Technical Report

New Technology of
Equipment/Material
in construction
Projects

Prepared by:
Dr. Shady Dokhan
 Instructions

§ Each Group to submit a technical report about a

new (Material / Equipment) used in construction as
agreed in the lectures.
 Contents
The report must include all of the following:

1. Cover Page
2. Introduction
3. The traditional method.
4. The new (Material / Equipment) technology
5. Comparison between the new technology vs. Traditional
and /or other alternatives.
6. Alternative Selection (Weighted evaluation method)
 Contents

1. Cover Page
Design your own cover page and
make sure that all the following
information is valid:
ü Faculty name & Logo
ü Report Title
ü Course name
ü Authors (Students Names)
ü Academic year
ü Date
ü Supervisor name
ü Revision number
Example
Report Title :

Study of Tunnel Formwork System as a new

technology in construction compared with
Traditional Formwork
 Contents
2. Introduction:
General introduction about the construction process the
(Material / Equipment) is used in.
Formwork is a temporary structure like a die or mould, used to contain poured
concrete, to give concrete the desired shape and support it until it attains sufficient
strength to carry its own weight. Formwork should be capable of carrying all
imposed dead and live loads apart from its own weight.
Formwork system has significant role in the construction process, making the right
decision by choosing the appropriate formwork system could lead to improvement
in the construction process.
 Contents
2. Introduction:
Different systems have their own advantages but one needs to choose a formwork
which best supports individual project requirement. Advanced Tunnel formwork is
one of the new formwork techniques to hit construction industry. It is found to be
suitable for mass construction conditions. It delivers quality and speed at a rate
which is higher than the speed achieved by most of the traditional formwork
systems. The labor in coordination with heavy machineries like tower crane speeds
up the construction, assures quality control and durability. This reduces overall time
and cost of the structure.
 Contents
2. Introduction:
Formwork, which holds and supports wet concrete till such time it cures, is a
very vital element in concrete construction . The objective of this report is to
Introduce advanced tunnel formwork systems as a new technology in
construction industry and lay emphasis on the high quality, speedy construction
and compare it with the traditional formwork systems showing advantages and
disadvantages of each system.
 Contents

3. The traditional method.

Provide explanation of the traditional method for doing
such work.
Traditional Formwork
The formwork is built on site out
of timber and plywood . It is easy to
produce but time-consuming for larger
structures. It is still used extensively where
the labor costs are lower than the costs for
procuring reusable formwork. It is also the
most flexible type of formwork, so even
where other systems are in use,
complicated sections may use it.
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3. The traditional method.

Traditional Formwork
This usually consists of standard framed
panels tied together supported by steel or
wooden shores . The ties are provided with
the basic function of resisting the horizontal
force of wet concrete. Plywood sheet in
combination with timber is the most common
material used. This allows for the plywood to
be easily removed and reversed and used on
both sides so as to increase the number of
reuses.
Special attention must be given to all
elements since the increased pressures applied
by wet concrete could cause the damage,
giving rise to unacceptable grout escape and a
poor finish to the cast element.
 Contents

4. The new (Material / Equipment) technology

Detailed explanation of the new (Material / Equipment)
technology used and its advantages and disadvantages.
 Contents

4. The new (Material / Equipment) technology

NEED FOR MODERN FORMWORK SYSTEMS
The earliest formwork systems made use of wooden scantlings and timber runners as it
enabled easy forming and making at site. But these wooden scantlings and timber
runners tend to increase waste and lose their structural and dimensional properties over
a period time and after repeated usage thus posing safety problems.

Swapnali M. Karke , et al. 2016

 Contents

4. The new (Material / Equipment) technology

NEED FOR MODERN FORMWORK SYSTEMS
Many of the accidents take place in Reinforced Cement Concrete (RCC) construction
because of inferior formwork and scaffolding. Now focus has to be shifted to other key
factor “Formwork”, to face the challenges for the completion of fast track projects. By
going in for system formwork, substantial savings are possible by faster return on
investments.
 Contents

4. The new (Material / Equipment) technology

TUNNEL FORM TECHNOLOGY
It is a highly efficient Industrialized System of On-Site Construction, which enables
putting-up stable structure on a 24-Hour cycle basis Tunnel form is a formwork
system that allows the contractor to build monolithic walls and slabs in one
operation on a daily cycle. It combines the speed, quality and accuracy of
factory/offsite produced ready-mix concrete and formwork with the flexibility and
economy of cast in-situ construction.
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4. The new (Material / Equipment) technology

TUNNEL FORM TECHNOLOGY
This fast-track method of construction is
suitable for repetitive cellular projects, such
as hotels, apartment blocks and student
accommodation. It offers economy, speed,
quality and accuracy, as well as utilizing the
inherent benefits of concrete, such as fire
and sound resistance.
Its components are made of steel. Its
usefulness also stems from the fact that no
starter concrete is required for walls; it allows
easy alignment and de-shuttering, hot air
curing to enable early stripping and favors a
standardized working sequence to improve
labor productivity.
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4. The new (Material / Equipment) technology

