Intelligent Modularisation of Decomposed Load-bearing Elements for Multifunctional Application in Hall and Frame Construction

• Applicants: Professor Dr.-Ing. Albert Albers; Professor Dr.-Ing. Alexander Stark
• Subject Area: Structural Engineering, Building Informatics and Construction Operation ; Engineering Design, Machine Elements, Product Development
• Term: since 2026
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 573348520

The transfer of methodological concepts for construction kit and platform development from mechanical engineering to structural engineering offers great potential for increasing labour productivity by exploiting economies of scale along the entire value chain. In particular, an integrated, interdisciplinary consideration of digital planning methods, standardisation methods, suitable design and manufacturing methods represents a promising approach to enable industrial, sustainable and digitalised modular concrete construction. The aim of the jointly proposed transfer project is to develop a modular system for reusable, modular, decomposed load-bearing elements with large span widths, multifunctional use and high material efficiency. The modular elements to be manufactured in the factory should have a large external variety with a small internal variety (high repetition rates) in accordance with a modular architecture to be derived, which enables multifunctional use as decomposed roof elements in hall systems and as decomposed wall or ceiling elements in building construction. To this end, the transfer of optimisation methods for calculating an efficient modular architecture of the decomposed load-bearing elements is being researched. This is based on reference systems that are derived in close cooperation with the project partners. The result of the optimisation process will yield several optimised modules that represent trade-off solutions to the conflicting goals of minimum internal variety and maximum external variety. The optimised modules and the set of rules of the construction kit will be integrated into a BIM planning software for digital planning with construction kits via an interface to be researched. Extensive numerical and experimental investigations are carried out to model joint designs and nodal connections as well as to research assembled large-scale decomposed load-bearing elements. In particular, manufacturing methods for high precision dry joints are analysed as well as prestressing techniques are derived in order to manufacture load-bearing, decomposed concrete components in a modular manner. In particular, the interfaces of the joints should enable efficient assembly and damage-free disassembly so that structural members can be reused for subsequent applications. Meeting the subobjectives of this research project enables savings in resources, time and construction costs through efficient planning, manufacturing and construction processes. The continuous exchange and interdisciplinary cooperation between the project partners promote the exchange and transfer of knowledge between scientific and practical institutions in product development and the field of concrete structures.

• DFG Programme: Research Grants (Transfer Project)
• Application Partner: BREMER SE; neoBIM GmbH