Circular, zero waste formwork - Sustainable and reusable systems for complex concrete elements

Abstract

The construction sector contributes significantly to global carbon emissions, leading to a new need and demand for sustainable and material-efficient construction technologies. Digital form-finding, simulation, and optimization methods are advancing, resulting in highly efficient, but often geometrically complex components. Concrete construction, which is currently dominant worldwide and crucial for sustainable material savings due to its large market volume, still faces challenges in implementing complex geometries. The significant requirements for formwork material and limitations in feasibility and cost at the current state of the art contribute to these challenges. This research presents a zero waste process using recyclable and reusable digitally fabricated formwork made from waste ingredients that can be immediately implemented in the construction industry. Residual sands (quartz and ceramics) were investigated as a basic moulding material in combination with biogenic binders (bentonite, eco-resin, sodium silicate, starch) for the production of stable formwork composites. The material compound were shaped into precise complex forms using 5-axis milling, and the removed material was recycled in a closed material cycle. Testing and characterization methods for evaluating mechanical properties such as compressive forces (20.1 N/mm2), surface roughness (Ra 9.1 μm), tolerances (0), and moulding processes indicate that the presented procedure conforms to common industry standards. Demonstrating feasibility, complex ultra-thin 1:1 concrete prototypes were designed and manufactured under industrial conditions using prefabricated formworks made of researched bio composite. The resulting high-resolution formwork surfaces and exposed concrete precast elements correspond to the highest fair-faced concrete class (SB04), with line roughness values of Ra 14.4 μm. The developed circulation concept allows reproducibility of different geometries and repeated concreting of formwork moulds. The formwork process is free from harmful additives, enabling recycling through grinding and reintegration into a closed material cycle. Sustainability has been continuously monitored and evaluated through a life cycle assessment. This system utilizes standard machines and offers an accessible and easily integrated approach for a holistic zero waste solution, suitable for efficient industrial applications.