How to Build Tunnel Formwork [Full Guide]

One of the classic structures in that project is the world project from the outward and upward direction to create some of the best construction towers. In modern technology, as it applies to creating formwork structures, the strategic factors can help develop formidable output with incredible structural strength and reduce costs. Some of the top commercial edifices may include hotels, private housing estates, and student accommodation. Others include commercial developments, community development, urban planning, and execution. 

How to Build Tunnel Formwork [Full Guide]

What is Tunnel Formwork

Tunnel formwork refers to a box-shaped steel fabricated form, which may include a slab that can be cast into a single operation. In addition, it can also help wall structures in the same project execution. As you reinforce the concrete slabs and walls, you can execute it in a single concrete pour after inputting the concrete mixture. According to modern standards, tunnel formwork can also be highly effective and efficient in repetitive cases as and cellular construction projects

The Significance of Tunnel Formwork 

Tunnel formwork also constitutes a comprehensive and highly systematic provision of an earthquake-resistant construction structure. In addition, it addresses the matter of sound transmission, which can reduce the sound emission level by u to 50 decibels. It also provides heating costs through a thermal mass and enhances the process of construction. Besides, the design is highly constructive, so contractors invest a great of expertise into tunnel formwork fabrication.

The tunnel in this structure also complies with the half units of the inverted L shape. Besides, the two halves are joined at the tip of the tunnel to form a couple or cell. The formwork can also move in and out through the effectiveness of the wheels and jacks. With the proper adjustment, concrete constructors can also be reused for up to 600 times the accurate or actual steel size that makes up the Tunnel formwork. Click here to learn about Hiring a Formwork Contractor in Sydney Australia.

The Process of Casting a Tunnel Formwork

You can choose the right channel for the tunnel formwork while manufacturing the in-situ concrete framework. More so, it has a 24-hour construction cycle and works in 7 significant steps through professional handling. The details are given below:

Stage 1: The first step of manufacturing Tunnel formwork involves prefabrication of wall reinforcement while positioning it correctly. This positioning may require a crane while moving the entire wing of the structure and casting kickers in their best position.

Stage 2: position two and a half tunnels using a crane into the right place where they should be and bolt or tie them together.

Stage 3: pour the mixed concrete into the wall

Stage 4: the fix the slab reinforcements 

Stage 5: Place the concrete slab in its proper place. You can also prepare to pour the formwork system and wrap it in the right place. You may also prepare the concrete pouring into the suitable tunnels while wrapping it up with tarps. The next thing is to supply butane heaters to keep a high temperature for the concrete to reach exceptional strength when you leave it over the night.

Stage 6: Remove the tunnel forms the following day

Stage 7: you can also repeat the same process for the next two days

Tunnel formwork enables the contractors to produce a highly durable quality of cellular structures to meet with the modern architectural designs. The concrete finish is of tremendously high quality, while it does not require much post-construction for plasters and electricians. A nice tunnel formwork can save a cost within the range of 15 and 25% of your total cost. When you also employ contractors with in-depth experience, you can be sure of unique workings to produce high-quality output under ideal conditions. Meanwhile, we strongly recommend BKH Group. 

BKH Group has a professional group of specialist engineers who value the essence of manufacturing tunnel formwork for efficient output. 

Formwork Systems for Engineers

Formwork solutions from top concrete construction engineering firms like the BKH Group include the following: 

  • Civil engineering systems that are ideal for tunnels, bridges, underpasses, and shoring 
  • Climbing systems for the right engineering solution in multiple working platforms and levels
  • Props and shoring systems that are perfect for cover tunnels shoring and provides an excellent option for tall structures
  • Horizontal systems that comprise formwork solutions for the construction of shoring and slabs
  • Vertical systems that comprise of formwork solutions columns, circular walls, piers, and walls

Regulatory Requirements of Formwork

Under the standard protocol, the following are the two most essential requirements of formwork;

  1. Formwork should be rigid, tied, watertight, and braced together to maintain a good position and shape during the construction process
  2. It should also be removable after the concrete must have dried up. Besides, it must also be free from causing damage to the concrete structure. At the same time, the components of the formwork must remain intact at the end of the finished form while the rest can be easily removed from the whole system. 
How to Build Tunnel Formwork [Full Guide]


On a final note, there are different types of formwork, which depend on the type of scaffolding or structure you intend to build in the right way. Any given project can also have its own specifications. Still, the supervisors or project managers must understand the essence of manufacturing quality components to produce an eventually powerful output. In today’s construction industry, there are several reasons why formwork is essential to construction projects. Remember also that formwork includes all forms of the skeletal structure before you pour the concrete into the frames and bracing with the right stability level. In addition to the central system, the other parts include joists, bearers, foundations, footings, and foundations. In addition, modern building technology has influenced the production of many commercial structures, including concrete formworks that can serve the proper purposes and stand the test of time. 

Lucas Lavarack Written by: