This page provides an overview of the planned research program of the project, outlining its main work packages and key activities. It summarizes the structured approach used to develop, test, and validate the proposed solutions, from material selection through engineering modeling and final system evaluation.

1. Material Selection and Characterization

This work package focuses on material selection and characterization for the development of high-performance precast modular elements. The aim is to identify suitable materials, understand their behavior under different conditions, and ensure they meet both structural and environmental requirements. The work covers three main material groups: the cementitious matrix, textile reinforcement, and short dispersed fibers. Each of these is evaluated in terms of mechanical performance and environmental impact, with particular attention to low-CO₂ options such as eco-friendly cement, provided they still satisfy the required structural performance.

Material identification and sourcing is based on manufacturer data, existing research, and the current state of the art, with a strong focus on embodied carbon. Candidate materials are selected based on their ability to meet requirements for strength, durability, and sustainability, and representative samples are sourced from suppliers and manufacturers for further investigation.

Experimental testing is carried out to evaluate the properties of the selected materials both individually and in combination. Cementitious materials are assessed through standard mechanical tests, including compressive strength, elastic modulus, and tensile-related behavior measured via flexural and splitting tests. Textile and fiber reinforcements are primarily tested in tension, while additional shear or specialized tests are performed when needed, including custom setups developed to capture specific material behavior.

Optimization of material mixtures focuses on improving both performance and sustainability. Different mix designs are explored to balance workability, such as flowability for pumping and casting, with mechanical performance, including crack and splitting resistance with minimal fiber content. At the same time, the environmental impact of each material and mixture is assessed using global warming potential data from the literature. The overall objective is to reduce environmental impact without compromising structural performance, either by adjusting mixture proportions or replacing high-impact components with more sustainable alternatives.

2. Development of Precast Modular Elements

This work package focuses on the development of high-performance precast modular elements using the materials selected in the previous stage. The goal is to design structural components that maximize material efficiency, durability, and sustainability, while also simplifying installation and enabling use in both new construction and retrofit applications. The development includes stay-in-place precast panels for new buildings and retrofit systems for existing structures, with careful attention to geometry, reinforcement layout (including textile fabrics), and manufacturability. The design process also considers production constraints and aims to define element shapes that ensure both structural performance and practical constructability.

The prototyping of precast modular elements begins with defining detailed design specifications that reflect both manufacturing requirements and performance targets. Initial concepts are developed based on structural needs and the material behavior identified in earlier stages, after which the first physical prototypes are produced to validate the design approach.

Performance testing is carried out on these prototypes using small- to medium-scale specimens to evaluate their structural behavior. Standard mechanical tests, such as tensile coupon testing for fiber-reinforced textile concrete elements, are used as the baseline approach. Depending on the observed behavior, additional or customized test setups may be introduced to capture specific performance aspects more accurately.

Element optimization is based on the results of the experimental testing and supported by advanced numerical modeling and simulation. This process is used to assess performance under different loading and boundary conditions and to iteratively refine the design, improving both structural efficiency and overall system behavior.

3. Development of Connections

This work package focuses on the development of connection systems for the precast modular elements. Reliable connections are essential to ensure structural continuity, load transfer, and overall stability in both new construction and retrofit applications. The work includes the design and refinement of connection details that allow forces to be safely transferred between elements and into the existing structure. Key technical challenges include anchoring the connections into the substrate concrete while accounting for typical failure modes in fastening systems, such as concrete breakout or splitting failure, as well as designing reliable joints between adjacent panels, including control of joint opening and overall deformation behavior. The initial approach relies primarily on mechanical fastening technologies, with a deliberate effort to avoid bonding agents where possible, although their use is not excluded. In some retrofit applications, thin layers of fresh cementitious material may be used, and cast-in-place lap splices may be considered to ensure continuity. The potential use of slight pre-tensioning effects, for example through controlled torque, is also explored as a way to activate the system during or after installation.

