Continuous Production of Thin‐Walled, Fiber‐Reinforced Precision Concrete Elements for Free‐Form Modular Construction ‐ KoBeMo

Abstract In the context of Industry 4.0, modern flow production is characterised by a digitally controlled and continuous value chain. The combination of lightweight principles with thin‐layer shotcrete and rib‐shaped supports — for example in façade elements — enables the production of highly efficient components with high load‐bearing capacity and excellent surface quality. A newly developed multi‐tool nozzle combines concrete spraying and extrusion, allowing both processes to be carried out within one system. In addition, the automated integration of anchors is a key element of flow production, supported by specially developed anchors and tool systems. The results demonstrate improved practicability and increased productivity based on determined characteristic values. These data form the basis for developing a digital twin in line with Industry 4.0 concepts. Furthermore, increased productivity in additive manufacturing shows positive economic effects. The use of high‐strength lightweight structures is becoming increasingly important in construction, as it enables the creation of large modular structures in free‐form designs.