Case Study: Subcontractor Concrete Formwork Failure Leads to Collapse in Illinois (2020)

Project Overview
• Name: Chicago Expressway Rehabilitation
• Location: Chicago, Illinois
• Year: 2020
• Project Size: $500 million
• Scope: Expressway structural repairs and concrete work
• Lead Agencies/Contractors: Illinois DOT /

Category of the Issue, Problem, or Challenge
• Subcontractor Management
• Structural Safety & Quality Control

Summary of the Issue, Problem, or Challenge
The formwork subcontractor’s inadequate installation and bracing led to a partial collapse of concrete forms during pouring, causing injuries and extensive delays.

Root Cause Analysis

• Insufficient engineering review of formwork design.
• Lack of adherence to formwork installation standards.
• Inadequate supervision and inspection during setup.
• Deficient subcontractor safety culture and training.

Impacts Due to the Issue, Problem, or Challenge

• Work stoppage for accident investigation and repairs.
• Project delay of over 6 weeks.
• Increased insurance and medical costs.
• Heightened regulatory scrutiny and enforcement actions.

Corrective Actions Taken

1. Conducted engineering validation of all formwork designs.
2. Enhanced installation procedures and training programs.
3. Increased onsite inspection and monitoring during formwork erection.
4. Instituted safety accountability measures for subcontractor crews.

Lessons Learned

• Proper formwork design and installation prevent structural failures.
• Continuous supervision is essential during critical construction steps.
• Strong safety practices reduce risk of accidents and delays.

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

• Is formwork engineering reviewed and approved before erection?
• Are installation crews properly trained and supervised?
• Are safety protocols strictly enforced onsite?