Development of an adaptable manufacturing process for modular lightweight concrete components using fully recyclable formwork systems

由于人口增长和自然资源日益稀缺，建筑业面临着用更少的材料建设更多的任务。在这方面，DFG优先方案2187的贡献具有重大的社会意义。通过加快生产过程，可以在更短的时间内建造更多的产品。所需的高精度还允许设计和实施能够以最少的材料完成任务的组件。计划中的SPP 2187“采用流水线制造方法的自适应模块化建造方法”宣布的目标是在模块化结构的基础上进行交互式、工业化的建造。模块化结构应基于新的流水线装配方法，通过生产确保部件以及整个系统的适应性、可变性和感官智能等特性。在工业制造技术中，加法制造被认为是实现这些目标的关键技术。如果一个人想要与工业制造技术竞争，那么将这种工艺提供给建筑业是明智的，即使生产线组装本身在该领域还不是普遍的做法。现在已经认识到，基于具有相同个体属性的模块并使用附加制造工艺来制造个体的、可扩展的产品是可以成功的。单元边界和连接接口的定义是在该制造方法中生产模块的相关因素。这些因素从根本上决定了模块的质量，包括。可实现的装配精度、加固材料的应用、部件信息的质量、成形性等。参与研究的研究机构将自己视为按照生产线装配过程中的信息流改革混凝土结构的关键一环。其基础是最新开发的水文绘图方法，该方法通过沿着指定的路径有选择地向沙子和有机粘结剂的混合物中注入水来生产空间的、完全可回收的模板。进一步的后续工艺产生稳定的模板，可以通过在模板中加入水来溶解模板，然后重复使用。通过将模板生产的这一过程与添加剂生产相结合，使得这两种方法可以组合为一个分层工艺，就有可能生产出单独的、结构可适应的和纤维增强的模块化部件。

Due to the population growth and increasing scarcity of natural resources, the construction industry is faced with the task of building more with less material. In this context, the contribution of DFG Priority Programme 2187 is of a great social relevance. By accelerating production processes, more can be built in less time. The required high precision also allows design and implementation of components that can fulfill their tasks with a minimum use of material. The declared goal of the planned SPP 2187 "Adaptive modular construction methods with flow manufacturing methods" is interactive, industrialized construction on the basis of modular structures. Modular structures should secure properties such as adaptability, changeability and sensory intelligence for the parts as well for the whole system through the production based on a new line assembly methodology. In industrial manufacturing technology, additive manufacturing is regarded as a key technology for achieving these goals. If one wants to compete with industrial manufacturing technology, so it is advisable to make such processes available for the construction industry, even if line assembly itself is not yet the widespread practice in that field. It has now been recognized that the manufacture of individual, scalable products, based on modules with equal individual properties and using additive manufacturing processes, can be successful. The definition of unit boundaries and the connecting interfaces are relevant factors for the production of modules within this manufacturing approach. Those factors fundamentally determine the quality of the modules, incl. achievable assembly accuracy, application of reinforcing materials, quality of the information about components, formability, etc. The participating research institutes see themselves in this new research approach as a key link in reforming the concrete construction in accordance with the information flow within the line assembly processes. The basis for that is the newly developed hydroplotting method, which makes it possible to produce spatial, fully recyclable formwork by selectively injecting water into a mixture of sand and organic binder along a specified path. Further subsequent processes produce stable formwork, which can be dissolved by the adding the water inside it and repeatedly used afterwards. By coupling this process of the formwork production with an additive production in such a way that these two methods can be combined as one layered process, it becomes possible to produce individual, structurally adaptable and fibre-reinforced modular components.