TUNNEL FORMWORK TECHNOLOGY

DHARMESH CHANDRA GOEL

Chief Engineer
South Zone I, CPWD
19-11-2018
 Types of Construction
Following two are the most commonly used construction methods :
1. Wall bearing structures
2. RCC structures

Wall bearing construction

In wall or load bearing construction, all load of roof and structure is
carried by walls down to its foundation. This type of construction may
not use supporting column. The size of walls needs to be bigger to carry
all the loads. Further, there is limitation to construct long walls at a
stretch. This is typically used in residential or 1–2 storied buildings. This
is economical than RCC structure or steel frame structures.

Reinforced cement concrete (RCC)

Most of the high rises building uses RCC techniques
 Reinforced cement concrete (RCC) structures

These could be –
(1) Framed structure – load is transferred from slab to beam and then
to columns and finally to foundations; walls are non load bearing
(2) Shear Walls – evolved to supplement framed structure for lateral
loads and torsion in high rise buildings; load is transferred from slab
to walls and finally to foundations; walls are load bearing
(3) Combination of frame and shear wall is generally used
(4) Now column less shear wall construction is also gaining popularity
 Constituents for RCC structures

Include -
(1) Reinforcement – normally steel rods
(2) Cement Concrete – comprising, cement, coarse aggregate, fine
aggregate

Concrete is poured in a mould.

Mould are removed after the concrete has gained strength – curing
time

In cast in-situ, the mould is called formwork.

Wikipedia defines formwork as –
Formwork is the term used for the process of creating a temporary
mould into which concrete is poured and formed.
Traditional formwork is fabricated using timber, but it can also be
constructed from steel, glass fibre reinforced plastics and other
materials.
TUNNEL FORM WORK
 Tunnel form
• Was invented over 50 years ago

• 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.

• Allows casting of walls and slabs in one operation in a daily cycle.

• Shear wall construction

• Combines the speed, quality and accuracy of factory/off-site

production with the flexibility and economy of in-situ construction and
is recognized as a modern method of construction.

• 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.
 Tunnel form (contd.)
• Produces 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.

• This technique is highly systematic, earthquake proven.

• It provides an ideal solution to the critical problem of sound

transmission.

• It gives a sound reduction of 50 decibels.

 Tunnel form (contd.)

• Produces strong and durable in-situ cellular structures

• Achieves time savings up to 25%
• Cost savings are claimed to be 15% but we have no statistical back up.
• Concrete finish is very good.
• Requirement for post construction trades such as plasterers and
electricians are greatly reduced.
 Tunnel form (contd.)

• comes in half units and in the form of an inverted “L”

• these are bolted together at the top to form each tunnel.
• inbuilt wheels and the jacks help the formwork move in and out of the
position and adjusted to the final height
 Tunnel form (contd.)

 these factory-made steel formwork can be reused up to 500

times
 can suit a variety of module sizes making the method of
construction versatile and economical

 allows a 24-hour construction

cycle to be achieved;
buildability of in-situ concrete
is improved
 when the two halves are
bolted together, the tunnel
formwork will appear like the
adjoining figure.
 Tunnel form (contd.)
The Casting Process
Stage 1

Prefabricated / Tied in place Wall reinforcement is

placed by crane along the entire wing prior to casting
the kickers (used to position wall formwork).
Service lines and connected requirements are laid
along with
 KICKERS
• These are like column starters.
• But with the special arrangement these are
cast along with the previous pour.
• Exceptional dimensional imaging from below
can be achieved.
• Hence the walls can be made to perfect
plumb with minimum Engineering effort.
 Tunnel form (contd.)
The Casting Process
Stage 2
Two and a half tunnel is craned into place, bolted together and
ties are added.
Stage 3
The slab reinforcements are placed either as prefabricated or
assembled at site.
Stage 4
Pipes for services such as electrical, fire-fighting and fire
alarms are laid along with.
FULL TUNNEL (Two Half Tunnel Combined)
 Tunnel form (contd.)
The Casting Process
Stage 5
Concrete with high flow value is placed.
The formwork system also 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, if required.
 Tunnel form (contd.)
The Casting Process

