Reusable Flexible Formworks for Constructing Complex Concrete Structures (2024-09)¶

This paper presents a workflow for the construction of bespoke concrete structures consisting of discrete geometries fabricated using a single uncoated knitted formwork. The workflow involves designing a structure that can be discretized into multiple smaller geometries. Then, a single knitted textile with various channel configurations that can produce all elements of the structure is manufactured and tensioned into a rig. Low-flow concrete is directly cast onto the uncoated flexible formwork, causing it to deform under the pressure of the concrete. The use of low-flow concrete ensures a consistent concrete thickness throughout. The result is a lightweight doubly curved element. Not coating the knit allows for easy demolding of the hardened concrete element, and the textile can be reused. With this approach, various geometries can be fabricated and modularly assembled to form larger structures. This circular fabrication method reduces the need for formwork material.