TUNNEL FORMWORK SYSTEMS - MD Group

Tunnel Formwork Manufacturing

Tunnel formwork manufacturing is the production process of high-strength formwork systems that enable walls and slabs to be cast simultaneously in reinforced concrete structures. It is widely preferred for residential complexes, high-rise buildings, hotels, dormitories, hospitals, and projects with repetitive layouts, providing fast, accurate, and safe concrete construction.

During the manufacturing process, formwork panels, structural steel frames, connection components, adjustment mechanisms, and working platforms are produced according to project specifications. Precision cutting, welding, and assembly processes are applied to ensure smooth concrete finishes, easy assembly and dismantling, and high resistance to concrete pressure.

Material quality, weld strength, surface accuracy, and connection reliability are critical in tunnel formwork systems. Protective painting, lubrication, and surface treatments are applied to extend the service life of steel components. As a result, the formwork system maintains its structural integrity and performance through repeated use.

The Tunnel Formwork System

Tunnel Formwork System is a modular method that optimizes projects by allowing simultaneous casting of walls and slabs,

maximizing time savings with a daily cycle.

1. Half Tunnel: The L-shaped main load-bearing module with wheels and jacks that forms the structure.

2. Slab Opening Form: Modular boxes that accurately create voids for stairs, elevators, and shafts.

3. Wall Opening Form: Template panels fixed between vertical forms to create precise door and window openings.

4. Outside Vertical Panel: High-strength panels that shape the exterior surface of facade shear walls.

5. Outside Panel Platform: A console-type safety platform providing a secure working area for external panels.

6. Kickers and Material: Guide elements that prevent displacement at the base and define the installation axis.

7. Balance Beam: A heavy-duty steel beam that distributes loads evenly and prevents deformation during crane transport.

8. Stripping Platform: A temporary console platform extended outwards for rolling out and hooking the forms via crane.

9. Slab Stopend: Boundary formwork that encloses slab edges or project-specific expansion joints.

10. Tunnel Lifting Element: An integrated high-capacity lifting eye used as a secure anchor point for crane chains.

11. Wall Stopend: A highly sealed vertical element that closes the ends of wall castings and facade joints.

12. Back Panel: A vertical panel that seals the rear of the tunnel formwork and shapes room corner lines.