The Challenge: Formwork Integrity & Safety
If lateral pressure—the horizontal force exerted by fresh concrete on the vertical surfaces of formwork during placement—exceeds the formwork’s design capacity, it can cause bulging or blowouts, leading to structural failure, safety hazards, and costly delays. Traditional formwork design is based on theoretical models (e.g., DIN 18218 or ACI 347R) that often assume conservative rates of rise. However, variations in concrete mix rheology—especially with Self-Compacting Concrete (SCC)—can cause unexpected pressure spikes, increasing the risk of formwork failure and safety hazards.
The Solution: Digital Hydrostatic Load Management
Real-time monitoring provides live visibility into the lateral pressure exerted by fresh concrete on the formwork. Pressure sensors mounted on the formwork transmit data to a dashboard, enabling precise control of pouring speed and ensuring structural integrity.
Engineering Impact & Key Benefits
- Optimized Pouring Speed: Safely maximize pouring speed by monitoring the complete pressure development—from initial build-up during placement to the reduction as the concrete sets.
- Blowout Prevention: Automated alerts at critical thresholds (e.g., 80–90% of formwork capacity) create a safety buffer for personnel and equipment.
- Safe Concreting of High Walls and Columns: Multiple vertically arranged sensors provide continuous pressure data, allowing safe and efficient pouring of tall structures.
- Reliable SCC Applications: Self-Compacting Concrete requires special attention due to its flow characteristics. Real-time monitoring ensures compliance with regulations and prevents pressure-related failures.
- Single-Sided Formwork Safety: When concreting against existing structures, sensors help maintain ideal pouring speed and protect both the formwork and adjacent elements.
- Controlled Pumping from Below: Pumping concrete upward can increase pressure unpredictably. Monitoring ensures safe operation and optimal results.
- Special Infrastructure Applications: Complex projects such as tunnels, bridges, and other heavy civil works often involve unique formwork geometries and high-pressure scenarios. Real-time monitoring enables precise control, reducing risk and ensuring structural integrity under challenging conditions.
