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

Applicants

Prof. Dr.-Ing. Dr. h. c. Albert Albers Karlsruher Institut für Technologie, IPEK – Institut für Produktentwicklung

Prof. Dr.-Ing. Lothar Stempniewski Karlsruher Institut für Technologie, Institut für Massivbau und Baustofftechnologie (IMB) – Abteilung Massivbau

Scientific staff

IPEK – Institut für Produktentwicklung, Karlsruher Institut für Technologie (KIT)

Agemar Manny, M. Sc., Institut für Massivbau und Baustofftechnologie (IMB) – Abteilung Massivbau, Karlsruher Institut für Technologie (KIT)

Project description

Modular construction methods make it possible to standardize products and processes in component production. Furthermore, these methods form a basis for taking advantage of economies of scale throughout the entire product life cycle. Ultra-high performance concretes with carbon and textile reinforcement make it possible to construct buildings that are more durable and additionally represent an economical and ecological alternative to regular reinforced concrete. The aim of the joint research project is the transfer of the methodical concept of construction kits and basic development from the field of mechanical engineering to civil engineering as well as the investigation of the ultra-high performance concrete components of the kit and the zero tolerance dry joints between them. Standardized modules can be produced efficiently and subsequently mounted on the construction site in a time and cost-effective manner. The segmentation process considers skeleton construction, which delineates a high flexibility in plan and elevation as well as an ideal construction type for the implementation of construction kit structure. The focus of the research project on part of the Institute of Concrete Structures and Building Materials (IMB) – Department of Concrete Structures is the development of a basic concept for the construction of rigid frames by using construction kit modules and series. The prefabricated elements are braced by implemented tendons, which form an entire support structure. Hereby the questions arise, how to ensure the static requirements for the force transfer in the zero tolerance dry joints, the standardized design of the interfaces between tendon and component, the correct implementation of the textile reinforcement within the component and the segment dimensioning of the high-performance components. The focus of the research project on part of the IPEK – Institute of Product Engineering is the construction kit development and its construction series development in the civil engineering context to make the efficiency and effectiveness advantages of this method available to civil engineering. Additionally the optimization of the construction kit architecture by an evolutionary algorithm, to gain a minimal inside diversity by getting a maximal outside diversity, is part of the aim. In particular, the selection of the construction kit’s architecture, the determination of necessary modules and the definition of specific dimensions will be investigated. The fulfilment of the defined aims in the joint research project facilitates the usage of the developed construction kit material, construction time and construction cost savings. The interdisciplinary work of both institutes facilitates the optimal knowledge exchange and transfer between the fields of civil engineering and mechanical engineering.

Poster on the project contents

Figure 1: Skeleton construction, modules and variants

Figure 2: Schematic illustration of a frame node

Publications

2023

[7] Kolbeck, L.; Kovaleva, D.; Manny, A.; Stieler, D.; Rettinger, M.; Renz, R.; Tošić, Z.; Teschemacher, T.; Stindt, J.; Forman, P.; Borrmann, A.; Blandini, L.; Stempniewski, L.; Stark, A.; Menges, A.; Schlaich, M.; Albers, A.; Lordick, D.; Bletzinger, K.-U.; Mark, P.
Modularisation Strategies for Individualised Precast Construction—Conceptual Fundamentals and Research Directions
Designs 2023, 7, 143. https://doi.org/10.3390/designs7060143

2022

[6] Manny, A.; Renz, R.; Albers, A.; Stempniewski, L.; Stark, A.
Numerical study on the behaviour of an innovative concrete dry joint: Investigations under shear loading
Proc. of the 14th fib International PhD Symposium in Civil Engineering

[5] Renz, R.; Sahin, K.; Albers, A.; Manny, A.; Stark, A.
Intelligente Modularisierung von Gebäuden für den Baukastenentwurf
NAFEMS Seminar: Generative Design und Optimierung.

[4] Manny, A.; Stempniewski, L.; Albers, A.; Simons, K.
Conceptual Design and Investigation of an Innovative Joint for the Rapid and Precise Assembly of Precast UHPC Elements.
Engineering Structures.

2021

[3] Mark, P.; Lanza, G.; Lordick, D.; Albers, A.; König, M.; Borrmann, A.; Stempniewski, L.; Forman, P.; Frey, A.; Renz, R.; Manny, A., Stindt, J.
Industrializing precast production - adaptive modularized constructions made in a flux
Civil Engineering Design 3(3), 2021, pp. 87-98. (DOI: 10.1002/cend.202100019)

[2] Mark, P.; Lanza, G.; Lordick, D.; Albers, A.; König, M.; Borrmann, A.; Stempniewski, L.; Forman, P.; Frey, A.; Renz, R.; Manny, A.
Vom Handwerk zur individualisierten Serienfertigung - Schwerpunkt adaptive Modulbauweisen mit Fließfertigungsmethoden
Bautechnik 98(3), 2021, S. 243-256. (https://doi.org/10.1002/bate.202000110)

2020

[1] Albers, A.; Stempniewski, L.; Kempf, C.; Manny, A.; Renz, R.; Spadinger, M.:
Intelligente Modularisierung für den skalierbaren Betonbau durch Adaption der Methoden zur Baukastenentwicklung.
In: BetonWerk International Nr. 3, 2020, S. 27
Link zum Artikel

Supervised theses

2022

[7] Masterarbeit, Konzeptionelle Entwicklung eines modularen Deckensystems für den Hochbau, 2022.
Karlsruher Institut für Technologie (KIT), Institut für Massivbau und Baustofftechnologie – Abteilung Massivbau (IMB), Betreuung: Agemar Manny, M.Sc.

[6] Masterarbeit, Entwicklung einer Bewehrungsführung aus nichtmetallischen Werkstoffen für den Einsatz bei Betonfertigteilen, 2022.
Karlsruher Institut für Technologie (KIT), Institut für Massivbau und Baustofftechnologie – Abteilung Massivbau (IMB), Betreuung: Agemar Manny, M.Sc.

[5] Bachelorarbeit, Detektion und Reduktion von produktionsbedingten sowie lastunabhängigen Abweichungen bei hochfesten Betonbauteilen, 2022.
Karlsruher Institut für Technologie (KIT), Institut für Massivbau und Baustofftechnologie – Abteilung Massivbau (IMB), Betreuung: Agemar Manny, M.Sc.

2021

[4] Masterarbeit, Entwicklung eines Spannankers mit textiler Wendelbewehrung für den Einsatz bei hochfesten Betonen, 2021.
Karlsruher Institut für Technologie (KIT), Institut für Massivbau und Baustofftechnologie – Abteilung Massivbau (IMB), Betreuung: Agemar Manny, M.Sc.

[3] Bachelorarbeit, Modellierung und Optimierung von Baukastensystemen mittels Gemischtganzzahliger Programmierung und Evolutionären Algorithmen, 2021.
Karlsruher Institut für Technologie (KIT), IPEK – Institut für Produktentwicklung

[2] Bachelorarbeit, Textilbeton: Entwicklung einer textilen Bewehrungsführung - Vergleich verschiedener Bewehrungsarten
Karlsruher Institut für Technologie (KIT), Institut für Massivbau und Baustofftechnologie – Abteilung Massivbau (IMB), Betreuung: Agemar Manny, M.Sc.

2020

[1] Bachelorarbeit, Bemessung eines repräsentativen Hochbaus in Skelettbauweise - Vergleich verschiedener Bewehrungsarten
Karlsruher Institut für Technologie (KIT), Institut für Massivbau und Baustofftechnologie – Abteilung Massivbau (IMB), Betreuung: Agemar Manny, M.Sc.