Search Results (19)

This critical review synthesizes evidence on the multifactorial coupling mechanisms and time-dependent evolution of lateral pressure in concrete formworks, addressing significant limitations in current design standards (GB50666, CIRIA 108, ACI 347). Through a structured analysis of 60+ experimental and theoretical studies, we establish that lateral pressure is governed by nonlinear interactions between concrete rheology, casting dynamics, thermal conditions, and formwork geometry. The key findings reveal that (1) casting rate increments >5 m/h amplify peak pressure by 15–27%, while SCC thixotropy (Athix > 0.5) reduces it by 15–27% at <5 m/h; (2) secondary vibration induces 52–61% pressure surges through liquefaction; and (3) sections with a width >2 m exhibit 40% faster pressure decay due to arching effects. (4) Temporal evolution follows three distinct phases—rapid rise (0–2 h), slow decay (2–10 h), and sharp decline (>10 h)—with the temperature critically modulating transition kinetics. Crucially, the existing codes inadequately model temperature dependencies, SCC/HPC rheology, and high-speed casting (>10 m/h). This work proposes a parameter-specific framework integrating rheological thresholds (Athix, Rstr), casting protocols, and real-time monitoring to enhance standard accuracy, enabling an optimized formwork design and risk mitigation in complex scenarios, such as water conveyance construction and slipforming. Full article

To resolve the critical issues of severe deformation, structural failure, and maintenance difficulties in the advanced reuse zone of gob-side-entry retaining roadways under pillarless mining conditions in ultra-long fully mechanized top-coal caving isolated mining faces, this study proposes a surrounding rock control technology incorporating pressure relief through roof cutting. Taking the 3203 ultra-long isolated mining face at Nanyang Coal Industry as the engineering case, an integrated methodology combining laboratory experiments, theoretical analysis, numerical simulations, and industrial-scale field trials was implemented. The deformation and failure mechanism of flexible formwork walls in gob-side-entry retaining and the fundamental principles of pressure relief via roof cutting were systematically examined. The vertical stress variations in the advanced reuse zone of the retained roadway before and after roof cutting were investigated, with specific focus on the strata pressure behavior of roadways and face-end hydraulic supports on both the wide coal-pillar side and the pillarless side following roof cutting. The key findings are as follows: ① Blast-induced roof cutting reduces the cantilever beam length adjacent to the flexible formwork wall, thereby decreasing the load per unit area on the flexible concrete wall. This reduction consequently alleviates lateral abutment stress and loading in the floor heave-affected zone, achieving effective control of roadway surrounding rock stability. ② Compared with non-roof cutting, the plastic zone damage area of surrounding rock in the gob-side entry retained by flexible formwork concrete wall is significantly reduced after roof cutting, and the vertical stress on the flexible formwork wall is also significantly decreased. ③ Distinct differences exist in the distribution patterns and magnitudes of working resistance for face-end hydraulic supports between the wide coal-pillar side and the pillarless gob-side-entry retaining side after roof cutting. As the interval resistance increases, the average working resistance of hydraulic supports on the wide pillar side demonstrates uniform distribution, whereas the pillarless side exhibits a declining frequency trend in average working resistance, with an average reduction of 30% compared to non-cutting conditions. ④ After roof cutting, the surrounding rock deformation control effectiveness of the track gateway on the gob-side-entry retaining side is comparable to that of the haulage gateway on the 50 m wide coal-pillar side, ensuring safe mining of the working face. Full article

The advancement of modern concretes, such as printable concrete, fluid concrete with adapted rheology, and ultra-high-performance concrete, has increased the importance of understanding structural build-up in cement-based materials. This process, which describes the time-dependent evolution of rheological properties, is a key factor to ensure the stability of concrete by influencing segregation, bleeding, formwork pressure, numerical modeling, and multi-layer casting. As a result, the structural build-up of cementitious materials has become a significant area of research in recent years. The structural build-up of cement based-materials results from both a reversible part (thixotropic behavior), driven by colloidal interactions, and an irreversible part, caused by cement hydration and the formation of C-S-H bridges. Various experimental techniques have been developed to investigate these processes, with various factors affecting the thixotropic behavior and overall structural build-up of cement suspensions. This review provides a comprehensive analysis of the current understanding of structural build-up in cement pastes. It covers measurement methods and key influencing factors, including the water-to-binder ratio (w/b), admixtures, temperature, and supplementary cementitious materials (SCMs). By consolidating the existing knowledge and identifying research gaps, this review aims to contribute to the development of sustainable, high-performance cement-based materials suitable for modern construction techniques. Full article

