PVC Parallel Bars Workbook
Science of Technology • Grades 9–12 Structural Fabrication Lab
PVC Parallel Bars Challenge
Shop Workbook
Team / Station #
Date
Period / Class
Partner 1: Lead Builder
Partner 2: Quality Inspector
Partner 3: Safety & Tool Manager (If 3)
The Engineering Mission
Build a matched pair of PVC parallel bars that can safely support 10 controlled push-ups in a teacher-approved functional test. All parts must be measured to the sixteenth of an inch, deburred, squared, dry-fitted, and solvent-welded with zero rocking.
*Objective Note: The finished pair must safely support 10 controlled push-ups during the teacher-approved load test; it evaluates structural integrity and does not require every student builder to perform them.
Critical Rule No adhesive until teacher approval.
Four-Stage Project Roadmap
1
Decode & Request
Analyze official tutorial schematics. Extract fitting types, sizes, and cut lengths. Submit complete request sheet before pulling pipe or fittings.
Checkpoint: Approved Request Form
2
Cut, Deburr & Label
Measure in inches and sixteenths. Partner verifies each line before cutting. Cut perfectly square, deburr both ends, and label every single piece.
Checkpoint: Precision Cutting Log
3
Dry-Fit, Check & Revise
Assemble both bars with NO adhesive. Check symmetry, handle level, and flat feet contact. Complete quality gate checklist and earn teacher signature.
Checkpoint: Teacher Sign-Off Required
4
Prime, Cement, Test & Clean
One joint at a time: purple primer, clear cement, full insertion with a quarter-turn, hold 30s. Execute push-up test and complete shop cleanup.
Checkpoint: 10 Push-Up Test & Rubric
Shop Safety & Quality Mandates
- Eye Protection: School safety goggles must be worn during all cutting, deburring, and chemical joining operations.
- Two-Person Verification: Inspector must verify every tape measurement before the lead builder makes a cut.
- Permanent Bond: PVC solvent cement chemically fuses plastic permanently. Zero adhesive until teacher approval on Page 4.
Official Source: https://assets.formufit.com/plans/pdfs/FORMUFIT\_Push-Up\_Handles.pdf Page 1 of 5 • Mission & Four-Stage Map
Stage 1: Specifications & Requisition Submit Prior to Material Issue
Decode & Request
Directive: Study the official FORMUFIT fitting shapes and pipe silhouettes below. All names, part numbers, quantities, lengths, and equations have been completely removed. Decode the exact bill of materials from visual geometry alone and submit this single-page list before receiving materials.
Official Fittings Geometry Decode Types
Fitting A [ Decode ]
Fitting B [ Decode ]
Fitting C [ Decode ]
Official Pipe Geometry Decode Lengths
Profile [ Decode O.D. ]
Segment 1 [ Decode In. ]
Segment 2 [ Decode In. ]
1. Material & Fitting Request (Total For Pair)
All fields required
| Item or Fitting | Size | Quantity | Reason / Location in Assembly |
|---|
| | | |
| | | |
| | | |
| | | |
2. Master Cut-List (Pipe Segments For Pair)
Measure to 1/16 in.
| Piece ID | Quantity | Target Length (Inches) | Purpose in Structural Frame |
|---|
| | | |
| | | |
| | | |
Stage 1 Material Gate Approval Instructor signature required to issue PVC stock and cutting station pass.
Teacher Signature: _______________________
Date: ________
Official Source: https://assets.formufit.com/plans/pdfs/FORMUFIT\_Push-Up\_Handles.pdf Page 2 of 5 • Stage 1: Decode & Request
Stage 2: Precision Fabrication & Quality Control 14 Pieces Total • Tolerance: 1/16 Inch
Cutting Log & Accuracy Scoring
Strict Scoring Rule Accuracy Max: 100 Pts
Every piece starts at 100 points. Subtract 5 points for each 1/16 inch away from target length. Minimum piece score is 0. Team accuracy is the average of all 14 piece scores.
• Partner verify before cut
• Ensure square 90° cut
• Deburr inner & outer edges
• Label ID on every piece
| Piece ID | Target (In.) | Actual (In.) | Error (1/16s) | Score | Deburred? | Labelled? |
|---|
| H-1 | | | | | [ ] | [ ] |
| H-2 | | | | | [ ] | [ ] |
| S-1 | | | | | [ ] | [ ] |
| S-2 | | | | | [ ] | [ ] |
| S-3 | | | | | [ ] | [ ] |
| S-4 | | | | | [ ] | [ ] |
| S-5 | | | | | [ ] | [ ] |
| S-6 | | | | | [ ] | [ ] |
| S-7 | | | | | [ ] | [ ] |
| S-8 | | | | | [ ] | [ ] |
| S-9 | | | | | [ ] | [ ] |
| S-10 | | | | | [ ] | [ ] |
| S-11 | | | | | [ ] | [ ] |
| S-12 | | | | | [ ] | [ ] |
Team Accuracy Calculation (14 Pieces)
Sum all 14 piece scores, divide by 14, and enter the average.
