Tunnel Formwork: A Brief Overview - Zolo

Tunnel formwork is a construction technique used to create tunnels, underground passages, and other structures that require a hollow, enclosed space. This method involves the use of formwork, which is the temporary mold into which concrete is poured to create a specific shape. Tunnel formwork is often used in infrastructure projects such as subway systems, sewage systems, and underground transportation networks.

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Types of Tunnel Formwork

There are several types of tunnel formwork, each designed for a specific purpose. One common type is the circular formwork, which is used to create round tunnels. This type of formwork is ideal for projects that require a circular shape, such as sewer pipes or ventilation shafts. Another type is the rectangular formwork, which is used for creating square or rectangular tunnels. This formwork is often used in projects where space is limited, as it can be easily adjusted to fit different size requirements.

Benefits of Tunnel Formwork

There are many benefits to using tunnel formwork in construction projects. One of the main advantages is that it allows for rapid construction of tunnels and other underground structures. The formwork can be assembled quickly and easily, allowing for a faster construction process. Additionally, tunnel formwork is highly versatile and can be used to create tunnels of various shapes and sizes. This flexibility makes it an ideal choice for projects with specific design requirements.

Tunnel Lining Formwork

Challenges of Tunnel Formwork

While tunnel formwork offers many advantages, there are also some challenges associated with its use. One of the main challenges is the complexity of the formwork itself. Tunnel formwork can be difficult to assemble and requires skilled workers to ensure that the concrete is poured correctly. Additionally, tunnel formwork can be expensive to purchase and maintain, making it less cost-effective for smaller projects.

Applications of Tunnel Formwork

Tunnel formwork is commonly used in a wide range of construction projects, including the construction of underground transportation systems, tunnels for water and sewage systems, and underground parking structures. This technique is also used in mining operations to create tunnels for extraction and transportation of materials. In addition, tunnel formwork can be used in the construction of underground storage facilities and other industrial structures.

FAQs about Tunnel Formwork

Q: What is tunnel formwork? 

A: Tunnel formwork is a construction technique used to create tunnels, underground passages, and other structures that require a hollow, enclosed space. 

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Q: What are the benefits of using tunnel formwork? 

A: Tunnel formwork allows for rapid construction of tunnels, is highly versatile, and can create tunnels of various shapes and sizes. 

Q: What are the challenges of using tunnel formwork? A: Tunnel formwork can be complex to assemble, requires skilled workers, and can be expensive to purchase and maintain. Q: Where is tunnel formwork commonly used? A: Tunnel formwork is used in construction projects such as underground transportation systems, sewage tunnels, mining operations, and industrial structures.

In conclusion, tunnel formwork is a valuable construction technique that offers a variety of benefits for creating tunnels and underground structures. While there are challenges associated with its use, the versatility and efficiency of tunnel formwork make it a popular choice for a wide range of construction projects.

Tunnel form is a formwork system that allows casting of walls and slabs in one operation resulting in a cellular RCC structure. It combines speed, quality, and accuracy with the flexibility and economy of in-situ construction. 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
Though the Tunnel form technology is more than 50 years old, its adoption in India has got traction only in the last few years.
The system creates an efficient concrete wall slab load-bearing structure for use in a wide variety of applications. The typical assembly of various elements of the tunnel formwork system has been shown in Picture # 1 below. It is most suitable for mass housing & fast build projects which require more repetitions at a faster rate of buildings construction. While the initial cost of formwork is very high, it is more than made up by faster construction, number of repetitions, zero rework, and low maintenance cost.

GEM has been appointed as a project manager by one of the reputed developers in India, at their project in Pune wherein tunnel formwork system is being used. This is our first experience with the Tunnel form technology. The project has a built-up area of 13.83 lakhs sq.ft. in (Phase 1) out of which about 10 lakhs sq.ft. built-up area will be made using tunnel form. RCC part of each of the 22 story buildings is planned to be completed in just 4 months with half set of formworks. The tunnel forms can thus be released and be available for Phase 2 of the same project!
Tunnel form technology like any other new technology requires attention to many aspects and challenges of construction in a different manner than in conventional works. Some of these challenges may be:

• The planning of the building should lend itself to the adoption of tunnel form technology. That is why the decision to use tunnel form should be taken even before the schematic of the building is finalized.
• Similarly, the tunnel form supplier should also be on board from an early stage so that their inputs to optimize cost of tunnel form can be incorporated in design if possible. In time delivery of tunnel forms can also be assured by having the vendor on board early.
• The number of flats (repetition) should be large enough to justify the higher capex on tunnel form.
• The concrete mix should be carefully designed to allow pouring all concrete in one pour and should have the right workability and early strength development.
• Other resources like tower crane, concrete batching and rebar handling and placement should match the speed afforded by tunnel form
• Trained manpower should be available to handle the tunnel form as it has more to do with assembly (mechanical work) than carpentry!
• The form work must be handled and maintained carefully else many of the advantages will evaporate.

At the same time, Tunnel form technology offers many advantages over conventional beam-column-slab construction which may overcome above mentioned challenges faced by designers, construction managers and contractors. Many of these advantages hold good even when it is compared with monolithic slab-wall type of construction using Aluform (popularly known as Mivan technology).
Major Advantages of Tunnel Form System:

• High seismic resistance due to monolithic slab & walls construction
• Monolithic structure reduces number of joints and improves water tightness
• Reduce labour costs (greater requirement of tower crane)
• Reduce mobilization costs on site
• Reduced construction times (2-3 days slab casting cycle can be achieved) which is up to 3 times faster than conventional
• Higher quality finishes –Fair faced finish concrete can be achieved
• No need for plastering

If the technology is adopted right from the planning and design stage, project costs savings up to 25% can be achieved.