Industry 4.0 Enabled Modular Precast Concrete Components: A Case Study

Abstract

The construction industry faces the challenge of building sustainable and ever faster. The modular construction method with serial precast concrete modules is suitable to achieve this. Here, entire load-bearing structures are segmented into identical or similar modules, which are prefabricated and merely assembled on the construction site. However, the production of precast concrete components has so far by no means been an automated process, as there are hardly any repetition rates. Therefore, Industry 4.0 (I4.0) methods are to be transferred to the prefabrication process, targeted here in line with serial production. The aim is to mass-produce precast concrete modules with high precision and quality assurance in modern production systems based on the I4.0 concept. I4.0 refers to automation through continuous digitalization and networking of production. In the sense of I4.0, smart products seek an optimal path through production systems that interact with machines and processes self-controlled and self-managed. Thereby, the digital twin as a virtual representation for capturing and providing all relevant data is a key component. As a first step towards a holistic digital representation, a high-performance precast concrete module is presented in this work as both a digital twin and a real demonstrator. This Y-shaped module is part of a wall-like honeycomb structure. It is produced using rapid heat treatment and monitored by geometrical and thermal sensors during production and afterwards. The Asset Administration Shell (AAS) as the technical implementation of the digital twin in I4.0 is used to provide suitable methods for communication and interaction.