Stage 6
The tunnel-forms are removed next day.
 Tunnel form (contd.)
The Casting Process

Stage 7
The process is repeated for the next two bays next day.
Benefits of tunnel formwork
Building

Quality

Design

Safety

Sustainability
 Benefits of tunnel formwork
Building
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.
 Benefits of tunnel formwork
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.
 Benefits of tunnel formwork

Design
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.
 Benefits of tunnel formwork
Safety
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.
 Benefits of tunnel formwork
Sustainability
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 minimizes heating costs and can even reduce air-conditioning
requirements

The factory-made steel formwork can be reused up to 600 times making

the method of construction very versatile and extremely economical.
 Concrete for tunnel formwork

• High flow concrete with High Range

Water Reducer (HRWR) admixture.

• Poly Carboxylate Ether (PCE) is used as

admixture.

• It is possible to fill the walls and slab

efficiently with a mild shutter
vibrators.
 De-shuttering

• In QC lab, Concrete Strength

requirements for De-shuttering is
checked.

• Then tunnels are removed in the most

systematic way(after 24hours )
• vibrators.
 Treatment of concrete surface

• Top surfaces are steamed or

water cured.

• De-shuttered surfaces are

applied with curing compounds.
GREEN & SUSTAINABLE
PROCESS
STRUCTURAL DESIGN -
THEORY
 DESIGN BASICS of tunnel structure

Open box structure

• Ductility

• Lateral Loads

• Effect of Height on Time period( Tn )

• Mode Shapes

• Proximity of Mode Shapes

• Soft storey
Earthquake Behaviour
DUCTILITY
Poor Ductility:
Brick work Structures

Medium Ductility:
RCC framed Structure

Good Ductility:
Ductility: Buildings are designed and detailed to
LLRE Box Structures
develop favorable failure mechanisms that possess
specified lateral strength, reasonable stiffness and,
above all, good post-yield deformability.
DUCTILITY
Poor Ductility:
Brick work Structures

Medium Ductility:
RCC framed Structure

Good Ductility:
LLRE Box Structures
Ductility is Deforming ability
beyond elasticity.
Lateral Load
Displacement Load:
Earth quake

Force Load:
Wind load

Displacement Loading versus Force Loading:

Earthquake shaking imposes displacement loading
on the building, while all other hazards impose force
loading on it
 EFFECT OF
HEIGHT
• < 2 floors:
Time period will be very
small hence less effect due
to earth quake

• 3 to 10 floors:
Time period will be small
hence very large forces due
to earth quake

• 11 to 20 floors:
Time period will be large
hence medium forces due
to earth quake

• 20 and more :
Time period will be large
hence earth quake forces Effect of building Height: Taller buildings have
will not rule but wind will
dominate. larger natural period
 TIME PERIOD

Tn
(period of
oscillation of
Building)

Tn is more Earth
quake forces are
less!!!
Effect of Natural Period on design horizontal seismic force
coefficient: In general, buildings with smaller translational
natural period attract higher design seismic force
coefficient.
 MODE
Mode Shape-1
X direction

Mode Shape-2
Y direction Mode shapes of buildings depend on
overall geometry of building, geometric
Mode Shape-3 and material properties of structural
Torsion members, and connections between the
structural members and the ground at the
.
base of the building. Buildings exhibit
flexural mode shape, shear mode
shape, or a combination of these
depending on the above factors.
PROXIMITY OF MODE

• Design Engineers need to

control both the mass
and stiffness of buildings.

• They should use this

freedom to tune the
stiffness of the building Proximity of Natural Modes:
in the two plan directions
X and Y in such a way Combined Response of two adjacent
that: Proximity of Natural modes should be avoided.
Modes are AVOIDED.
 STILT FLOOR
Stilt floor or soft
storey has a
Detrimental effect on STILT +4 STILT +4
all buildings due to
sudden change in
stiffness hence to be
avoided.

