EPS Irregular Concrete Formwork

Adhesive-free irregular formwork using LOM-cut EPS boards secured with pipes and plates

This technology features an EPS irregular concrete formwork system. It consists of a formwork body created by stacking LOM (Laminated Object Manufacturing) 3D-printed EPS boards to form internal irregular casting spaces and vertical through-holes. The boards are secured by combining a fixing pipe that passes through the holes with bottom and pressure plates. Multiple formwork units can be placed side-by-side and connected using tie modules to create a single, larger formwork assembly.

While demand for irregular concrete structures with complex curves is rising, traditional methods have limitations. Wooden formwork is inexpensive and fast but struggles with complex shapes, while CNC-machined steel formwork is precise but costly and time-consuming. Previous attempts to stack EPS boards using thin-film layering required wet adhesives between layers, which slowed production due to curing times and made disassembly and reuse difficult.

This technology uses a dry-assembly method, securing board layers with fixing pipes and plates instead of adhesives. The pressure plate is tightened onto the pipe's male thread, and a heating tool is used to melt plate-shaped grooves into the boards for a secure fit. Units are stacked vertically using threaded rods and nuts, while side-by-side units are secured with longitudinal/transverse frames featuring corner wings, tie bands, and lockers. Suitable for landmark buildings with curved facades, irregular sculptures, pavilions, curved bridge railings, and precast components, this system allows for immediate assembly and casting without waiting for adhesive to cure, and can be disassembled for reuse.

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Key Features:

• An EPS formwork body where EPS boards are cut and stacked via thin-film layering to form internal irregular casting spaces and vertical fastening through-holes
• A fixing pipe that passes through the fastening through-hole, with a bottom plate coupled to one end and a pressure plate coupled to the other
• A pressure plate coupled transversely to the other end of the fixing pipe to apply pressure to the top surface of the EPS formwork body
• A tie module that connects and secures the pressure plates of adjacent formwork units arranged side-by-side

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This invention was developed with support from the Ministry of Land, Infrastructure and Transport for the development of 3D printing equipment and production technology for irregular components.

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