Modular Interconnecting Formwork System

Description

The construction industry is one of the world's largest sources of waste materials. Formwork in particular (the 'moulds' used to erect concrete and other poured mediums) is very often single-use or degraded when used. Unlike other applications for timber in construction, plywood used in formwork is a particularly polluting form of waste. Developing an open source set of tools, that produce plastic formwork that can replace those products should help reduce the amount of waste in the sector.

The basic block that we're producing to allow for the construction of most square structures is derived from the Precious Plastic Brick, with a new tool design, to enable good tolerances, sharp corners and flat surfaces. Additional tools will be designed that are compatible with this brick, that can be dropped in place by construction workers when needed.

We also hope to enable more people to produce sustainable buildings with techniques such as rammed earth.

Details

Initial drawings for the tool are published here: https://www.thingiverse.com/thing:5467974

The cost for the production of one heated mould is approximately $300aud / $200usd

No other tools are required to produce a brick, however shredding your plastic, using an extruder to fill the mould, and mechanical assistance to close the mould will speed up production. Early experimental bricks were made by standing on the mould to close it.

I'm currently building a mechanical ram and jig with components I had on hand, as I only need one of them to produce bricks from several moulds. I'm using mechanical compression with the intent of measuring the stroke, and resistance from the viscous plastic, so as to document this for more efficient machines later down the track.

Full details about the project will eventually be published here: https://recyclopaedia.org.au/wiki/Modular_Interconnecting_Formwork_System

My objective broadly in the project is to enable more people to be able to build formwork suitable for sustainable building techniques, in particular Rammed Earth, which enables more energy efficient buildings, with low embodied energy. Formwork manufacturing is one of two primary barriers to producing Rammed Earth structures. The second is labour intensivity. I aim to produce number of robotic and mechanical aids, designed to work with this formwork, to reduce the labour requirements.

Files