Tunnel form is a formwork system that 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 and is recognised as a modern method of construction (MMC).
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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, student accommodation, barracks and prisons.
The formwork is specially adapted for each project. 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. The techniques used are already familiar to the industry, but with tunnel form construction there is less reliance on skilled labour.
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.
The large bays constructed using tunnel form provide exceptional flexibility in the design and layout of the building and allow a high degree of freedom in the final appearance.
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Tunnel form has integral working platforms and edge protection systems. In addition, the repetitive, predictable nature of the tasks involved encourages familiarity with operations, and, once training is complete, productivity improves as construction progresses. The minimal requirement for tools and equipment when moving the tunnel form further reduces the risk of accidents on site.
The insitu 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
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Tunnel Form Construction Technique was invented over 50 years ago. The use of tunnel-form produces high quality monolithic structures. It eliminates the use of any subsequent wet trades (Plastering etc). It is basically an operation to cast walls and slabs in one operation in a 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 degree of repetition such as:was invented over 50 years ago. The use of tunnel-form produces high quality monolithic structures. It eliminates the use of any subsequent wet trades (Plastering etc). It is basically an operation to cast walls and slabs in one operation in a 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.with high degree of repetition such as:It reduces the heating costs by providing &#;Thermal Mass&#; and speeds up the building process. However, specialist contractors with tunnel-form experience is high recommended in order to tailor the design to suit best construction method.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 reused 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-formwork 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. In practice, when the two halves are bolted together, the tunnel formwork will appear like the following figure.Prefabricated Wall reinforcement is placed by crane along the entire wing prior to casting the kickers (used to position wall formwork).Two and a half tunnel is craned into place, bolted together and ties are added.The wall concrete is poured.The slab reinforcements are fixedThe 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.The tunnel-forms are removed next day.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 g ood, the requirement for post construction trades such as plasterers and electricians are greatly reduced.
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