Fully automated quality control system for CRC components

Project data

Titel | Title TP Analyse der Rolle qualitätssichernder Maßnahmen auf die Verteilung zulassungsrelevanter Kenngrößen für die Carbonbetonbauweise im Verbundvorhaben Precast Quality: Entwicklung einer vollautomatisierten Qualitätskontrolle für Carbonbetonbauteile | Subproject Analysis of the role of quality assurance measures on the distribution of approval-relevant parameters for carbon-reinforced concrete construction in the joint research project Precast Quality: Development of a fully automated quality control system for carbon-reinforced concrete components Förderer | Funding Bundesministerium für Wirtschaft und Klimaschutz (BMWK) Zeitraum | Period 07/2022 – 12/2024 Teilprojektleiter und Bearbeiter | Subproject leader and contributor Dr.-Ing. Frank Schladitzz Projektpartner | Project partners Betonwerk Oschatz GmbH, Oschatz | Symate GmbH, Dresden | TESTING Bluhm & Feuerherdt GmbH, Berlin | Hochschule für Technik, Wirtschaft und Kultur Leipzig | Deutscher Ausschuss für Stahlbeton e.V., Berlin

Short description

The precast industry has been working intensively on the subject of carbon reinforced concrete for around five years. Numerous production tests have already been carried out in many precast plants and the first products have been converted from steel reinforced concrete to carbon-reinforced concrete. The thin construction method promises material savings and cost reductions.

However, this construction method is also associated with new challenges. With the reduction in component thickness, the issue of accuracy becomes more important. For 20 cm thick components, 5 mm deviation of the reinforcement layer from the planned reinforcement layer is acceptable. With 3 cm thick components, however, even minor deviations of 2 mm can significantly impair the load-bearing capacity. Processes and technologies must therefore be developed and implemented that enable greater accuracy than previously possible in the industrial manufacture of mass-produced concrete products.

This is precisely where the project comes in: The aim is to significantly reduce quality fluctuations in the production of finished and semi-finished carbon-reinforced concrete parts. By implementing comprehensive, continuous and fully automated process monitoring directly in the precast plant, the aim is not only to improve quality, but also to significantly increase the cost-effectiveness and ecology of these processes.

At our institute, requirement profiles were derived from current regulations. The aim is to limit quality fluctuations in the production of finished and semi-finished carbon-reinforced concrete parts to an acceptable level. Among other aspects, manufacturing accuracy and load-bearing capacities were evaluated. The results of the investigations were incorporated into the adjustment of the processes and process monitoring.

As a result of the work, it is now possible to predict quality fluctuations in the final product already during the production process and to correct process parameters at an early stage so that fluctuations in the final product are reduced. The findings from the project shall be incorporated into the new version of the DAfStb guideline “Concrete Components with Non-Metallic Reinforcement”.