Team Accuracy Score:
/ 100
Partner Pre-Assembly Verification
Quality Inspector confirms all 14 pieces meet squareness, deburring, and labelling standards.
Inspector Signature: _______________________
Verification Date: _________________
Official Source: https://assets.formufit.com/plans/pdfs/FORMUFIT\_Push-Up\_Handles.pdf Page 3 of 5 • Stage 2: Cutting Log
Stage 3: Mechanical Assembly & Verification Zero Adhesive Gate
Dry Fit & Quality Gate
Quality Gate Directive Stop Before Gluing
Assemble both parallel bars completely without adhesive. Test every joint for full seating. Check all 7 quality gate criteria below. You may not open or apply primer or cement until the teacher signs this page.
Official FORMUFIT Tutorial Assembly Sequence (Steps 1–4) Dry-fit in exact numbered sequence
Step 1: Handle 2x
Press 90° elbows onto ends of handle pipe. Keep elbows parallel.
Step 2: Base Tee 4x
Insert vertical riser into center socket; two base pipes into side sockets.
Step 3: End Caps 2x
Press end caps onto all 4 outer base pipe ends of both foot assemblies.
Step 4: Integration Check
Join top handles onto all 4 base risers. Complete dry-fit checkpoint.
Seven-Point Quality Gate Inspection
1. Correct Fitting Orientation: All fittings align squarely to 90 degrees; pipes are inserted to full socket stop depth.
2. Left and Right Sides Match: Both parallel bars are identical in height, base width, and top handle span.
3. Handles Level: Torpedo level shows bubble centered along each top handle bar on a flat work surface.
4. All Feet Touch: All four rubber or PVC end caps make solid contact with the surface simultaneously.
5. No Rocking: Zero wobble, rocking, or teetering when alternating diagonal finger taps on the frame.
6. Stable Under Careful Hand-Pressure Test: Frame withstands firm downward body pressure without joints slipping or shifting.
7. Revisions Completed: Any uneven pieces recut, deburred, or reseated before presenting to instructor.
Dry-Fit Revisions / Adjustments Made (If Any):
Teacher Quality Gate Approval Required before team is issued primer and cement.
Teacher Signature: _______________________
Date: ________
Official Source: https://assets.formufit.com/plans/pdfs/FORMUFIT\_Push-Up\_Handles.pdf Page 4 of 5 • Stage 3: Dry Fit & Quality Gate
Stage 4: Permanent Chemical Joining & Evaluation 100-Point Lab Rubric
Joining & Final Rubric
Chemical Joining Protocol (Only After Teacher Approval) Permanent Chemical Fusion
1. Disassemble One joint at a time. Do not tear down whole frame.
2. Purple Primer Apply inside fitting socket and outside pipe end.
3. Clear Cement Even coat immediately over wet primer.
4. Quarter-Turn Insert fully with 1/4 turn to seat and distribute glue.
5. Hold 30s Hold firmly for 30 seconds to prevent joint push-out.
Shop Cleanup Protocol
Close primer and cement cans, contain drips, collect scraps, sweep, and return tools and supplies.
Functional Load Test
Parallel bars must safely support 10 controlled push-ups in a teacher-approved test (verifies structural strength; individual completion not required).
Final Evaluation Rubric
Total: 100 Points
| Performance Criteria | Max | Student | Teacher |
|---|
| 1. Cut Accuracy: Average of all 14 piece scores from cutting log (each piece starts at 100, -5 pts per 1/16" error). Accuracy rubric points = team average piece score divided by 2. | 50 | | |
| 2. Deburred & Labelled: Both ends deburred smooth; every piece marked with Piece ID prior to assembly. | 10 | | |
| 3. Symmetry, Level & Stability: Left and right units match; handles level; all 8 feet touch flush; zero rocking. | 10 | | |
| 4. Joint Quality & Correct Sequence: One joint at a time, purple primer, clear cement, full socket insertion with 1/4-turn, held 30s. | 10 | | |
| 5. Safely Supports 10 Controlled Push-Ups: Apparatus safely supports 10 controlled push-ups in a teacher-approved test with zero failure (structural capacity). | 10 | | |
| 6. Clean Workspace & Returned Tools: Primer and cement cans closed, drips contained, scraps collected, station swept, and all tools and supplies returned. | 10 | | |
| Total Project Score | 100 | | |
Final Instructor Assessment
Evaluator Signature: _______________________ Date: ________
Final Grade Recorded
_______ / 100
Official Source: https://assets.formufit.com/plans/pdfs/FORMUFIT\_Push-Up\_Handles.pdf Page 5 of 5 • Stage 4: Joining & Final Rubric
