Digital Twin‐Based Quality Control: Ensuring Precision in Precast Concrete Elements

Abstract Ensuring geometric accuracy in precast concrete production is becoming increasingly critical, especially for modular, tolerance‐sensitive designs. This is particularly evident in segmental structures with dry joints, where even minor deviations can significantly affect assembly and structural performance. Within this context, a demonstrator for Digital Twin (DT)–based quality monitoring is developed using a modular precast segmental pedestrian bridge as a test case. High‐resolution geometric data for individual segments are acquired via structured‐light scanning and linked to digital representations of the segments. These are subsequently integrated into a DT of the overall structure, enabling the combined consideration of design and as‐built information. The demonstrator illustrates how scan‐based data can support the identification of geometric deviations and contribute to quality‐related decision‐making during production. In addition, the integration of measurement data into a DT environment is outlined, highlighting opportunities for improved traceability and consistency across production stages.