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A PhD student has developed an innovative formwork system that promises to transform construction by drastically reducing material use and emissions.
A PhD student at ETH Zurich, one of the most renowned universities in the world, has developed a formwork system innovator which promises to transform civil construction and the use of concrete.
called Unfold Form, the formwork system is made with plywood strips connected by textile hinges, allowing a reduction of up to 60% in the use of concrete and 90% in steel reinforcement.
In addition to being reusable, it is lightweight, easy to transport and can support up to 1 ton of concrete.
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The developed solution stands out for its many advantages. The formwork system is foldable and reusable, making storage and transportation easier.
It weighs only 24 kg and its nature-inspired, shell-like geometry provides structural strength.
The technology used, known as curved ridge 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 regions with few resources.
Tests carried out in South Africa have 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 construction, but it is also one of the most polluting. The production of cement, the main component of concrete, is responsible for around 8% of global CO₂ emissions.
Therefore, 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%, while also reducing reinforcing steel consumption by 90%. This represents a significant saving of resources and a considerable reduction in carbon emissions.
Under the guidance of Professor Philippe Block, the Block Research Group (BRG) has been exploring new forms of construction with a focus on sustainability. The technology is being commercialized through VAULTED AG, a spin-off from ETH.
Challenges of vaulted structures
Building vaulted structures has been a challenge due to the need for disposable and inefficient forms. PhD student Lotte Scheder-Bieschin developed the Unfold Form system to solve this problem.
Using flexible plywood strips and textile hinges, the system can be deployed in a fan shape, creating a zigzag structure. After the concrete has been poured, the formwork can be easily dismantled, folded and reused.
Formwork – Design inspired by nature
Unfold Form’s design is inspired by clam shells, which feature zigzag edges to increase rigidity without adding weight. Curved Ridge Folding (CCF) technology allows for the formation of complex, strong structures without the need for additional reinforcement.
The evolution of CCF, called Unified Curved Ridge (UCC) folding, allows the use of prefabricated panels that unfold like a fan, forming curved and resistant structures. This approach combines geometric precision with practicality in installation.
Unfold Form Technical Sheet
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
Flooring system results
Dimensions: 3,0 m x 1,8 m Thickness of concrete shell: 5-13 cm Total thickness of the system: 40 cm (70% less than 25 cm) Weight of concrete shell: 1000 kg (60% less than a conventional slab) Weight of steel: 10 kg (90% less than a conventional slab)
Real-world testing: an example from South Africa
The system was tested under real conditions and obtained promising results. In partnership with the local company nonCrete, specializing in sustainable housing solutions, a double structure was erected using a bioconcrete produced from shredded invasive vegetation.
This practical test demonstrated that alternative materials can be viable, reducing costs without compromising structural quality.
Furthermore, the portability of the system was impressive: the entire formwork was transported in just two surfboard bags, proving ease of use and assembly.
Advantages and disadvantages of technology
Like any innovation, the Unfold Form system has positive aspects and challenges to 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.
Benefits
- Material savings: Technology makes it possible to reduce concrete consumption by up to 60% and the use of steel in 90%, making construction more efficient and cheaper.
- Sustainability: The reduction in the carbon footprint is significant, contributing to a greener sector.
- reuse: The mold was designed for multiple uses without loss of quality, increasing its useful life.
- Lightness and easy transport: With only 24 kg, the structure can be transported without difficulty, facilitating logistics.
- Accessibility: The system does not require advanced machinery or specialized technical knowledge.
- Versatility: Unfold Form is compatible with many types of concrete, including bioconcrete.
- Efficient design: Zigzag geometry provides structural strength with reduced weight.
- Easy assembly: The materials used are accessible and assembly is quick, without the need for complex tools.
- Positive social impact: Promotes social inclusion by empowering local communities to build affordable housing.
- Adaptability: Can be applied in different regions and climatic conditions.
Disadvantages
- scale limitations: The system may not be suitable for large projects or projects requiring high load capacity.
- Learning curve: Despite its ease, initial training is still necessary to ensure correct application.
- Dependence on specific materials: The system uses plywood and textile hinges, which may not be widely available.
- Performance with standard concrete: Variation in concrete quality may affect results.
- Initial production: Although affordable, each project requires a custom design, which can increase execution time.
- Climate restrictions: The formwork may be vulnerable to exposure to extreme moisture and heat conditions.
- Innovation in development: The technology is still in the experimental phase and has not been widely adopted by the market.
Social impact and the long-term vision
The creator of Unfold Form, Scheder-Bieschin, does not only intend to market its product, but also to empower local communities. The idea is to provide training so that residents themselves can build their own structures, boosting 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 researcher postdoctoral fellow at ETH Zurich. The long-term vision is to expand technology, combining innovation with positive social and environmental impact.
With solutions like this, civil construction can become more efficient and accessible, offering alternatives for communities that need quality housing without compromising the environment.
Unreinforced concrete is so safe I don't even go near it.
Excellent👏🏽👏🏽👏🏽
Congratulations! You discovered that you can do it like you used to! Awesome!