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A PhD Student Developed An Innovative Formwork System That Promises To Transform The Construction Industry By Drastically Reducing The Use Of Materials And Emissions.
A PhD student from ETH Zurich, one of the most prestigious universities in the world, has developed an innovative formwork system that promises to transform the construction industry and the use of concrete.
Called Unfold Form, the formwork system is made with strips of plywood connected by textile hinges, allowing for a reduction of up to 60% in concrete usage and 90% in steel reinforcement.
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In addition to being reusable, it is lightweight, easy to transport, and can support up to 1 ton of concrete.
The developed solution stands out for several advantages. The formwork system is foldable and reusable, facilitating storage and transport.
It weighs only 24 kg, and its geometry inspired by nature, similar to shells, provides structural strength.
The technology used, known as Curved Crest Folding (CCF), ensures stability and reduces the need for additional materials.
Another important point is the accessibility of the formwork system. Its installation does not require technology, making it ideal for resource-limited regions.
Tests conducted in South Africa demonstrated its versatility, especially with the use of bioconcrete. The system fits into small bags, which is an advantage for projects in remote areas.
The Environmental Impact Of Concrete
Concrete is one of the most widely used materials in the construction industry but is also one of the most polluting. Cement production, the main component of concrete, is responsible for about 8% of global CO₂ emissions.
Thus, the search for sustainable solutions is essential to reduce the carbon footprint of the construction industry.
ETH Zurich estimates that the Unfold Form can drastically reduce concrete usage by up to 60%, also reducing steel reinforcement consumption by 90%. This represents a significant resource saving and a considerable reduction in carbon emissions.
Under the guidance of Professor Philippe Block, the Block Research Group (BRG) has been exploring new ways of construction focused on sustainability. The technology is being commercialized through VAULTED AG, a spin-off from ETH.
Challenges Of Arch Structures
Building arch structures has been a challenge due to the need for disposable and inefficient formwork. PhD student Lotte Scheder-Bieschin developed the Unfold Form system specifically to solve this problem.
Using flexible strips of plywood and textile hinges, the system can be deployed in a fan shape, creating a zigzag structure. After the application of concrete, the form can be disassembled, folded, and easily reused.
Formwork – Nature-Inspired Design
The design of the Unfold Form is inspired by shellfish shells, which have zigzag edges to increase stiffness without adding weight. The Curved Crest Folding (CCF) technology allows for the formation of complex and sturdy structures without the need for additional reinforcements.
The evolution of CCF, called Unified Curved Crest Folding (CCU), enables the use of prefabricated panels that unfold like a fan, forming curved and strong structures. This approach combines geometric precision with installation practicality.
Technical Specifications Of The Unfold Form
Weight: 24 kg Packed Dimensions: 160 x 40 x 25 cm Material: 8 mm Plywood and PVC Coated Polyester Fabric Cost: 650 CHF Assembly Time: 30 minutes
Floor System Results
Dimensions: 3.0 m x 1.8 m Concrete Shell Thickness: 5-13 cm Total System Thickness: 40 cm (70% less than 25 cm) Concrete Shell Weight: 1000 kg (60% less than a conventional slab) Steel Weight: 10 kg (90% less than a conventional slab)
Real-World Tests: A Case Study In South Africa
The system has been tested in real conditions and has shown promising results. In partnership with the local company nonCrete, specializing in sustainable housing solutions, a double structure was erected using bioconcrete made from crushed invasive vegetation.
This practical test demonstrated that alternative materials can be viable, reducing costs without compromising structural quality.
Additionally, the system’s portability was impressive: the entire form was transported in just two surfboard bags, proving its ease of use and assembly.
Advantages And Disadvantages Of The Technology
Like any innovation, the Unfold Form system presents positive aspects and challenges to be overcome. Below is a detailed analysis of the aspects that make this system an attractive option and the limitations that still need to be addressed.
Advantages
- Material Savings: The technology allows for concrete consumption to be reduced by up to 60% and steel usage by 90%, making construction more efficient and cost-effective.
- Sustainability: The reduction of the carbon footprint is significant, contributing to a more ecological sector.
- Reusability: The formwork was designed for multiple uses without loss of quality, increasing its lifespan.
- Lightweight and Easy Transport: At just 24 kg, the structure can be transported easily, facilitating logistics.
- Accessibility: The system does not require advanced machinery or specialized technical knowledge.
- Versatility: The Unfold Form is compatible with various types of concrete, including bioconcrete.
- Efficient Design: The zigzag geometry provides structural strength with less weight.
- Easy Assembly: The materials used are accessible, and assembly is quick, without the need for complex tools.
- Positive Social Impact: It promotes social inclusion by empowering local communities in building affordable housing.
- Adaptability: It can be applied in various regions and weather conditions.
Disadvantages
- Scale Limitations: The system may not be suitable for large-scale projects or those requiring high load capacity.
- Learning Curve: Despite the ease of use, initial training is still necessary to ensure proper application.
- Dependency on Specific Materials: The system uses plywood hinges and textiles, which may not be widely available.
- Performance with Standard Concrete: Variations in concrete quality may affect the results.
- Initial Production: Although accessible, each project requires a customized design, which may increase execution time.
- Climatic Restrictions: The formwork may be vulnerable to exposure to extreme humidity and heat conditions.
- Innovation in Development: The technology is still in the experimental phase and has not been widely adopted in the market.
Social Impact And Long-Term Vision
The creator of the Unfold Form, Scheder-Bieschin, intends not only to commercialize her product but also to empower local communities. The idea is to provide training so that residents can build their own structures, promoting autonomy and creating economic opportunities.
A concrete example of this approach is the construction of a community market in Cape Town, where the formwork system is being used to develop an accessible and sustainable commercial space.
The project has received international recognition, and Scheder-Bieschin continues her development as a postdoctoral researcher at ETH Zurich. The long-term vision is to expand the technology, combining innovation with positive social and environmental impact.
With solutions like this, the construction industry can become more efficient and accessible, offering alternatives for communities that need quality housing without compromising the environment.
Telha de Eternit, isso sim, também tem a exposição ao clima, menos material mais propício a degradação.
Parabéns! Descobriu que pode fazer como antigamente! Show
Excelente👏🏽👏🏽👏🏽