About Our Product
STB Forms are the first-ever stay-in-place formwork system with a geometry (arches, vaults) designed to allow concrete to work purely in compression such that reinforcement is not needed. This means no steel reinforcement bars or FRP bars or steel decking. No setting up or taking down of formwork, no installation of steel or FRP rebars, no corrosion, concrete reduction by 20%, and more.
The idea of geometry pushing concrete to compression is as old as Roman and Gothic architecture times, yet the application of this tried-and-true, time-tested engineering concept to formwork has, until now, not been conceived. Remarkable but true.
Architect Michael Molinelli (Molinelli Architects) came up with the innovation when collaborating with Ashok Chaudhari of ST Bungalow LLC in 2013.
Patents were filed, grants were awarded, an angel investor came on board, and now the design is poised to transform the construction industry by simplifying the flat concrete slab construction work performed every day globally. The design means cost savings, time savings, and improved worker safety.
The market for this construction technology, or fashionably “ConTech,” is enormous — at least $300 billion USD, which is the size of the steel reinforcement bar market.
Add sustainability to the innovation (the formwork can be made of recycled wind blade material and plastic for a 100% recycled product) and one has an unbeatable building product innovation at a time when the built world greatly needs and demands it.
Our design means:
- Digital fabrication — allowing for tailor made solutions in situ, or modular, for client.
- Lightweight: a 12ft form that is 1/8" thick or 3.5mm would weigh only 50 lbs.
- No formwork set up / take down + no steel rebar / deck pans installation and material cost = massive savings $$
- No precast concrete flat slab transportation costs.
- Safety improvements (no steel rebar installation risk, better building structure).
- Labor / trades shortage solution — no skilled labor or trades needed for rebar work (steel or FRP).
- Carbon footprint reduction — concrete and steel contribute to 12% and 8% GHG emissions.
- 20% less concrete used and low carbon concrete use is possible.
- No tension ties are required.
- The product is made from 100% recycled materials (plastic, glass fibers).
- Circularity achieved by providing end purpose solution for wind turbine blade recycling.
A live load of 243 psf was achieved in scaled model testing as depicted above. FEA calculations show that 300 psf is possible.