The prototyping of connection systems begins with defining performance requirements based on different load conditions and structural demands. These requirements are considered separately for new structures and retrofit applications, as well as for connections to the existing substrate and between modular elements. Based on these requirements, initial design concepts are developed and first prototypes are fabricated.

Performance testing is carried out on these prototypes to evaluate structural integrity and load transfer efficiency. The experimental program mainly consists of small-scale tests, such as pull-out tests and related mechanical assessments, to capture key failure mechanisms and connection behavior under load.

Optimization of the connection system is based on the experimental results and supported by advanced numerical modeling and finite element simulations. This allows for detailed evaluation of connection performance under different conditions and iterative refinement of the design to improve reliability, safety, and efficiency.

4. Prototyping and Testing of Final Solutions

This work package focuses on the final stage of Project SCORE, where the optimized precast modular elements and their connection systems are combined into complete structural solutions and tested as integrated systems. The main objective is to validate their performance under realistic structural conditions for both new construction and retrofit applications. Prototypes are fabricated for use in new structural members as well as for strengthening existing ones, and they are tested under a wide range of loading scenarios. The test setups are designed to represent typical load-bearing situations and include loading from serviceability levels up to ultimate limit states, allowing the identification of relevant failure modes within a full structural context. During testing, internal force distribution, stress–strain development, and crack initiation and propagation are monitored using both conventional and advanced measurement techniques, including LVDTs, strain gauges, fiber optic sensors, and digital image correlation systems. The results are used to support the development of reliable engineering models that capture the key failure mechanisms and load transfer behavior between the modular elements and lower-strength concrete, ensuring that the final validated solutions can be used as a solid technical basis for practical implementation in construction.

The full prototype design and fabrication begins by integrating results from all previous work packages to develop complete systems for both new and existing structures. The process starts with system-level design, followed by the fabrication of prototypes intended for experimental validation.

Laboratory testing is conducted on these full-scale or large-scale prototypes to evaluate their structural behavior under realistic loading conditions. Detailed testing protocols are defined in advance, and advanced measurement technologies are used to capture a comprehensive picture of structural response throughout the tests.

Evaluation and validation of the solutions are carried out by analyzing the experimental results and comparing the performance of the proposed systems with conventional construction and retrofit approaches. This assessment is also used to further refine and improve the solutions, ensuring that the final outcomes are robust, reliable, and suitable for practical application.

5. Development of Engineering Models

This work package focuses on the development of engineering models to predict the structural performance of the precast modular elements and their connection systems in both new construction and retrofit applications. These models are intended to simulate different loading scenarios, capture structural behavior under varying conditions, and support the design and assessment of the proposed solutions. They are validated against experimental results and are essential for ensuring the reliability and practical usability of the final system. The modeling approach covers both local and global behavior: local models address failure mechanisms such as anchorage-related issues and other connection-level failure modes, while global models describe the interaction between high-performance precast panels and conventional structural materials. On the local level, the work also leads to the formulation of detailing rules and design recommendations to prevent premature failures. On the global level, the models capture composite action within hybrid structural systems using analytical and semi-empirical approaches based on standard reinforced concrete assumptions, such as rigid sections, material homogeneity, and full bond conditions. The development process includes sensitivity analyses to identify the most influential parameters and improve model robustness.

Model development focuses on creating practical engineering tools for predicting and designing the behavior of the systems developed in Project SCORE. A range of methods is used, including analytical approaches and, where appropriate, advanced data-driven techniques such as symbolic regression. The models are calibrated and validated using experimental results from testing campaigns as well as numerical simulation data, ensuring consistency between observed and predicted behavior.

Simulation and analysis are carried out using advanced numerical tools to study the behavior of the systems under a wide range of conditions. This includes both the precast elements and their connection systems, with particular attention to composite action in hybrid structural configurations. The simulations are designed to reproduce the behavior observed in experiments and to support further refinement of both the models and the structural concepts.