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造更多建筑的任务。在这方面，DFG优先方案2187的贡献具有很大的社会意义。通过加快生产流程，可以在更短的时间内生产更多产品。所需的高精度还允许设计和实施能够以最少的材料使用完成其任务的组件。SPP 2187计划的目标是“自适应模块化施工方法与流程制造方法”，是基于模块化结构的交互式工业化施工。模块化结构应确保零件以及整个系统的适应性、可变性和感官智能等特性，以新的生产线装配方法为基础进行生产。 在工业制造技术中，增材制造被视为实现这些目标的关键技术。如果一个人想与工业制造技术竞争，那么建议将这些过程用于建筑行业，即使流水线装配本身在该领域还没有广泛应用。现在已经认识到，基于具有相同个体属性的模块并使用增材制造工艺来制造个体的可扩展产品是可以成功的。单元边界和连接接口的定义是在这种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、增强材料的应用、有关部件的信息质量、可成形性等。参与研究的研究机构将自己视为根据生产线装配过程中的信息流改革混凝土结构的关键环节。 其基础是最新开发的水力绘图法，通过选择性地将水注入沙子和有机粘结剂的混合物中，沿着特定的路径沿着，可以生产出空间性的、完全可回收的模板。后续的工艺生产出稳定的模板，可以通过向其中加水溶解并重复使用。通过将该模板生产过程与增材生产相结合，使得这两种方法可以组合为一个分层过程，可以生产单个的、结构上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.