Mesh Mould Prefabrication

Mesh Mould Prefabrication is an innovative patented technology that combines formwork and structural reinforcement into one robotically fabricated construction system. Thanks to the fruitful collaboration between Gramazio Kohler Research and the Chair of Concrete Structures and Bridge Design, both at ETH Zurich and the industrial partners external pagePERI GmbHcall_made and external pageSIKA AGcall_made, this novel method allows for the industrial and full-scale realization of complex curved, steel-reinforced concrete structures without the need for any formwork. It is based on previous extensive research conducted at ETH Zurich and has counted with the support of the external pageNational Competence Centre in Research (NCCR) Digital Fabricationcall_made.

Mesh Mould Prefabrication involves the rapid as well as material and cost efficient industrial robotic prefabrication of 3D mesh structures which act as both formwork and structural reinforcement. The team developed a novel, patented robotic wire application process, making it possible to fabricate Mesh Moulds with continuous reinforcement in both directions. This automated bending and welding process enables the fabrication and layering of doubly curved meshes from steel rebar of up to 12 mm diameter. Thanks to the implementation of an innovative and automated structural design approach, complex Mesh Mould structures can be dimensioned and optimised following international standards for steel reinforced concrete structures in a very efficient manner.

The process includes the development of a competitive and efficient formworkless concrete mixture and filling method. The prefabricated Mesh Moulds can be assembled on site, then filled and finished with standard concrete processing and construction equipment.