Zero-Waste Sand Formworks for Leightweigth Concrete Structures

ADAPTABLE MANUFACTURING PROCESS FOR MODULAR LIGHTWEIGHT CONCRETE COMPONENTS USING FULLY RECYCLABLE FORMWORK SYSTEMS

To ensure a sustainable future, the concrete construction industry needs to achieve net carbon neutrality by 2050, using specific scenarios for this as early as 2030. Experts estimate that emissions in the industry could be reduced by more than 35% through structurally efficient designs combined with the integration of circular economy principles throughout the value chain. The use of lightweighting construction principles is a key approach to simultaneously reducing material consumption, emissions and waste. However, its implementation in concrete construction will only be future-proof if sustainable, fast and inexpensive production methods are available.

In this context, the current project focuses on the zero-waste production of lightweight concrete structures using water-soluble sand formwork systems. It will explore how additive manufacturing of recyclable formwork materials can maximise the freedom to design resource-efficient structures while avoiding production waste by keeping formwork materials in circulation for as long as possible. The project will conceptualise and develop the closed-loop production cycle. Investigations will include the research into recyclable material systems, their processing techniques, and the design and construction of a pilot 3D printing manufacturing unit, where research findings can be tested in the production of formwork for small and medium sized concrete components.

PRINCIPAL INVESTIGATORS

Prof. Dr.-Ing. M.Arch. Lucio Blandini
Institute for Lightweight Structures and Conceptual Design (ILEK), University of Stuttgart
Prof. Dr.-Ing. Dr.-Ing. E.h. Dr. h.c. Werner Sobek
Institute for Lightweight Structures and Conceptual Design (ILEK), University of Stuttgart
Prof. Dr.-Ing. Dr. h.c. mult. Alexander Verl
Institute for Control Engineering of Machine Tools and Manufacturing Units (ISW), University of Stuttgart

RESEARCHERS

Daria Kovaleva (ILEK)
Maximilian Nistler (ISW)