TUNNEL FORM TECHNOLOGY
Tunnel form can accommodate room widths from 2.4
to 6.6m. When rooms are wider (up to 11m), a mid-
span table is incorporated between the tunnels. The
main component of the system is the half tunnel.
Manufactured entirely from steel, including the face of
the form, the half tunnel provides the rigidity and
smooth face necessary to produce a consistently high
quality finish to the concrete.
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4. The new (Material / Equipment) technology

TUNNEL FORM TECHNOLOGY
When two half tunnels are put together this creates a tunnel. The tunnel sections come
in two lengths, 1.25 and 2.5m. These are fixed together to produce a tunnel length that
suits either the building dimensions. The tunnel is tailored to the room width and height
by the inclusion of infill sections which are sacrificed at the end of the job. These are not
loose fittings but are an integral part of the tunnel.
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4. The new (Material / Equipment) technology

TUNNEL FORM TECHNOLOGY
For optimizing the volume of formwork, equipment & work-force overall structure is
divided into a number of more or less similar construction phases and sizes correspond
to daily work to cast concrete. In order to save the time reinforcement mesh are used in
place of normal steel bars.
The wall and slab reinforcement is laid
and kickers are placed for positioning
formwork for wall. Two half tunnels are
bolted on site to make one tunnel and
lifted by crane to desired location. The
ties are added. The concrete is poured
and hot air blowers are placed for early
settling of concrete. Thus concrete
reaches striking strength overnight and
the tunnel forms are removed the next
day. The tunnel form are cleaned and
oiled for reuse.
 Contents

4. The new (Material / Equipment) technology

TUNNEL FORM TECHNOLOGY

Video 1 (Tunnel Form Animation #1)

https://www.youtube.com/watch?v=5vD62cZN4LE

Video 2 (Tunnel Form Animation #2)

https://www.youtube.com/watch?v=z_CCKgA_o9k

Video 3 (TUNNEL FORMWORK CONSTRUCTION – TIMELAPSE)

https://www.youtube.com/watch?v=zKMxq_mwumA&t=1s
 Contents

4. The new (Material / Equipment) technology

TUNNEL FORM TECHNOLOGY
Advantages
The overall advantages of tunnel formwork are categorized into four categories as
follows.
1) Design:
1. Hi-tech all-steel system of tunnel form with 3 mm. steel surface provides durability and
strength.
2. Collapsible strut provides clearance for form stripping, the composite wheel
assemblies help in accurate form positioning and blackouts eliminate nailing.
3. Multiple rooms can be concreted and that provides flexibility in scheduling.
4. Proper concreting of ceiling to the wall results in lack of formation of beams.
5. Tunnel form can be adapted to special building features, like balconies. It gives
freedom and variety in architectural designing.
6. The dimensional accuracy of the concrete structure allows the placement of partition
walls and fixing of all other finishing material such as joinery right after casting.
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4. The new (Material / Equipment) technology

TUNNEL FORM TECHNOLOGY
Advantages
2) Quality
1. Installation of all utility conduits in the shell reduces the internal finishing work.
2. High quality and dimensional accuracy is achieved.
3. The obtained surface is smooth which minimizes much of finishing work and allows
direct application of paint or wall paper after sanding off the fins at the joints connecting
two forms and smoothing with paint filler.
4. Monolithic elements of the building prevent thermal cracks which are observed in the
heterogeneous mate-rials because of temperature variation.
5. Low scope of change in the original design of the building results in application of
standard dimen-sions of doors, windows, partition wall etc.
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4. The new (Material / Equipment) technology

TUNNEL FORM TECHNOLOGY
Advantages
3) Time
1. In the high temperature zones and/or by thermal treatment, with the use of ordinary
cement, the normal pace is one day per cycle. Achievable cycle of production is of 1-3 days.
2. A monolithic structure with simultaneous casting of walls/cross-walls and slab results in
reduction in total construction time.
3. Installation of electrical conduits, water and gas pipes in the shell reduces the internal
finishing work, internal finishing proceeds in accordance with the concrete shell construction
resulting in reduced total building time. Reducing minor works and overlapping activities
yields into high quality and speed of implementation.
 Contents

4. The new (Material / Equipment) technology

TUNNEL FORM TECHNOLOGY
Advantages
4) Cost
1. Tunnel form can be reused and this reduces the over-all cost of
formwork for per m2 or per housing unit.
2. The amount of rework and finishing work is reduced thus
additional material, machinery and labour cost is saved.
3. High quality and early completion of project helps minimize
cost in long run.
4. Tunnel form system comes with highest jobsite safety due to
full perimeter platform system. This reduces cost associated with
risk.
 Contents

