Unfold Form, a 'curved-crease un-foldable formwork for sustainable vaulted floors'

Casting Creased Vaults at ETH Zurich

John Hill | 12. February 2025
Photo: Andrei Jipa

The Block Research Group, headed by structural designer and professor Philippe Block, is dedicated to “pioneering novel design and engineering approaches for efficient structural forms and proposing economical construction methods.” Based at ETH Zurich, their research proposals and prototypes have been exhibited at Venice Architecture Biennale and other venues around the world. Their projects have explored a variety of structural assemblies, using traditional building materials like concrete and stone, but also looking at how waste, mycellium, and even fabrics can be used in architecture and engineering.

The latest project, Lotte Scheder-Bieschin's Unfold Form, is aimed at using concrete, the most common structural material today, more efficiently. The lightweight formwork made from plywood panels connected by textile hinges, capable of supporting 1,000 kg (2,200 lbs) of concrete, results in corrugated vaults that save up to 60% concrete and 90% reinforcement steel per typical concrete floors. Although the fabrication of the intricate formwork appears time-consuming, as seen in the photographs and short film below, the formwork is reusable, which is a plus, and it results in a beautiful finished product.

Learn more about Unfold Form, first through some photographs of its construction:

Prefabrication assembly of the Unfold Form-work (Photo: Lotte Scheder-Bieschin)
 
Unfolding of Form-work (Photo: Lotte Scheder-Bieschin)
Casting of fan-vaulted concrete shell onto Unfold-ed Form-work (Photo: Lotte Scheder-Bieschin)
Decentring of Unfold-ed Form-work (Photo: Lotte Scheder-Bieschin)

Second, watch a short film on the design and construction of Unfold Form:

Third, here are a few photographs of the finished product:

Side view of fan-vaulted floor with Mark and Lotte (Photo: Andrei Jipa)
Perspective of fan-vaulted floor with Heidi and Lotte (Photo: Andrei Jipa)
Intrados of the fan-vaulted floor towards a capital (Photo: Andrei Jipa)
Detail of the intrados of the fan-vaulted floor along crown (Photo: Andrei Jipa)
 

Finally, visit ETH Zurich's website to read more about Lotte Scheder-Bieschin's Unfold Form.

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