The structural build-up of cementitious materials is the subject of more and more attention since it conditions several processes such as formwork pressure and multi-layer casting. However, this phenomenon originating from flocculation and chemical changes is complex and its reversibility is not clearly elucidated. The aim of this paper is to examine the effect of temperature on the reversibility of structural build-up. The results show that irreversible structural build-up remains negligible despite a rise in temperature. It represents between 0.5–7.3% of the total structural build-up. The addition of SCMs allows for a decrease in this irreversible structural build-up. Therefore, a large part of the chemical contribution is expected to be reversible. The effect of temperature can be explained by the increase in the dissolution rate leading to an increase in flocculation and to the bridging effect induced by early hydrates. Finally, the results suggest that the interparticle distance could be the key parameter governing the irreversibility of structural build-up. Full article

This study provides a comprehensive review of the engineering challenges of formwork in concrete construction. The paper investigates different formwork systems, their design based on form pressure, and the difficulties of form stripping. Alternative binders are gaining more and more interest by opening new opportunities for sustainable concrete materials and their impact on form pressure and concrete setting is also investigated in this paper. The discussion involves several engineering challenges such as sustainability, safety, and economy, while it also explores previous case studies, and discusses future trends in formwork design. The findings pinpoint that choosing an appropriate formwork system depends significantly on project-specific constraints and that the development of innovative materials and technologies presents significant benefits but also new challenges, including the need for training and regulation. Current trends in formwork design and use show promising possibilities for the integration of digital technologies and the development of sustainable and ‘smart’ formwork systems. Continued research within the field has the possibility to explore new formwork materials and technologies, which will contribute to the implementation of more effective and sustainable practices in concrete construction. Full article

A new type of non-dismantling composite insulation panel, namely a steel-wire-enhanced insulation panel, was proposed. Compared to traditional organic insulation panels, the construction procedure is reduced, and the fire resistance is improved. The flexural performance was explored experimentally and numerically to evaluate its ability to withstand lateral pressure when it was used as the formwork of a cast-in-place concrete wall. First, 6 groups of 12 specimens of steel-wire-enhanced insulation panels were conducted under 2 loading modes: 3-point bending loading and 4-point bending loading. The failure modes of these specimens included a straight crack at the bottom of the panel and the yielding of steel wire. The test results showed that the maximum bending moment of the specimens with an 80 mm thickness could reach 2.415 kN·m. Second, finite element (FE) models were developed for the steel-wire-enhanced insulation panels by ABAQUS, which were validated by the experimental results. Third, a parametric study with parameters, including the thermal insulation cover, the square gird spacing of the steel wire mesh, and the diameter of the steel wire, was performed. It was observed that the insulation cover had a significant effect on the flexural capacity in the simulated range. Finally, theoretical formulas for panel stiffness and flexural capacity were presented, which can predict the bending performance more conservatively compared to the experimental results. The research and analysis of this study could offer a valuable reference for designing this panel in practical applications. Full article

Since it is impossible to reconstruct the top level that has collapsed, a formwork is constructed to squeegee mortar or spray mortar, and repair kits are being used in Korea to chip away the damaged concrete of the bridge deck structure. In Korea, a technique called hydro-demolition replaces water blasting and water jetting by using high-pressure water to remove not only asphalt but also old and broken concrete. Additionally, dry materials including cement, aggregate, and additives are carried via the inside of a hose to the field using compressed air, where they meet water and are ejected at a high rate of speed. This technique is known as dry mix shotcrete. Using the devised automatic hydraulic dismantling technology and high-performance dry-mix shotcrete, field application results are discussed in this study. Full article

To assist in addressing the problem where an aluminum alloy formwork (AAF) deforms more greatly under the action of lateral pressure and therefore does not meet the requirements of plaster-free engineering, we propose a method for determining the geometric parameters of this formwork based on a PSO algorithm and BP neural network with ABAQUS as the platform. The influence of six geometric parameters of the formwork on the maximum deflection value of the panel under the action of lateral pressure is studied using finite element analysis. The maximum deflection value of the panel is used as the index, and the influence of each factor is analyzed with an orthogonal test, and a set of optimal geometric parameters is obtained via extreme difference analysis and analysis of variance. The sample data are obtained via finite element simulation, and the PSO-BP neural network model is established using the six factors of the orthogonal test as input values and the maximum deflection of the panel as the output value, and the optimal geometric parameters are optimized using the PSO algorithm. The results indicate that the maximum deflection for the panel in the orthogonal scheme is 1.446 mm. The PSO-BP neural network prediction model demonstrates greater accuracy and a 31.74% reduction in running time compared to the BP neural network prediction model. The optimized PSO-BP neural network prediction model scheme reveals a maximum panel deflection of 1.296 mm, a 10.37% decrease compared to the orthogonal solution. These findings offer technical guidance and a foundation for optimizing AAF designs, presenting practical applications. Full article

