Case Study: QC Deficiencies in Concrete Formwork on Chicago Riverwalk Extension (Illinois, 2017)

Project Overview
• Name: Chicago Riverwalk Expansion
• Location: Chicago, Illinois
• Year: 2017
• Project Size: $150 million
• Scope: Concrete formwork and structural pours along the riverwalk
• Lead Agencies/Contractors: City of Chicago /

Category of the Issue, Problem, or Challenge
• Quality Control
• Structural

Summary of the Issue, Problem, or Challenge
Formwork failures and misalignment caused surface defects and structural inconsistencies, requiring partial demolition and rework.

Root Cause Analysis

• Poor inspection of formwork alignment and integrity before pours.
• Insufficient training for formwork carpenters and QC inspectors.
• Lack of standardized formwork erection and inspection checklists.
• Inadequate communication between formwork and concrete placement teams.

Impacts Due to the Issue, Problem, or Challenge

• Delay of 2 months due to demolition and re-pour.
• Increased costs for labor, materials, and schedule extension.
• Potential long-term durability risks from formwork defects.

Corrective Actions Taken

1. Developed detailed formwork erection and inspection checklists.
2. Conducted training for formwork crews and QC inspectors.
3. Enhanced communication protocols between formwork and concrete teams.
4. Increased QC inspections prior to concrete placement.

Lessons Learned

• Proper formwork inspection prevents costly defects.
• Training and standardized procedures improve quality.
• Coordination between crews is key for seamless pours.

Audit & Prevention: Project Control Questions to Ask on Future Projects to Help Control the Situation

• Are formwork structures inspected and approved before pouring?
• Are formwork crews and inspectors adequately trained?
• Is communication maintained between formwork and concrete teams?