A doctoral student in architecture at ETH Zurich has designed an innovative solution for the **use of concrete** in a more environmentally friendly way. By using less material and [reducing associated carbon emissions](https://noticiasambientales.com/innovacion/la-construccion-incorporo-el-uso-de-canamo-hace-20-anos/), this proposal promises to revolutionize the construction industry.
The key to this innovation lies in a **lightweight, robust, and reusable formwork design** that significantly reduces the use of concrete and steel.
According to ETH Zurich, this **new type of formwork** could reduce concrete usage by up to 60% and reinforcing steel by 90% in traditional reinforced concrete slabs, resulting in a significant decrease in carbon emissions and **waste materials** associated with construction.
Under the direction of Professor Philippe Block, the Block Research Group (BRG) has introduced a **vaulted concrete floor element** that, thanks to its optimized geometry, achieves much thinner sections without requiring steel reinforcements. This technology is being commercialized through VAULTED AG, a company spun off from ETH.
## Non-standard concrete structures: challenges and solutions
In projects with non-standard concrete floor designs, the main issue has been the single-use nature of formwork, especially in vaulted shapes.
Doctoral student **Lotte Scheder-Bieschin** has created a foldable formwork system called **Unfold Form**, which is not only reusable but also more resource-efficient.
The system consists of thin and flexible plywood strips connected by textile hinges, which can be unfolded like **a fan to form a zigzag mold** onto which concrete is poured directly.
Once it sets, the formwork can be easily disassembled, folded, and stored for future use. Despite its lightness (weighing only 24 kilograms), this system is **capable of supporting up to 1 ton of concrete**.
## Inspiration from nature and traditional techniques
The design of Unfold Form is inspired by **natural structures**, such as the zigzag edges of seashells, which provide stiffness without significantly increasing weight.
Furthermore, it utilizes principles of geometry and curved folding (CCF), a technique inspired by origami, to achieve **structural stability and reduce deformation** under load.
Scheder-Bieschin’s innovation lies in adapting this technique for use in construction. Her solution allows starting from prefabricated 2D panels, which easily unfold to **form 3D structures** with the necessary stiffness to support the concrete.
## Real-world testing of this new type of concrete
In addition to the prototype built on the ETH campus in Zurich, the Unfold Form system has been successfully tested in South Africa. There, it was used to build a twin structure in collaboration with the local company nonCrete, specialized in [sustainable construction](https://noticiasambientales.com/compromiso-ambiental/a-partir-de-2030-las-construcciones-en-europa-deben-ser-edificios-cero-emisiones/) and affordable housing solutions.
This version used a **bio-concrete** made from crushed invasive vegetation, demonstrating that premium-grade concrete is not necessary to achieve robust results. The formwork system was easily transported in two surfboard bags, highlighting its portability and ease of use.
The reuse of the formwork without a loss of quality reinforces its attractiveness as a **sustainable solution** for future projects.
## Social impact and long-term vision
Scheder-Bieschin aims not only to commercialize her product but also to empower local communities through training programs that enable them to independently build the formwork and structures. This approach has great potential to address the **needs for sustainable housing** in developing countries, such as communities in South African municipalities.
Currently, Scheder-Bieschin is designing a market in a municipality in Cape Town using her formwork system and plans to continue developing this technology as a postdoctoral researcher at ETH Zurich. Her goal is to combine technological innovation with a **positive social and environmental impact**.
This solution not only opens up new possibilities for sustainable construction but also underscores the importance of global collaboration in seeking a **greener and more equitable future**.
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