Flexible Formwork: A Textile-Centric Approach

Abstract

Traditional methods of building with concrete are materially wasteful, highly polluting, and often structurally inefficient. The vast global consumption of concrete plays a large role in the construction industry’s negative effects on the environment, necessitating a significant change in the way we design and build with concrete. The fluid properties of concrete combined with the flexibility of knit textile formwork makes it possible to shape concrete into complex, innovative structures that drastically reduce material consumption and waste.
KnitCrete, which employs CNC-knitted textiles as flexible formwork for casting with concrete, has demonstrated the extraordinary potential of this technology to efficiently fabricate complex geometries without the need for costly, time-consuming rigid molds.
The objective of this research is to develop a pattern-specific knowledge base to support the future design of innovative architectural forms and structures using CNC-knit textile formwork. Through three main parts, the research approach investigates the implications of pattern selection on the behavior of the resulting concrete forms. The study employs a combination of information-based and inspiration-based design research methodologies. In the first phase, a comprehensive pattern repository is developed which catalogues relevant information for 21 different knit patterns. In the second phase, rigorous testing of each pattern under hydrostatic loading is performed and a deformation analysis is performed. The third phase involves an exploration of pattern combinations, supported by the information gathered in phases one and two, which demonstrates the potential of this technology to create complex or double curved geometries.
Key findings reveal that pattern selection significantly influences the structural and aesthetic properties of the resulting concrete forms. The comparison between warp and weft properties highlights distinct behaviors under hydrostatic loading with significant implications for flexible formwork design. Challenges in the precise calibration of combined patterns and controlling deformation during casting underscore the complexity of implementing CNC-knit formwork. Contributions to this field include advancements in understanding knit textile behavior, a replicable research approach, and interdisciplinary connections between textile engineering, material studies, and architectural design. In summary, this research lays a robust groundwork for future research and design in the field of CNC-knit textile formwork with a specific focus on knit pattern behavior.