Structural 3D Printed Concrete Formwork for Post-Tensionned Ribbed Slabs

Developed by Empa with BBR VT International and ETH Zurich, this research explores a new floor slab system using 3D-printed concrete formwork that remains part of the final structure.

The system combines concrete 3D printing, post-tensioning, and concrete casting. Full-scale tests showed spans of up to 5 m without temporary supports and up to 10 m with only one support.

By reducing the need for temporary formwork, the project helps save materials, time, labor, and construction waste while expanding the use of concrete 3D printing in structural applications.

Saim Raza, Mahsa Sakha, Zohaib Hassan, Behzad Manshadi, Xiaomeng Wang, Haifeng Fan, Benjamin Dillenburger, Moslem Shahverdi, Flexural behavior of stay-in-place load-bearing 3D-printed concrete formwork for ribbed slabs, Engineering Structures, Volume 338,2025, 120531,ISSN 0141-0296, https://doi.org/10.1016/j.engstruct.2025.120531.