Adaptable Manufacturing Process for Modular Lightweight Concrete Components Using Fully Recyclable Formwork Systems

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

To ensure its sustainable future, the concrete construction industry needs to achieve net carbon neutrality by 2050, applying 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. Using lightweight construction principles is a key approach to simultaneously reducing material consumption, emissions, and waste. However, their implementation in concrete construction can only be future-proof if sustainable, fast, yet 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 examines how additive manufacturing of recyclable formwork materials can maximize the freedom in designing resource-efficient structures while avoiding production waste by keeping formwork materials in circulation for as long as possible. During the project, the closed-loop production cycle is being conceptualized and developed. The investigations include the research on recyclable material systems, their processing techniques, and the design and construction of the pilot 3D printing manufacturing unit, where research findings can be tested in production of formworks for small- and medium-scale concrete components.

PRINCIPAL INVESTIGATORS

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

RESEARCHERS

Daria Kovaleva (ILEK)
Maximilian Nistler (ISW)