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Mesh Mould Prefabrication, ETH Zurich, 2019-2021
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 for Concrete Structures and Bridge Design, both at ETH Zurich and the industrial partners PERI GmbH and SIKA AG, 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 National Competence Centre in Research (NCCR) Digital Fabrication.

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.

See as well:

Mesh Mould

Mesh Mould Metal

Mesh Mould and In Situ Fabricator

Gramazio Kohler Research, ETH Zurich

In cooperation with: PERI GmbH, SIKA AG, Department of Architecture, ETH Zurich, Department of Civil, Environmental and Geomatic Engineering, ETH Zurich, IBK Institute of Structural Engineering, ETH Zurich, ITA Institute of Technology in Architecture, ETH Zurich, NCCR Digital Fabrication, matrics engineering GmbH, MEP SpA, ABB Schweiz AG, SCHUNK Intec AG
Collaborators: Dr. Ammar Mirjan, Mattis Koh, Marvin Rüppel, Tobias Hartmann, Nik Eftekhar
Selected experts: Dr. Jaime Mata Falcón, Dr. Marius Weber, Nathalie Reckinger (Concrete Structures and Bridge Design, Prof. Dr. Walter Kaufmann, ETH Zurich); Frank Ilg, Janin Herkrath (PERI GmbH); Dr. Carsten Rieger, Sebastian Jehle (SIKA AG); Philippe Fleischmann, Andreas Reusser, Michael Lyrenmann (ITA Institute of Technology in Architecture, ETH Zurich)
Industry partner: PERI GmbH, SIKA AG

Copyright 2023, Gramazio Kohler Research, ETH Zurich, Switzerland
Gramazio Kohler Research
Chair of Architecture and Digital Fabrication
ETH Zürich HIB E 43
Stefano-Franscini Platz 1 / CH-8093 Zurich

+41 44 633 49 06
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