Displacement monitoring of modular formwork in sustainable concrete fabrication using 3D laserscanning

The concrete industry faces major challenges, including high carbon emissions, labour shortages, and stagnating productivity. This study presents a novel modular, reusable formwork system designed for integration into automated mass production of concrete elements, enabling efficient formation of internal voids. The system, composed of reconfigurable modules, is engineered to withstand real-world casting conditions and support automation. A representative test setup was used to assess its dimensional and positional stability during curing, with a focus on shrinkage-induced effects. High-resolution 3D laser scanning tracked displacements and rotations of modules throughout the curing cycle. Results show the system maintains dimensional accuracy within tolerances and allows for practical manual assembly and disassembly. Shrinkage effects were minor compared to deviations from vibration compaction. Future work includes refining point cloud analysis and adapting the system for alternative materials. The study lays the groundwork for fully automated implementation, including robotic placement using a six-axis industrial robot. • Successful deployment of modular formwork system under real-scale. • 3D scanning applied for dimensional accuracy and quality control of structurally optimized concrete elements. • Advancement toward fully digital and automated fabrication workflow integrating formwork and scanning systems.