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Tunnel Form Construction Technique and Process

Tunnel form construction was invented over 50 years ago and produces monolithic structures without needing subsequent trades like plastering. It involves casting walls and slabs in a single daily cycle using reusable steel formwork assembled into tunnels. This high-quality, earthquake resistant technique provides sound insulation and allows construction at a 24-hour pace, improving buildability for in-situ concrete structures like prisons, hotels, and housing developments.

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Manish Shashikant
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196 views5 pages

Tunnel Form Construction Technique and Process

Tunnel form construction was invented over 50 years ago and produces monolithic structures without needing subsequent trades like plastering. It involves casting walls and slabs in a single daily cycle using reusable steel formwork assembled into tunnels. This high-quality, earthquake resistant technique provides sound insulation and allows construction at a 24-hour pace, improving buildability for in-situ concrete structures like prisons, hotels, and housing developments.

Uploaded by

Manish Shashikant
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Tunnel Form Construction Technique was invented over 50 years ago.

The use of tunn


form produces high quality monolithic structures. It eliminates the use of any subsequent w
trades (Plastering etc). It is basically an operation to cast walls and slabs in one operation
daily cycle. This technique is highly systematic, earthquake proven and provides an ideal
solution to the critical problem of sound transmission. It gives a sound reduction of 50
decibels.

Tunnel form is widely used in the construction of cellular structures with high degr
of repetition such as:

Prisons
Hotels
Student Accommodation (Hostels)
Private Housings
Commercial Developments
It reduces the heating costs by providing “Thermal Mass” and speeds up the building proce
However, specialist contractors with tunnel-form experience is high recommended in order
tailor the design to suit best construction method.

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 formwor
move in and out of the position and adjusted to the final height.

The factory-made steel formwork can be reused up to 600 times and it can suit a variety o
module sizes. This makes the method of construction very versatile and extremely
economical.

Tunnel-formwork allows a 24-hour construction cycle to be achieved and thus the buildabil
of in-situ concrete is improved by choosing this type of formwork.

In practice, when the two halves are bolted together, the tunnel formwork will appear like
following figure.

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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