RC Frame buildings with open ground storeys

collapsed (left unit one and right unit two) in
Gandhidham (Gujarat, India) during the 2001
.
Bhuj (India) Earthquake.
 Basic modelling of
tunnel structure

Open Box Structure

• Line Elements
• Plane Elements
• Boundary Elements
• Spandrels
 1D-line Element
One dimensional
Elements

Example:
• Truss members
• Railway Rail
• Boom of a crane
 2D-plane Elements
Two dimensional
Elements

Example:
• Slab (thin slab)
 2D-plane Elements
Two dimentional
Elements

Example:
• Pier
 2D-plane Elements
Two dimensional
Elements

Example:
• Water Tank wall
 Boundary Elements
2D-Pier Boundary
Element Design
Example:
• Boundary zones will be
provided with steel to
resist TS2 or C (tension &
Compression)
• Which happen due to
reversal of Stresses.
 SPANDREL
Design

In Etabs Forces are

calculated at right and
left most corner of Spandrel design
these beams
 Wall spandrel design is performed only at the right-
most and left-most end of each spandrel. If spandrel is
expected to behave mostly in flexure, (i.e high length to
depth ratio), the user should use different spandrels
labels along the span in order to capture bottom
positive reinforcement at mid span.
 SPANDREL
Design
Longitudinal
Reinforcement is for
moment demands
 Within seismic spandrels, longitudinal and
diagonal reinforcement are resolved
independently :
 Longitudinal reinforcement is based on the
flexural stresses that are resolved according to
conventional beam conditions at end of each
spandrels label as described above. These values
are dependent upon section dimensions and
moment demands.
 SPANDREL
Design

Diagonal Reinforcement is
for Shear demand

 Diagonal reinforcement is determined through

shear calculation, and reported in addition to
orthogonal shear reinforcement only when
spandrel length/depth is less than 4.0, as
required by code. Spandrels with small
legth/depth ratio are typically governed by shear
demand, rather than flexural.
CASE STUDY
 TUNNEL FORM CONSTRUCTION
532 Nos Quarters for Income Tax at Annanagar
Chennai
 Salient features of Project
Construction of 532 Nos Quarters for Income Tax

A/A & E/S - Rs. 208.95 Crores.

The scope of work includes –
 Dismantling of existing dilapidated old
quarters.
 Pile Foundation of length varying from 25 to
30m depth.
 Execution on design & built mode with rates
quoted on plinth area basis as per
Architectural drawings prepared by Senior
Architect of CPWD properly finished complete
as per schedule of finishes incorporated in
tender.
 Salient features of Project

Construction of 532 Nos Quarters for Income Tax

•Four Towers - Each G+18
• Type-2 One Block : (8 units per Floor Total 152 Nos.)
• Type-3 Two Block : (8 units per Floor Total 304 Nos.)
• Type-4 One Block : (4 units per Floor Total 75 Nos.)
• Total Plinth Area : 57,706 Sq.m
• Plinth Area per Block / per floor
• T2 = 767.18 Sqm
• T3 = 866.15 Sqm
• T4 = 661.63 Sqm
• Plinth Area per Quarters
• T2 = 67.60 Sqm
• T3 = 78.57 Sqm
• T4 = 120.13 Sqm
 Contract conditions

 Technology neutral contract

 Work taken up on “design & built” mode

 Rates quoted on plinth area basis.

 Architectural drawings were prepared by Senior Architect of

CPWD got approved from client and made integral part of tender
document.

 Schedule of finishes incorporated in tender – client satisfaction

ensured by lateral participation at decision stage.
 Contract conditions

 Stage payments defined for intermediate bills.

 The contractor to choose from RCC shear wall or framed

structure.

 Structure design in contractor’s scope.

