Adaptable manufacturing process for modular lightweight concrete components using fully recyclable formwork systems

DFG | SPP 2187: Adaptive modularized constructions made in a flux | Subproject 12

Institute for Lightweight Structures and Conceptual Design (Prof. Werner Sobek) | Institute for Control Engineering of Machine Tools and Manufacturing Units (Prof. Alexander Verl)

Zero-Waste Sand Formwork Technology


Zero-waste production of lightweight concrete structures using water-soluble sand formworks

In the face of climate change and increasing resource scarcity, the construction industry is confronted with the need to significantly reduce resource consumption, emissions and waste. The application of lightweight construction strategies in combination with circular production processes offers a comprehensive approach to this problem. In the framework of the GFG-funded Priority program SPP 2187: "Adaptive modularized structures made in flux" this project focuses on the development of a zero-waste production process for lightweight concrete components using recyclable sand formworks. The powder bed-based 3D-printing of water-soluble material enables the production of geometrically complex and optimized concrete structures and the reuse of formwork material in subsequent production cycles.

Closed-loop production cycle (left) and the automated production unit (right)



Institute for Lightweight Structures and Conceptual Design, University of Stuttgart
Dipl.-Arch. Daria Kovaleva

Institute for Control Engineering of Machine Tools and Manufacturing Units, University of Stuttgart
Maximilian Nistler M.Sc 



German Research Foundation (DFG) 



Kovaleva, D.; Nistler, M.; Blandini, L.; Sobek, W.; Verl, A.:
Rezyklierbare Sandschalungen: Auf dem Weg zur Kreislaufproduktion leichter Betonbauteile
Beton- und Stahlbetonbau (5), 2022,

Kovaleva, D.; Nistler, M.; Verl, A.; Blandini, L.; Sobek, W.
Zero-waste Production of Lightweight Concrete Structures with Water-Soluble Sand Formwork
Proceedings of The 3rd RILEM International Conference on Digital Fabrication with Concrete (Digital Concrete 2022), Loughborough, UK, 2022 (accepted)

Nistler, M.; Kovaleva, D.; Tepper, L.; Blandini, L.; Sobek, W.; Verl, A.
Camera-based Process Monitoring for Powder Bed Additive Manufacturing in Construction
Proceedings of the 55th CIRP Conference on Manufacturing Systems (CIRP CMS 2022)


This image shows Daria Kovaleva

Daria Kovaleva


Research Assistant

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