For the foreseeable future, we're simply not going to stop building with concrete and the steel necessary to reinforce it, despite the carbon emissions producing those materials requires. So it would be better if we could do more with less.

Thanks to research done by Lotte Scheder-Bieschin, a PhD student of Architecture at ETH Zurich, we can. Scheder-Bieschin developed the "Unfold Form," a reusable formwork system for making vaulted concrete structures. Her method yields a vaulted form that is as strong as a conventionally-built variant and uses less concrete and far less steel.

Even more impressive is that Scheder-Bieschin also designed the formwork to be less wasteful. Creating forms for large, complicated concrete geometry often involves Styrofoam, and the forms are single-use. Scheder-Bieschin designed an origami-inspired reusable form that is easy to transport, as it folds down. It consists of flexible plywood strips joined by nothing more than textile hinges and staples. Each form weighs just 24kg, but can support a literal ton of concrete. And they're easy to move.

"I was looking for a solution that would allow me to use strength through geometry, not only to optimise the final structure but also the formwork itself," says Scheder-Bieschin. "This approach reduces material usage and makes the entire process more environmentally friendly." The formwork's distinctive geometric structure allows for reductions of up to 60 percent in concrete and 90 percent in reinforcement steel.

"The Unfold Form formwork can be produced and assembled without specialised knowledge or high-tech equipment," notes Scheder-Bieschin. One of her aims was to create a simple and robust system that could be used worldwide, even with limited resources. Currently, formwork for non-standard concrete shapes typically requires digital fabrication. "This creates barriers for sustainable concrete construction in developing countries, where the need for new buildings is especially high," she says.

The formwork can be produced cheaply. "The only things needed in addition to the materials are a template for the shape and a stapler," adds Scheder-Bieschin. The materials for the prototype cost only 650 Swiss francs in total.

The individual components are light and compact enough to transport easily. Scheder-Bieschin demonstrated the system's simplicity by assembling it herself during her pregnancy. "I wanted to ensure my design was simple enough for anyone to build, regardless of their circumstances," she says.

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Thus far two structures have been built using the Unfold Form, one at ETH Zurich, the other in South Africa. Once Scheder-Bieschin has gained her doctorate later this year, she plans to bring the product to market.