4. The new (Material / Equipment) technology

TUNNEL FORM TECHNOLOGY
Limitations in implementation of Tunnel Form
1. High initial investment is high and it further increases for small sized projects.
2. Implementing all internal walls in the form of reinforced concrete is unnecessary which
causes lack of changes in the plan and concrete increases dead load of the building.
3. Precast elements like stairs, parapets etc are used and this requires separate workshop
arrangement.
4. The activities involving erection, removal and carriage of formwork, scaffolds, and
placing of precast components to the required place involves use of tower cranes and
this increases cost.
5. All activities need to be planned and executed according to the dependency to
minimize time and cost. This requires efficient construction management and high cash
flow.
6. Large spans of slab cannot be executed due to increased gap between the tunnel form
panels. Here combination of formwork system may be adopted. Very short span of slab
incorporates difficulty in removal of tunnel form at the time of stripping and suspended
ceiling is needed. Basement stories are avoided as it is difficult to remove formwork.
 Contents

5. Comparison between the new technology vs.

Traditional and /or other alternatives.
Tunnel Form Technology vs. Conventional Formwork System
 Contents
Tunnel Form Technology vs. Conventional Formwork System
 Contents

6. Alternative Selection (Weighted evaluation

method)
Consider yourself as the project manager for a construction project and use the weighted
evaluation method (discussed in the previous lecture “concrete work”) for selecting the best
alternative for your project. (show calculations and assume reasonably any data required)
 Contents

6. Alternative Selection (Weighted evaluation

method)
Criterial Selected will be as follow :
1- Economic factors .
Cost – Initial Investment – Speed of Construction
2- Engineering factors.
Wastage of Material – Quality of surface- Preplanning of a system

The evaluation method steps:

1- The weighted of desired criteria.
2- The analysis of desired criteria.
Contents
Criteria of evaluation:
A- Cost.
B- Initial Investment .
C- Speed of Construction. Scale 1 → 5
D- Wastage of Material .
E- Quality of surface
F- Preplanning of a system B C D E F
A A-3 C-2 A-D A-2 A-2

B C-4 D-2 E-1 F-1

C C-2 C-4 C-4

D D-2 D-2

E E-F
Contents
Criteria of evaluation:
A- Cost.
B- Initial Investment .
C- Speed of Construction.
D- Wastage of Material .
E- Quality of surface
F- Preplanning of a system

Row
Criteria Normalized weight
weight
A- Cost. 8 23%
B- Initial Investment 0 0%
C- Speed of Construction 16 46%
D- Wastage of Material 7 20%
E- Quality of surface 2 5.5%
F- Preplanning of a system 2 5.5%

Total 35 100%
Contents
Rank 1 → 5
Alternatives
Evaluation Normalized Conventional Formwork
Tunnel Form Technology
criteria weight System
Rank Score Rank Score

A- Cost 23% 2 46 4 92
C- Speed of
46% 4 184 1 46
Construction
D- Wastage of
20% 4 80 3 60
Material
E- Quality of
5.5% 4 22 2 11
surface
F- Preplanning
5.5% 2 11 4 22
of a system

Total 343 231

Contents
CONCLUSION
Different formwork systems provide a wide range of concrete construction solutions that can
be chosen to suit the needs of a particular development. Traditional formwork for concrete
construction normally consisted of bespoke solutions requiring skilled craftsmen. This type of
formwork often had poor safety features and gave slow rates of construction on-site and huge
levels of waste inefficient and unsustainable. Modern formwork systems such as tunnel
formwork , which are mostly modular, are designed for speed and efficiency. They are
engineered to provide increased accuracy and minimize waste in construction and most have
enhanced health and safety features built-in.
This report sets out the key features for tunnel
formwork process efficiency, safety,
sustainability and other considerations in order
to help construction professionals to take
advantage of them to achieve modern,
efficient concrete construction. By using
Tunnel Form system we can achieve cost
reduction in less time. By reducing cycle time
than conventional method overall financial
cost saving can be achieved.
Contents
REFERENCES
[1] Ketan Shah, (2005) “Modular formwork for faster, economical and quality Construction”,
Indian Concrete Journal, Vol-79, pg. 6-23.
[2] C.S.Poon, Robin C.P. YIP, (2005) “Comparison of conventional and low waste formwork in
HongKong” World Sustainable Building Conference, Tokyo, 27-29 September 2005, pg. 42-48.
[3] Nuzul Azam Haron, Ir. Salihuddin Hassim, Mohd. Razali Abd. Kadir and Mohd Saleh Jaafar,
(2005)“Building Cost Comparison Between Conventional and Formwork System: A Case Study
of FourstoreySchool Buildings in Malaysia”, American Journal of Applied Sciences, pg 819-
823.
 Instructions
§ Due Date : 9/4/2020

§ Report to be submitted as soft copy PDF file

§ Presentation to be submitted as soft copy power point
file

§ A guide for writing technical reports may be useful.

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