and Green Energy, positioning itself in the rapidly expanding IoT in the Energy market. This partnership is paving the way for a more sustainable and efficient future in construction, bringing the industry closer to carbon neutrality.

Services

• Prototyping

• Electronic design, Schematic / PCB

• Firmware development

• CE Certification

• Production / Test

• Energy software development services

Results

Although still in development, Pilar’s collaboration with Wirtek is creating the world’s first comprehensive monitoring device for screw pile installations, demonstrating its value to a broader audience. This geotechnical engineering tool accurately captures the parameters needed to document screw pile installations:

• Compliance & Structural Reliability – real‑time monitoring captures torsion, speed, advancement ratio and depth, ensuring reliable installation and regulatory approval

• Automation & Faster Construction – IoT‑powered measurement streamlines the installation process and minimizes the risk of errors, leading to faster project completions

• Sustainability & Cost Savings – optimized material use reduces waste, lowers costs and supports greener construction practices

This scientifically validated solution makes screw pile foundations a reliable and scalable alternative to concrete, helping the construction industry achieve sustainability goals while maintaining performance and safety standards.

Technologies and Frameworks

• ESP‑IDF Espressif IoT Development Framework

• High‑precision analog data acquisition

• Wi‑Fi

• Sensor fusion, 9‑DOF

• Battery‑powered device

• Altium / KiCad for schematic and PCB design

Client testimonial

Mikkel Ibsen, CEO & Co‑Founder of Pilar, states that developing a first‑of‑its‑kind innovative IoT device is not straightforward; obstacles and challenges require altering plans and theories. He credits Wirtek’s expertise and adaptability in overcoming these challenges as crucial in developing a state‑of‑the‑art IoT device while staying on schedule. Their support ensured Pilar did not fail in the quest to create an IoT device that can be used universally among all screw pile installers and remain reliable and robust for tough environments.

About Pilar

Pilar, winner of the prestigious Velux and Villum Foundation’s Building Component Prize (2023), is a visionary force in the construction sector. Born from cutting‑edge research at Aalborg University, the company bridges academic excellence with practical application in its mission to revolutionize sustainable construction through technology.