 Proof check done by IIT Madras appointed by the department.

 Local body approvals in the scope of contractor.

 MEP designs carried out by contractor and approved by the

department.
 Type II Type III Type IV
Per unit Per Unit Per Unit
Plinth Area (sqm) as per
70 80 128
Yard stick
Plinth Area (sqm) as per
changes to Plan for 70 80 128
tunnel form
Cost as per Sanctioned
Estimate
Per Block 44.58 Cr 50.17 Cr 36.18 Cr
Per Flat 0.29 Cr 0.33 Cr 0.47 Cr
Per sqm 41428.00 41250.00 36718.00
Tendered Cost
Per Block 43.11 Cr 47.89 Cr 40.18 Cr
Per Flat 0.28 Cr 0.32 Cr 0.53 Cr
Per sqm 40000.00 40000.00 41406.00
 Design Challenges – Architectural

 Due to high cost of customized form work, it

was essential to allow sufficient numbers of
repetition, slight modifications in architectural
drawings were carried out to achieve
symmetry.
 Wall projections minimized to facilitate
removal of tunnels after stripping.
 Doors, windows and other opening were
finalized beforehand as they had to be
provided in the fabrication of the form work.
 Front face of the structure has to be kept
open for removal of tunnels.
 Design Challenges – Architectural

 Sun shades were avoided.

 Building orientation done in a manner (Shorter
length in E&W) to achieve thermal comfort.
 Clearstory windows are oriented in N & S
directions to get North light and air circulation
without direct sun light.
Conventional Architectural Plan
Architectural Plan for Tunnel
Form
 DESIGN CHALLENGES -
STRUCTURAL

 Front portion of RCC tunnels was required to be

kept open for taking out formwork.

 This posed challenges in seismic design.

 Many iterations were carried out to satisfy design

requirements.
Structural Wall Configuration
Structural Wall & Non Structural walls
 Design challenges – SERVICES
(MEP)

 All services have to be designed

beforehand as it would not be possible
to create openings in future.
 Openings were provided not only for
present requirements but considering
future requirements also.
 3-D modelling using REVIT was carried
out and all services were planned and
conflicts resolved.
Electrical Lay Out
Plumbing Lay Out
Sanitary Lay Out
 Experience from the project so far

 The Tunnel form work was received in India on

30.03.2018. Assembly of tunnels and trials were
completed by April 2018. 1st casting for four Dwelling
units was carried out on 2nd May 2018.
 In the month of May 2018 itself total of three floors
casting were done. Completing 24 Dwelling units in the
3 floors.
 We are now on 17th Floor in Six and half months; after
discounting layover of one and half month due to non-
availability of budget, the effective working time is five
months only.
 The pace of execution doubled with another set of
Form work being used for casting of Type-III block.
 Targets for the project

 Mission – a flat in a day

 Vision – Technology adaption

 Plan – Complete 532 flats structurally by

30.06.2019 and finish them by 30.09.2019.
INSPIRATIONS
DG CPWD
Secretary, MoHUA
ACADEMIA

Structural Engineering Professors from IIT

Madras
LEARNINGS
Architectural Challenges
• Basement stories can not be constructed by
using tunnel formwork system, removal of
formwork is not possible.
• Distances of blocks facing each other must
allow removal of formwork.
• All the Structural walls needs to be parallel
and curved walls are not feasible in this
structural form work system.
• If a railway system is decided, blocks should
be arranged by considering the crane
circulation.
•
Design CHALLENGES

• Dimensional limitations must be considered.

• Low degree of modular flexibility (105
cm+1,2,3...n x 30 cm for a half tunnel)
formwork.
• Minimum Room size 210 cm.
• Ribbed or waffle slab can not be applied.
• Minimum 150 cm thickness of wall and slabs
Design CHALLENGES

• It is not convenient for music halls, theaters,

etc., that contains large spans.