Based on the advantages of the silicone graphene composite thermal insulation board, it was used to replace traditional plywood in the external wall formwork system, and the active embedded steel wire knot form in silicone graphene composite thermal insulation structure integrated system was designed. Firstly, the theoretical model of steel wire drawing resistance was established by theoretical analysis method, and the rationality of the theoretical model was verified by combining relevant experimental data. The relationship between multiple variables and steel wire pull-out resistance was analyzed. Then, combined with the theory of wind pressure strength of the exterior wall of a building structure, the layout form and the corresponding number of embedded steel wires of thermal insulation board under different building heights were analyzed. Finally, the silicone graphene composite thermal insulation board and ordinary plywood were compared and analyzed from the force of perspective of external wall formwork. The results showed that the pull-out resistance of steel wire was directly proportional to the diameter of steel wire, embedded depth, and embedded deflection angle. With the increase of building height, the number of steel wires to be arranged also increased. When the thickness of the silicone graphene composite thermal insulation board is not less than 80 mm, the anti-deformation effect is close to that of the ordinary plywood, which can meet the construction requirements of the external wall formwork. It can ensure the energy conservation and thermal insulation of the external wall, integrate the building’s exterior wall and thermal insulation structure of the building, and achieve the purpose of exemption from formwork removal. Full article

Despite the advantageous benefits offered by self-compacting concrete, its uses are still limited due to the high pressure exerted on the formwork. Different parameters, such as those related to concrete mix design, the properties of newly poured concrete, and placement method, have an impact on form pressure. The question remains unanswered on the degree of the impact for each parameter. Therefore, this study aims to study the level of impact of these parameters, including slump flow, T500 time, fresh concrete density, air content, static yield stress, concrete setting time, and concrete temperature. To mimic the casting scenario, 2 m columns were cast at various casting rates and a laboratory setup was developed. A pressure system that can wirelessly and continuously record pressure was used to monitor the pressure. Each parameter’s impact on the level of pressure was examined separately. Casting rate and slump flow were shown to have a greater influence on pressure. The results also demonstrated that, while higher thixotropy causes form pressure to rapidly decrease, a high casting rate and high slump flow lead to high pressure. This study suggests that more thorough analysis should be conducted of additional factors that may have an impact, such as the placement method, which was not included in this publication. Full article

Active rheology control (ARC) or active stiffening control (ASC) is a concept with which the conflicting rheological requirements during different stages of concrete casting can be reconciled. For instance, formwork leakage could be reduced by actively controlling structuration at the formwork joints, without having the negative impact of increased structuration during pumping and form filling. Using the concepts of magnetorheology, an active control methodology was thus recently developed by the authors to study the control of formwork leakages under pressure. This was performed using a small-scale laboratory test setup, using cementitious pastes containing magnetisable particles. To upscale from paste to mortar, the effect of volume fraction of sand on the magnetorheological (MR) response and blocking mechanisms of mixtures containing Fe₃O₄ nanoparticles is thus investigated in the current study. The MR response is determined using storage modulus tests, and the impact of ASC for leakage reduction is investigated by measuring the flow rate. Experimental results show that increasing the sand volume beyond a threshold causes a reduction in mobility of the magnetic particles, and thus lowers the MR effect. Despite this reduction in the MR effect at high sand volume, the increased particle interactions induce clogging and filtration effects, drastically lowering the flow rate. Applying the ASC method refines the voids in the clog, thereby eliminating the filtration effect. It is concluded that ASC can be used on mortar, with the expectation that there would be a reduction in the magnetorheological effect with increasing volume of fine aggregates. Full article

