Module 5: Practical Applications & Case Studies
1. Hands-on Workshops
This module bridges theory and practice through immersive training with real-world formwork systems and cutting-edge technology.
Erection & Dismantling of Advanced Systems:
Step-by-Step Assembly: Trainees practice with climbing formwork, jump forms, and modular systems, focusing on:
Sequencing (correct order of panel installation)
Tolerances (permissible deviations as per ACI 117)
Connection Integrity (ensuring bolts, wedges, and locks are secure)
Stripping Techniques: Safe removal without damaging concrete or formwork, emphasizing:
Stripping Time (based on concrete strength testing)
Cleaning/Reconditioning (extending formwork lifespan)
Laser Scanning for Alignment Checks:
Quality Control: Laser scanners (e.g., Faro or Leica) verify:
Dimensional Accuracy (deviation ≤3mm per 3m as per EN 13670)
Plumbness/Levelness (critical for high-rise cores)
BIM Integration: Scan data overlays on digital models to detect errors before pours.
2. Industry Case Studies
Real project examples highlight both pitfalls and breakthroughs in formwork technology.
Failures & Lessons Learned:
Collapse Case Study (2004, Singapore):
Cause: Inadequate bracing during heavy rain.
Lesson: Mandatory wind bracing and real-time weather monitoring.
Formwork Deflection (2018, UAE):
Cause: Overloading modular panels beyond design capacity.
Lesson: Strict enforcement of load limits via IoT sensors.
Innovations Shaping the Future:
3D-Printed Formwork:
Benefits: Custom geometries (e.g., organic shapes for façades), reduced waste.
Example: ETH Zurich’s "Eggshell" concrete structures.
Robotics & Automation:
Formwork Robotics: Doka’s X-Day robot automates panel handling, cutting labor by 30%.
AI-Powered Inspection: Drones with ML algorithms detect formwork defects.
Key Takeaways:
Workshops build competency in handling advanced systems and tech.
Case Studies underscore the cost of negligence and value of innovation.
3D Printing/Robotics are revolutionizing speed, safety, and design freedom.
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