Project Details
Projekt
Flow-production methods for adaptive material-minimized modular slabs with micro-prestressing and high-precision joints
Subject Area
Structural Engineering, Building Informatics and Construction Operation
Term
since 2022
Project identifier
Deutsche Forschungsgemeinschaft (DFG) - Project number 510048037
The objective of this research is to develop an efficient flow-production methodology for the industrialized fabrication of material-optimized, high-precision floor slab modules. We aim to characterize the structural behavior of both, individual modules with complex geometry and fully-assembled adaptive slab systems and will devise a consistent set of mechanical models for general design of precast modular members with minimized material demand. Engineering methods accounting for the arrangement of supports, static-mechanical principles and fabrication constraints defined through the flow-production process are used to fractionize the floor slab layout into viable module geometries. Each floor slab module consists of a thin top slab and a contoured rib structure and is made from high-performance materials. All modules are prestressed by directly bonded high-strength micro-reinforcement located in the global tension zone of each module. Additional reinforcement is largely omitted. High fabrication speed and reliability of execution through use of robots are essential criteria in the development of the production process. The produced high-precision slab modules are assembled using detachable joints and externally prestressed to form a braced slab system. To achieve the research objectives, a coordinated work program consisting of coordinated experimental and theoretical investigations is proposed: In WP 1, we will develop flow-production methods for individual modules and set up a scripting platform to digitally link planning and manufacturing, including all interactions. Investigations on micro-prestressing with direct bond (WP 2) and on the design of joints (WP 3) clarify fundamental issues of the new modular construction method and provide physical models to describe the transfer of prestressing, to predict the ultimate capacity of the joints and to analyze their load transfer mechanisms. WP 4 extends existing physical models for shear and punching shear behavior to micro-prestressed, ribbed cross-sections, which allow us to fundamentally describe the structural performance of precast material-minimized modules. The assembly of a demonstrator in WP 5 will provide insights into system behavior, and production tolerances and deformations, which are necessary for automated manufacturing. The planned work program will provide a fundamental methodology for automated flow-production, structural design, and assembly of adaptive modular slabs in high-rise structures. Since the new fabrication methods for adaptive and reusable floor slabs yield material savings of 60–70% compared to conventional massive flat slabs while maintaining the same structural resistances, the project substantially fosters resource efficiency and CO2 savings in concrete construction.
DFG Programme
Priority Programmes
