Sustainable construction with reusable carbon concrete panels
The ZHAW has developed carbon concrete panels that are being used in building construction for the first time. This innovation enables considerable CO2 and material savings and offers a flexible, reusable component system.
The introduction of carbon fibre-reinforced concrete slabs by the ZHAW marks a significant advance in building construction. These panels, which are prefabricated and cut to size in the factory, can be quickly assembled on site. “Our carbon concrete construction system works in a similar way to Lego, but like a modern version of it, with customised components,” explains ZHAW researcher Josef Kurath. This system not only significantly shortens construction times, but also enables flexible adaptations and extensions to buildings.
Sustainability and reuse
A prime example of the application of this technology is the 120 square metre pavilion in Winterthur, which serves as an innovation laboratory for sustainable construction. Thanks to a new sharing model, around 90 per cent of the material used can be reused, which represents significant progress compared to conventional methods, where only around 10 per cent can be reused. In view of the fact that cement is responsible for eight per cent of global greenhouse gas emissions, this development represents an important contribution to reducing the ecological footprint.
Carbon fibres at the heart of
The CPC (Carbon Prestressed Concrete) concrete slabs are characterised by their durability and environmental friendliness. “Thanks to the new lightweight construction method in concrete, we reduce the CO2 footprint by a factor of two to four and save up to 75 per cent material compared to conventional construction methods,” explains Kurath. The combination of pre-stressed carbon fibres and concrete offers outstanding structural properties: carbon absorbs tensile forces, while concrete absorbs compressive and shear forces. As a result, no cracks occur under load and the panels retain their shape and load-bearing capacity despite their reduced thickness.
Industrial production and future prospects
The CPC slabs are manufactured by Holcim in the first plant in Germany, while the carbon fibres are produced in Switzerland, in future using bio-based carbon. “The developed panels will also be produced in this country in the future and the new construction system will be widely used in building construction – the Swiss market in particular is predestined for this,” says Kurath. Further research will focus on optimising the panels for sound insulation and fire protection as well as on earthquake-proof constructions. Innovative joining techniques enable almost endless horizontal planes without additional connecting elements, which further increases the flexibility and efficiency of construction.