New Concrete Molds Boost Sustainable Construction

Imagine construction sites where concrete structures are shaped not by rigid forms but by pliable fabrics, where buildings emerge like sculptures with optimized material efficiency and aesthetic appeal. This vision is becoming reality through advancements in concrete formwork technology, particularly through flexible mold systems.

Concrete formwork, often called shuttering, serves as temporary scaffolding that defines the shape and quality of concrete structures. Evolving from traditional wood to modern metal, plastic, and composite materials, formwork technology reflects the construction industry's pursuit of efficiency, cost-effectiveness, and sustainability.

Wooden formwork remains popular for its adaptability and material accessibility, yet proves labor-intensive for large-scale projects with limited durability. Engineered formwork systems using prefabricated metal frames with various facing materials improve construction speed and reusability. However, these conventional systems still struggle with complex geometries and contemporary sustainability requirements.

Reusable plastic formwork gains popularity for lightweight projects due to its durability and ease of handling. Insulated Concrete Forms (ICF) integrate formwork with insulation, streamlining construction while enhancing thermal and acoustic performance. Permanent structural formwork using fiber-reinforced plastics provides shape definition while reinforcing structural integrity.

Departing from rigid molds, flexible formwork systems utilize high-strength textiles to harness concrete's fluidity, creating structurally optimized forms. This approach significantly reduces concrete consumption, lowering carbon footprint while enabling architecturally expressive designs. By controlling fabric geometry, engineers can create variable cross-sections that precisely match structural load requirements, achieving unprecedented material efficiency.

As critical horizontal elements, floor slabs have witnessed continuous formwork evolution. Ancient Roman engineers pioneered arched and domed structures to compensate for concrete's weak tensile strength. Modern slab construction only became mainstream following the invention of Portland cement and reinforced concrete.

• Timber Beam Slab Formwork: Modernized traditional approach using engineered wood beams with adjustable metal supports
• Conventional Slab Formwork: Adapts carpentry techniques with timber supports and plywood sheathing
• Metal Beam Slab Formwork: Aluminum or steel beams enhance durability and reusability
• Modular Slab Formwork: Prefabricated timber or metal components with quick-connect systems
• Table/Flying Form Systems: Large preassembled units moved by crane for rapid construction

Tunnel forms represent room-sized systems that cast walls and floors simultaneously, ideal for repetitive unit construction. While significantly reducing construction time, these systems require substantial working space and demand careful structural planning.

Climbing or jump forms provide vertical casting solutions that ascend with building progress. Essential for high-rise construction, these systems range from manually adjusted versions to automated climbing mechanisms, particularly suited for towers, bridge piers, and elevator cores.

With growing emphasis on reducing construction's carbon footprint, the industry faces pressure to optimize concrete usage. As concrete production remains energy-intensive, innovative formwork solutions like flexible molds offer pathways to material efficiency through shape optimization.

Textile-based formwork represents a niche advancement using flexible materials to shape fresh concrete. Supported by the International Fabric Formwork Association, this technology enables complex geometries while minimizing material waste. Russian innovations like the "Proster" steel-plate system demonstrate additional flexibility for curved structures.

Proper demolding requires concrete to achieve sufficient strength, typically after minimum 24-hour curing. Premature removal risks structural failure. Engineers must account for hydrostatic pressure during placement, with maximum pressure occurring at the base of fresh concrete. Formwork reinforcement typically involves steel bracing and tie systems to withstand these forces.

Some permanent formwork systems provide additional structural benefits, serving as reinforcement while maintaining shape integrity. As material science and digital fabrication advance, the construction industry moves toward more efficient, sustainable, and architecturally expressive formwork solutions that promise to redefine built environments worldwide.