Tolerance‐Free Series Production of High‐Performance Concrete Modules through Transient‐Interactive Coupling of Design and Production

This paper presents the results of the interdisciplinary research project “Tolerance‐free series production of high‐performance concrete modules through transient‐interactive coupling of design and production” within the priority program “SPP 2187”, funded by the German Research Foundation (DFG). The project aims to enable tolerance‐compensating, resource‐efficient serial production of modular precast structures by integrating material behavior, structural design, manufacturing, and assembly. Methods for coupling design and production address final and intermediate construction states, assemblability, and sustainability. Placement strategies and specification heuristics link structural performance and assembly requirements with adaptive heat‐treatment control. The production system is modeled using discrete‐event simulation. Uncertainties are modeled probabilistically and the decision problem is formalized as a Markov Decision Process. Single‐ and multi‐agent deep reinforcement learning systems select module‐specific heat‐treatment durations to reduce dimensional variability. A virtual demonstrator, complemented by experimental and pilot‐scale structures, demonstrates the benefits of the integrated approach for precise, sustainable, industrialized precast concrete construction.