Incorrect Formwork and Reinforcement Positioning
The concrete upstand or kicker was formed out of alignment with the reinforcement cage, leaving the starter bars positioned close to one edge rather than centrally within the intended concrete section. If the next concrete element were cast in this position, the reinforcement could have insufficient concrete cover, while the completed wall or column could be incorrectly sized or misaligned. The setting-out, formwork dimensions and reinforcement position should be checked against the approved structural drawings and corrected before further concreting.
- NCQLE reference
- NCQLE-2026-00025
- Quality topic
- Installation quality
- Lesson type
- Failure
- Evidence rating
- Experience
- Published
- 2 August 2026
- Last reviewed
- 2 August 2026
Evidence basis: Supported by relevant professional experience. This learning is provided for professional consideration and does not replace project-specific competent advice, statutory duties or contractual requirements.
Context
The issue was identified during construction of a reinforced concrete wall or column at slab level, after the concrete kicker had been cast but before the next section of formwork was installed. The projecting reinforcement cage appeared out of alignment with the completed kicker, raising concerns about the position, dimensions, concrete cover and continuity of the next concrete lift. The discrepancy required verification against the approved structural drawings before work continued. The concrete upstand or kicker had been formed and cast out of alignment with the reinforcement cage. The starter bars were positioned close to the edge of the concrete rather than centrally within the intended wall or column section. This created concern that the required concrete cover, element dimensions and structural alignment could not be achieved when the next section was cast.
The transferable lesson
Formwork setting-out and reinforcement positioning must be checked together before concrete is poured. Correct bar location, alignment, stability and concrete cover are essential to achieving the structural design, durability and fire resistance of the completed element. Once concrete has been placed, correcting an incorrectly located kicker or reinforcement cage can require significant breaking out and engineered remediation. A formal pre-pour inspection should therefore verify both systems against the approved structural drawings.
Recommended action
Introduce a mandatory pre-pour hold point for reinforced concrete elements. Check the formwork dimensions, line, level and location against the approved structural drawings, and survey the reinforcement cage to confirm bar position, spacing, laps, anchorage and required concrete cover. Secure the cage using suitable spacers, chairs and ties so it cannot move during the pour. Record the inspection with measurements and photographs, and do not permit concreting until any discrepancy has been corrected and formally accepted. Where concrete has already been cast incorrectly, obtain a structural engineer’s assessment and approved remedial detail before continuing.
Limitations and application
The required reinforcement position and concrete cover will depend on the approved structural design, element type, exposure conditions and fire-resistance requirements. An eccentric cage or irregular kicker may be intentional in some details, so photographs alone cannot confirm structural non-compliance. The actual dimensions, bar locations and cover should be measured and compared with the current approved drawings. Any remedial work, including bending bars, breaking out concrete or enlarging the section, must be designed or approved by the structural engineer.