Re-usable and flexible GFRP formwork for the production of double curved concrete lightweight elements

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A flexible formwork for a cost efficient production of single and double curved façade elements with defined modification of the curvature radius is developed to allow a repeatable usage for elements with similar curvature states. Thus, a material and resource efficient production can be permitted. The current results of the DFG SPP 1542 about anisotropic material behavior of multi-layered glass fiber reinforced plastic (GFRP) formworks are used to realize the practical application of suchlike formwork. In the former project a flexible alignment of surfaces with several curvature states was achieved by modification of the GFRP laminate lay-up with respect to the bending stiffness values. Within the knowledge transfer project the first goal is the development of a formwork system with interconnected component measurement (camera system) for a readjustment of modular, thin-walled fiber and textile reinforced concrete elements. Ambitions are the realization of a fair-faced concrete, a precise front panel alignment and a defined arrangement of the force transmission elements. The second goal of the project is the data processing from a design-specific volume model into a formwork-specific line model which can be transferred onto the controllable substructure. Rating the GFRP formwork shell and the intelligent control system is task of the TU Chemnitz, SLK. Construction and validation of the controllable substructure is realized by the TU Chemnitz (LBW). Additionally, the manufacturing technology as well as the experimental verification including the optical measurement and readjustment of the formwork/concrete setup is executed by the industrial partners FIBER-TECH Group and Betonwerk Schuster GmbH. Finally, a prototype of a flexible multi-layered GFRP formwork and a representative cover element for infrastructure (e.g. traffic route elements, cable ducts) are realized.