Third patent issues for vaulted concrete SIP formwork system
Vaulted stay-in-place (SIP) reinforcement system for strengthening concrete structures in construction moves toward commercialization.
A 17.25 L × 3.75 W × 4 H inch scaled model featuring ConTech’s capabilities was printed with PETG and 30% recycled wind blade material. Source | University of Maine
Another patent for the vaulted stay-in-place (SIP) composites formwork system by ST Bungalow LLC (Garrison, N.Y., U.S.) and Molinelli Architects (Briarcliff Manor, N.Y., U.S.) has been awarded by the U.S. Patent and Trademark Office (USPTO).
Over the past decade, inventors Michael Molinelli and Ashok Chaudhari have been developing the patents and most recently — the past 2 years — doing so from a U.S. grant awarded in October 2024. The first patent in the portfolio was issued in 2015 and the second in 2016. This announcement makes the third patent (US 12,516,522 B2) in a portfolio that covers the core concept and additional materials behind making concrete flatwork/structures.
The patent is a concrete reinforcement system that stays in place and uses geometry — i.e., shapes such as arches and vaults — to achieve high compression in flat concrete structures (e.g., floors, roof, bridge decking). This compression greatly improves a structure’s overall strength while simultaneously reducing the amount of concrete needed.
One hundred percent of the SIP formwork system is made of recycled materials — composites from wind turbine blades and plastics from bottles — and provides whatever tensile strength may be needed even with the added compression. Thus, no steel reinforcement bars or decking are required.
This technology provides cost savings through reduced labor, material and transportation costs by replacing costly and labor-intensive steel rebar (or FRP rebar), steel decking and concrete. The structure’s embodied carbon footprint is also reduced.
Modeling shows that a live load capability of 300 PSF is possible, which is far above the standard live load requirements for residential and commercial buildings, 40 PSF and 100 PSF, respectively.
“The idea of using geometry such as arches or vaults when strengthening concrete is as old as Roman times,” says Chaudhari, founder and co-inventor, ST Bungalow LLC. “But using it for concrete flatwork reinforcement in place of rebar is — remarkably — new.”
The commercial prospects are enormous, partners report. The SIP formwork system is expected to be of particular interest to contractors building data centers and for other infrastructure such as bridges.
Molinelli Architects and ST Bungalow LLC are currently in discussions to license and commercialize the patented technology and welcome any inquiries toward this end.
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