• Lowered/Sunken slab is not allowed since it

prevents the removal of formwork,
suspended ceiling is required.

• Load bearing walls must be designed

continuously on the same axial system due
to the resistance requirements against
horizontal forces.
Design CHALLENGES

• Continuous footing or raft (mat) foundation is

required.
• Various geometrical forms and angles are possible
but these forms must not prevent removal of
formwork.
• Erecting and dismantling of cranes took
approximately three weeks.
ADVANTAGES
Advantages of Tunnel Form

• Advantages related to TIME

• Advantages related to COST

• Advantages related to QUALITY

Advantages on TIME
• A production cycle of 1-3 days/Floor can be
achieved.
• The project can be completed in a short time
compared to traditional construction systems.
• Due to accelerated production, effects of
climatic conditions on productivity are
minimized.
• Labours obtain specialization and “zero
defect” production pattern is possible.
Advantages on QUALITY
• Higher precision in production of walls and slab units
(1/1000 deformation is allowed and can be achieved)
• Smooth surfaces for the walls and slabs are obtained
that can be covered with wall putty direct with out
Plastering.
• Standard dimensions for the other components such as
carpet, windows, and doors can be applicable due to
strict dimensions of Form work elements.
Advantages on COST
• Early completion of project provides
financial opportunities such as rental
incomes.

• Repetitive nature of buildings provides

effectiveness in production and
minimization of labour costs.

• Formwork cost per m2 (or per Dwelling unit)

can be reduced by using formwork up to 600
cycles.
DISADVANTAGES
 Construction limitations

• Tower cranes are required for the erection,

removal and carriage of formworks, scaffolds,
and pre-cast components.
• Staircase has to be cast-in-situ or can be
designed as precast component.
• A crane can serve max. 2 blocks at the same
time
• Movement of cranes has difficulties according to
some topographicphic conditions.
 Disadvantages
• A continuous and fast cash flow that
complies with
the speed of production is essential.
• Due to high production speed management-
related functions are vital.
• Coordination problems cause remarkable
delays in schedule.
• Demand of Skilled labour force.
• Equipment costs are relatively higher due
to the cranes that are needed by each
block.
Building Production Systems
 Comparison of various wall formwork

Aluminum
Tunnel Form
Form
Aluminum Form work Conventional Formwork
SI.No. Characteristics Tunnel Form Technology
System System
1. Speed of construction One day’s cycle per Four days cycle per Min. cycle time is of
floor. floor. 21 days.
2. Quality of surface finish Excellent. Plastering is Excellent. Plastering Bad. Plastering
not required is not required is required
3. Pre-planning of formwork Required Required Not required
system
4. Type of construction Cast-in-situ Cellular Cast-in-situ Cellular Simple RCC
construction construction framed construction
5. Wastage of formwork Very less Very less In great amount.
material
6. Accuracy in construction Accurate construction Accurate construction Accuracy is Less
than Modern Systems
7. Coordination between Essential Essential Not necessarily
different agencies required
8. Resistance to earthquake Good resistance Good resistance Less than
Modern Systems91
Removing of floor slab forms Possible Possible Not possible
9. without removing props
 Comparison of various wall form
work

Tunnel Aluminum
Form Form
Aluminum Form work Conventional Formwork
SI.No. Characteristics Tunnel Form Technology
System System
10. Need of any timber or Not required Not required These are the
plywood main components
11. Re-usage value of formwork 500 – 600 250 – 300 Maximum 50

12. Suitability for high rise Very much suitable Very much suitable Not suitable
construction
13. Initial investment in the High High Less
system
14. Economy in construction Economical for Economical for mass Economical on
mass housing housing small scale
15. Design flexibility Very low scope Very low scope High scope

16. Tower Crane Required Not required For tall building

required.
17. Staff required Less Moderate High
92

18. Type of labour Highly skilled Moderate skill Skilled

Customize to Optimize

Tunnel formwork is a
specific tool
-
not the end of
Technology Tunnel