Tunnel Form

TUNNEL
FORMWORK
TUNNEL FORMWORK SYSTEM
•Tunnel formwork system allows the contractor to cast walls and slabs in one
operation in a daily cycle.
•It combines the speed, quality and accuracy of factory/off-site production with
the flexibility and economy of in-situ construction
• Recognized as a modern method of construction (MMC).
The result is a cellular reinforced structure, the surfaces of which are sufficiently high
quality to require only minimal finishing for direct decoration, while the end walls and
facades are easily completed with thermally insulated units that can be clad as
required.
The system creates an efficient load-bearing structure for use in a wide variety of
applications.
It is particularly effective in projects suited to repetitive cellular construction such as

residential blocks, hotels and etc.
ADVANTAGES:
Cost
cost-effective, high quality construction,
generating significant savings in time
and costs over alternative methods
without compromising on design
Building
The repetitive nature of the system and the use of prefabricated forms and
reinforcing mats/cages simplifies the whole construction process, producing a
smooth and fast operation
Quality
Quality is enhanced despite the speed of construction. The precise, even steel face of
the formwork creates a smooth, high quality finish capable of receiving direct
decoration with the minimum of preparation (a skim coat may be required). This
reduces the requirement for following trades, thus providing additional cost
savings and speeding the entire process.
Design
The large bays constructed provide exceptional flexibility in the design and layout
of the building and allow a high degree of freedom in the final appearance.
Safety
Integral working platforms and edge protection systems. The repetitive, predictable
nature of the tasks involved encourages familiarity with operations. The minimal
requirement for tools and equipment further reduces the risk of accidents on
site.
Sustainability
The in-situ casting of units on site and the local availability of ready-mixed
concrete supplies reduce transportation impacts.
Just-in-time deliveries and near zero wastage produce an overall tidier site with
associated cost savings and safety benefits.
Concrete’s thermal mass coupled with correct insulation and boiler design
minimises heating costs and can even reduce air-conditioning requirements.
GENERAL FACTS :
Tunnel formwork come in half units and in the form of an inverted “L” which
are bolted together at the top to form each tunnel. The inbuilt wheels and the jacks
help the formwork move in and out of the position and adjusted to the final height.
The factory-made steel formwork can be re-used up to 600 times and it can suit a
variety of module sizes. This makes the method of construction very versatile and
extremely economical.
Tunnel-form work allows a 24-hour construction cycle to be achieved and thus
the buildability of in-situ concrete is improved by choosing this type of formwork.
The Casting Process of Tunnel Formwork:
1) Stage One: Prefabricated Wall reinforcement is placed by crane along the
entire wing prior to casting the kickers (used to position wall formwork).
2) Stage Two: Two and a half tunnel is craned into place, bolted together and
ties are added.
3) Stage Three: The wall concrete is poured.
4) Stage Four: The slab reinforcements are fixed

5) Stage 5: The slab concrete is placed. The formwork system provides for a pour to
be wrapped in tarpaulins and for the use of butane heaters to maintain a sufficiently
high temperature for the concrete to reach its striking strength overnight.
6) Stage 6: The tunnel-forms are removed next day.

7) Stage 7: The process is repeated for the next two bays.
Tunnel form can produce strong and durable in-situ cellular structures. This
method of construction can achieve time savings up to 25% with cost savings
of 15%.
Since the concrete finish is very good, the requirement for post construction
trades such as plasterers and electricians are greatly reduced.

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TUNNEL

It is particularly effective in projects suited to repetitive cellular construction such as

4) Stage Four: The slab reinforcements are fixed

6) Stage 6: The tunnel-forms are removed next day.

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