Manufacturer of standardized steel formwork: How much impact does leakage of formwork joints have on structural safety?

Leakage of grout at template joints may have varying degrees of impact on structural safety, as follows:
The impact on the concrete structure itself
Reducing structural strength: Leakage of grout can lead to the loss of cement slurry in concrete, causing an imbalance in the ratio of cement slurry to aggregate inside the concrete, forming defects such as honeycombs, holes, and exposed reinforcement, thereby reducing the compressive, tensile, and shear strength of concrete and affecting the load-bearing capacity of the structure.
Impact on structural durability: Defects caused by grout leakage can damage the compactness of concrete, making it more susceptible to external harmful substances (such as water, chloride ions, carbon dioxide, etc.), accelerating concrete carbonation, freeze-thaw damage, and steel corrosion, thereby reducing the durability of the structure.
Weakening structural integrity: Concrete structures are an integral load-bearing system, and local defects caused by leakage of formwork joints can damage this integrity, resulting in uneven stress distribution and stress concentration, which reduces the overall stability and seismic performance of the structure.
Potential threats to structural safety and stability
Influence on structural stress performance: The strength and stiffness of concrete structures directly affect their stress performance. The decrease in strength and defects such as honeycombs and holes caused by grout leakage will result in the structural performance not meeting the design expectations in actual use, unable to meet the load-bearing capacity required by the design, and increasing the safety hazards of the structure during use, such as the risk of cracks, deformation, and even collapse.
Reducing the reliability of structural connections: In some nodes or component connections, leakage of grout in the formwork joints may lead to loose and unstable concrete connections, weaken the connection strength between structures, affect the overall force transmission performance of the structure, and reduce the safety and reliability of the structure. For example, leakage of grout at beam column joints may affect the connection stiffness and bearing capacity between beams and columns, reducing the seismic performance of the structure under earthquake and other actions.
Increasing structural uncertainty: Concrete defects caused by template joint leakage increase the uncertainty of structural performance. The existence of these defects makes it difficult to accurately evaluate and predict the actual strength, stiffness, durability, and other performance of the structure, which poses difficulties for the safe use and maintenance of the structure and increases the risk of long-term use of the structure.
Impact on construction safety
Impact on construction process safety: Severe leakage during concrete pouring may cause uneven stress on the formwork support system, increase the risk of instability of the formwork support system, and even lead to formwork collapse accidents, posing a threat to the safety of construction personnel.
Increasing the difficulty of later repair: Defects such as honeycombs and holes formed by grout leakage require repair treatment, which not only increases construction costs and time, but also may not fully restore the original design performance of the repaired parts, leaving safety hazards. Meanwhile, the repair work itself may also cause certain disturbances and impacts on the structure.
To ensure structural safety, effective measures should be taken to prevent and deal with template joint leakage, such as improving the quality of template production and installation, strengthening inspection and acceptance during the construction process, etc. Once concrete defects caused by grout leakage are discovered, they should be evaluated and repaired in a timely manner to ensure the safety and reliability of the structure.