This document discusses tunnel formwork systems, which is a mechanized construction method for building cellular structures efficiently. Tunnel formwork involves casting concrete walls and floors simultaneously using reusable tunnel-shaped molds. Key advantages include reduced construction time of one floor every 3 days, cost savings from fewer workers and repeated formwork use, and improved structural strength and earthquake resistance of the completed buildings. Case studies demonstrate tunnel formwork being used to construct high-rise residential towers in Atlanta and Pune more quickly and affordably than conventional construction methods.

1. F O R M W O R K S Y S T E M
I N D U S T R I A L I Z E D B U I L D I N G S Y S T E M ( I B S )

2. INDUSTRIALIZED BUILDING SYSTEM (IBS)
A technique of construction, components are manufactured
in a controlled environment, either at site or off site, place
and assembled into construction works.

3. INDUSTRIALIZED BUILDING SYSTEM (IBS)
Generally, there are five types of IBS in Malaysia that are:
● Pre-cast concrete frames
● Formwork systems
● Steel frame systems
● Prefabricated timber frames
● Block work systems

4. FORMWORK SYSTEM
• Serves as a mould for concrete structural components in which fresh concrete
is poured only to harden subsequently.
• IBS Formwork system includes steel, aluminum, timber formwork system and so
on.

5. TUNNEL FORMWORK SYSTEM
• A mechanized system for
cellular structures.
• Known as a modern method
of construction (MMC).
• Used widely in the
construction of cellular
structures that consists of high
degree of repetition.

6. TUNNEL FORMWORK CONSTRUCTION PROCESS
• A 24-hour construction cycle can be achieved and the buildability of in-situ
concrete is improved by using tunnel formwork system.
• Tunnel formwork can produce strong and durable in-situ cellular structures.

7. CASTING PROCESS OF TUNNEL FORMWORK
1
2

8. CASTING PROCESS OF TUNNEL FORMWORK
4
3

9. CASTING PROCESS OF TUNNEL FORMWORK
5
7
6

10. TUNNEL FORMWORK SYSTEM
ADVANTAGES
Quality
Time
Cost
DesignSafety
Efficiency
Sustainability

11. TUNNEL FORMWORK SYSTEM
DISADVANTAGES
• Cost
• Dimensional
Limitation
• Coordination
Issues
• Skilled Labour
Required

12. CASE STUDY

13. THE PARAMOUNT BUCKHEAD - ATLANTA
(by The Hanover Company, Houston)
At 44 storeys, it is one of the
tallest residential structure
ever constructed using tunnel
form.

14. Efficient in concrete casting
One floor can be completed in every 3 days. Completion of shell was
completed one month ahead as per schedule.
Affordable single family residence & apartment
Tunnel form help reduce time to build structure because workers
formed both walls and decks in one operation hence reduce
overhead cost
Speed of construction with a small crew, most marketed benefit
Only a few worker are required to place ask the formwork needed for
an entire floor. Workers help to give instruction to the crane
operator during installation.
Refinements purpose
On the Paramount project, Stull reports that workers could easily
locate the tunnel forms precisely each time they were moved,
so the building was only 3⁄8 inch out of plumb in its 44 stories.
THE PARAMOUNT BUCKHEAD - ATLANTA

15. 25 towers with 12 residential
levels and 2 ground floors
each, the first project to
employ the tunnel form
technology for constructing
the towers and the individual
apartments in each tower in
Pune.
ROHAN ABHILASHA - PUNE, INDIA
(By Rohan Builders India Pvt Ltd.)

16. SHORTER ERECTION PERIOD PERMITS AN EARLIER RECOVERY OF CAPITAL
● Has a production cycle of 1-3 days per floor, cost of financing the
construction capital is considerably decreased with high construction speed
ASSURANCE OF GOOD QUALITY
● Precast products that manufactured and cured in plant such as staircases were
used result in increased productivity after erection at a very short period of time
EFFECTIVENESS IN PRODUCTION AND MINIMIZATION OF LABOUR COSTS
● Reuses the formwork from housing units a few times & only required a
few number of workers
STRONG AND DURABLE AGAINST EARTHQUAKES
● Tunnel formwork system that creates efficient load-bearing structures
which are known as the most earthquake resistant structures were used.
ROHAN ABHILASHA - PUNE, INDIA

17. SAFETY PRECAUTIONS
• Training session
• Employer’s responsibility
• Safe working environment

18. CONCLUSION
TUNNEL FORMWORK SYSTEM CONVENTIONAL FORMWORK SYSTEM
• One day’s cycle per floor • Minimum cycle time of 21 days
• Plastering is NOT required • Plastering is required
• Can be reuse up to 300-500 times • Maximum number of reuse is 50 only

19. CONCLUSION
TUNNEL FORMWORK SYSTEM
COST
EFFECTIVE
TIME
EFFICIENT
QUALITY
ASSURANCE

20. T H A N K Y O U
WONG JIA JING (0327221)
YEAP PHAY SHIAN (0322243)
YEE JYH LIN (0322408)