Integration of Zip-formwork and conventional formwork systems for shape-optimized concrete in large scale construction

Abstract

Cast-in-place concrete production plays a dominant role in the architecture, engineering and construction (AEC) industry, particularly in large-scale projects, contributing significantly to global material consumption, construction costs, and embodied carbon emissions. Shape optimized concrete has been developed as a solution for more affordable and sustainable construction using less material to create efficient structures that meet structural demands. Although extensive research and development has focused on applying shape optimization to prismatic concrete beams, these beams are often limited by the constraints of available formwork and are primarily designed as pre-cast components. This paper presents the results of optimizing the Zip-Form, a digitally fabricated formwork system made from mild steel, designed for forming shape-optimized concrete beams, and its integration with conventional formwork equipment. The study evaluates the structural performance, embodied carbon, and cost of the Zip-Form integrated system in comparison to a traditional formwork platform used for prismatic beams. The findings highlight the Zip-Form’s potential for forming shape-optimized concrete beams using cast-in-place methods, making it a viable solution for sustainable large-scale construction projects in the current industry. The methodology outlined in this thesis provides a comprehensive design process, beginning with the structural design of the shape-optimized concrete beams, followed by the design of the Zip-Form integrated formwork system to cast the beams, and concluding with an embodied carbon and cost analysis to evaluate the environmental and financial benefits. This thesis aims to bridge academic research and innovation with practical, real-world applications.