Formwork lateral pressures are critical with respect to engineering safety, and laboratory tests are often limited by time, height, etc. Formwork lateral pressures are related to early concrete fluid behavior (e.g., thixotropy). In this paper, we propose the use of ultra-deep underground diaphragm walls instead of formwork for conventional lateral pressure testing. During the construction process, three measurement points were set up in an ultra-deep diaphragm wall at −40 m, −80 m and −100 m. The concrete was divided into 22 casts, and the development of lateral pressure and the effect of time on lateral pressure were observed under each of the casts. We found that the characteristic height of all three measurement points was approximately 21 m. The average casting speed for this test was 16.846 m/h, with the fastest speed of 32.148 m/h. A time-dependent phenomenon of rapid rise and fall in lateral pressure with each casting was observed. This method provides a new way to conceptualize formwork lateral pressure, with the advantages of long testing time, high casting height and multiple tests, not only for formwork lateral pressure but also for early age thixotropy measurement of concrete. Full article

Concrete construction harms our environment, making it urgent to develop new methods for building with less materials. Structurally efficient shapes are, however, often expensive to produce, because they require non-standard formworks, thus, standard structures, which use more material than is often needed, remain cheaper. Digital fabrication has the potential to change this paradigm. One method is Digital Casting Systems (DCS), where the hydration of self-compacting concrete is controlled on the fly during production, shortening the required setting time and reducing hydrostatic pressure on the formwork to a minimum. This enables a productivity increase for standard concrete production. More importantly, though, it enables a rethinking of formworks, as the process requires only cheap thin formworks, thus, unlocking the possibility to produce optimised structural members with less bulk material and lower environmental cost. While DCS has already proven effective in building structural members, this process faces the challenge of moving into industry. This paper covers the next steps in doing so. First, we present the benchmark and expectations set by the industry. Second, we consider how we comply with these requirements and convert our fast-setting self-compacting mortar mix into a coarser one. Third, we present the next generation of our digital processing system, which moves closer to the industrial requirements in terms of size and the control system. Finally, two prototypes demonstrate how DSC: (a) increases standard bulk production by 50% and (b) can be cast into ultra-thin formworks. We discuss the results and the short-term industrial concerns for efficiency and robustness, which must be addressed for such a system to be fully implemented in industry. Full article

When the vertical joints of monolithic precast concrete structures are cast by self-compacting concrete, the design of the formwork under rational lateral pressure of self-compacting concrete becomes a key technical issue. In this paper, a prototype simulation test was conducted for the pouring of self-compacting concrete in the vertical joint of precast concrete walls. The self-compacting concrete was continuously poured from the top of vertical joints with a height of 2.8 m without any assistance such as a delivery tube. The formwork pressure of self-compacting concrete was measured at different heights with varying casting time. Results showed that the lateral pressure increased with the increase in slump-flow of fresh self-compacting concrete, reaching a peak value of about 70 kPa at a height of about 600 mm from the bottom of formwork. Compared to the concrete with a slump-flow of 550 mm, the self-compacting concrete with the slump-flow reached 655 mm and 755 mm, presenting an increase in the peak lateral pressure by 31.5% and 44.9%, respectively. A method for calculating the lateral pressure of self-compacting concrete on the joint formwork is proposed using the analysis of enveloped test curves. Under the condition with enough strength and limited deformation of the joint formwork, the optimal design of aluminum alloy formwork is determined using finite element analysis. This provides a sci-tech foundation of the optimal design to lighten the weight of joint formwork to improve the installation efficiency and reduce the manual power cost. Full article

The correct estimation of earth pressure is important for the design of earth retaining structures and depends, among others, on the surface morphology of retaining structures. The diaphragm wall created as a protection of a deep excavation located in an urbanized area was selected as a research object. Terrestrial Laser Scanning (TLS) was used for the investigation of the unique surface (in real-world dimension) obtained by tremieying the concrete in different soil layers. An original and innovative procedure for concrete surface description was developed, which includes steps from the TLS measurement to the determination of the roughness parameters. The tested samples from anthropogenic soil, medium sand, and sandy gravel, map the real diaphragm wall surface. The surface roughness parameters in different soil layers were compared with the reference surface obtained by cast against steel formwork. The following parameters: Sa, Sdr, and Vmc are indicated as being the most useful in numerical description of the concrete surface type and in allowing the determination of the soil surface friction. The novelty of this study is the estimation of the parameter δ (friction angle between the retaining wall surface and the soil), which is, among others, a function of the wall surface roughness. The influence of the type of surface on earth pressure are generally recognized in laboratory tests. Based on the estimated in situ values of δ, the more reliable active and passive pressure coefficients K_a, K_p were calculated for the tested soil layers. The conducted study has a practical significance for designing of retaining construction and makes progress in determination of surface roughness required in Eurocode 7. Full article