Intelligent modularization for scalable concrete construction by adaptation of the methods for modular construction development

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Modular construction with construction kit systems in combination with serial flow production of prefabricated concrete members made of high-performance materials and their representation in continuous digital models offers a resource saving and economical alternative to conventional reinforced concrete construction methods due to short construction times with slender segments. In the first funding period of the research project, the transfer of basic methodical concepts to develop modular systems used by mechanical engineering to civil engineering problems was investigated for straight structures. For the example of frame construction subdivided into modules, methods were explored to achieve a large external (many buildings) with small internal variety (few module variants). To solve this research question, the Institute of Product Development (IPEK) developed an optimisation approach for modular systems that takes into account requirements of building structures, materials and number of joints. It enables the identification of resource-saving module variants which are easy to transport and to assemble. The Institute of Concrete Structures and Building Materials (IMB) investigates rigid frame structures composed of modules with theoretical and experimental methods. In particular, initially the force transmission in dry joints, concentrated loading and the load-carrying behaviour of prestressed modularly assembled members were investigated. The objective of the second funding period is the research of novel modular systems for building construction, which enable a great architectural variety by means of curved structural members at the same time. Based on the results of the first funding period, intermediate components are investigated which are used to establish curved members (in-plan and out-of-plane) with partly straight beam and plate elements. Further, the integration of components for special single use purposes into the modular system and the formulation of the associated rules and standards are explored. IPEK develops methods for assessing whether a component should be included in the modular system as a module or as a special component. Furthermore, it is explored which architecture, modules and module variants are essential for a modular system for frame buildings including curved structures. At IMB, nodes made of high-performance materials under multi-axial loading are investigated using theoretical and experimental methods. In addition, materials, prestressing as well as joining techniques are explored to establish load-bearing structures with curved shapes by prestressing using straight regular and intermediate components, which are reusable for further applications. Meeting the objectives of this research project will allow for resource, time and construction cost savings. The interdisciplinary collaboration of both institutes promotes the transfer of knowledge between institutions of product development and concrete structures.