Robot‐Assisted Flow Production of Modular Concrete Components: Research Facility and Digital Model

Abstract Adaptive modular construction methods enable resource‐efficient, rapid construction. Their implementation requires precise, quality‐assured prefabrication. However, available suitable prefabrication facilities are still rare in the construction industry. This contribution introduces a research facility for automated production of adaptive reinforced concrete modules. The facility is equipped with three industrial robots and covers the process chain of reinforcement, formwork, and rapid curing with integrated quality assurance controls. In a cooperative process involving two robots, reinforcement elements are welded automatically, enabling all standard reinforcement layouts. The developed formwork system allows for variable cross‐sections and surfaces (adaptability) with dimensional deviations of less than ±2 mm. In‐process geometric and mechanical inspections using a laser line sensor, stereo camera, and a rebound hammer serve for quality assurance and can be used to control subprocesses. A curing chamber with controllable temperature and humidity conditions accelerates the curing of the concrete to completion in as little as 1 hour. During and after construction of the physical facility, a digital facility model enables simulation and virtual commissioning.