FormFlow, an Australian innovator in the design and construction industry, has made significant strides by developing a groundbreaking metal forming process that redefines how corrugated iron sheets are used. The firm’s patented technology enables corrugated iron sheets to bend around a 90-degree corner without experiencing the usual stretching or crushing that occurs in traditional methods. Introduced as the C90 bend, this revolutionary technique was commercialized in 2016 and has since become pivotal in modern construction for its seamless, gapless corners, greatly enhancing both the aesthetic appeal and functionality of buildings.
The Road to Innovation: Partnership and Challenges
The journey to achieve the C90 bend was fraught with considerable engineering and academic challenges. FormFlow navigated these hurdles through strategic local partnerships with key players such as Austeng and Deakin University. These collaborations bore fruit in the form of an industrial-scale machine capable of bending commercial-grade corrugated sheets with precision. This essential piece of machinery allowed FormFlow to license their technology to Bluescope, which has successfully marketed the product under the name CUSTOMFLOW. By combining Lysaght Custom Orb sheets with the FormFlow C90 corners, Bluescope has been able to deliver a product that aligns with high industry standards.
Among the crucial alliances, FormFlow’s partnership with Orrcon Steel stands out significantly. Orrcon provides the essential steel products and exceptional customer service necessary to sustain the manufacturing process. Nick Bernard, FormFlow’s Director of Commercial Partnerships, underscores the importance of these relationships in alleviating the manufacturing burdens and driving continuous innovation forward. Without such cooperative efforts, achieving the current level of precision and quality would have been a far more arduous task.
Transformative Impact on Housing and Fire Safety
According to Professor Matthias Weiss from Deakin University, FormFlow’s structural innovation holds immense potential for revolutionizing housing construction. One of the notable advantages is the technology’s ability to create continuous corners which not only improve the energy efficiency and safety of buildings but also simplify the installation process. A critical aspect of this innovation is its impact on fire safety—particularly relevant in Australia where bushfires pose a significant threat. The C90 bend’s gapless design effectively prevents ember attacks, a primary cause of house fires during bushfire events in Australia. The technology’s ability to form a better seal makes homes less vulnerable to the entry of embers, thereby reducing the risk of fire.
Beyond immediate fire safety benefits, FormFlow’s technology shows promise in the domain of prefabricated modular building systems. The company is actively working on developing BAL-FZ rated homes that are not only fire-resistant but also visually appealing and affordable. These modular homes aim to cater to areas at high risk of bushfires, thereby providing a practical solution for sustainable housing. Andrew Curtis, the branch manager at Orrcon Steel in Geelong, expresses optimism about continued collaboration with FormFlow in their mission to create sustainable, efficient housing solutions. Their partnership underscores a shared commitment to enhancing the durability and safety of residential constructions against natural calamities.
Collaborative Efforts and Future Prospects for Sustainable Building
FormFlow, an Australian pioneer in the design and construction sector, has significantly advanced the industry with its innovative metal forming process that transforms the utilization of corrugated iron sheets. This breakthrough technique, protected by a patent, allows corrugated iron sheets to bend at a 90-degree angle without the typical stretching or crushing that conventional methods incur. Branded as the C90 bend, this method was commercialized in 2016 and has since become instrumental in modern architecture. The technique’s ability to create seamless, gapless corners not only improves the visual appeal of buildings but also enhances their functionality. By eliminating the common issues associated with bending corrugated iron, FormFlow’s process brings a new level of precision and efficiency to construction projects. The C90 bend has been particularly lauded for its application in various architectural designs, offering a sleek, modern appearance while maintaining structural integrity. As a result, FormFlow continues to be at the forefront of innovation in the construction industry.