Hollow-core concrete slabs from ETH Zürich. Save up to 70% on concrete and cut carbon emissions

The Swiss Federal Institute of Technology in Zurich (ETH Zürich) has developed a special 3D-printed foam formwork system that makes it possible to cast concrete slabs with hollow cells.

The system, called "FoamWork," uses an ordinary rectangular mold along with 24 foam elements of different shapes and sizes printed on a 3D printer. Concrete is then poured in and left to cure, after which the foam elements can be pulled out and recycled, reused, or left inside as insulation.

The shape of the internal stiffeners is designed so that the slab remains very strong. Concrete is concentrated in the areas under the greatest tension, which gives the slab maximum compressive strength while using the least amount of material.

Another benefit of such a slab is its lighter weight, which further reduces the effort required for transportation and work at the construction site.

The World Cement and Concrete Association has issued a statement of intent to reduce carbon emissions to zero by 2050, and FoamWork could be one of the many solutions it puts to use.