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Tunnel Formwork Systems
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ERTF - Modular Tunnel Formwork System
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Tunnel Form is a system that allows casting of walls and slabs in one operation on a daily cycle. Construction durations are reduced significantly by this rapid system when compared to conventional methods. Tunnel Form System brings speed, quality and accuracy to concrete construction and provides big savings in finishing and M&E works. Hi-tech technologies for steel formwork production make tunnel forms strong & durable. The system creates efficient load-bearing structures which are known as the most earthquake resistant structures.

ADVANTAGES OF ERTF TYPE TUNNEL FORM SYSTEM

Longest lifetime: Hi-tech all-steel system with 3 mm. steel surface provides durability and strength. Service life of ERTF Tunnel Form system is good for 500 reuses as long as the system is used properly in accordance with instructions.

Surface quality: Steel panel surface provides smooth concrete finish. Together with dimensional accuracy these features of the system eliminates finishing works like plastering.

Work safety: Tunnel form system comes with highest jobsite safety due to full perimeter platform system.

Modular tunnel form: ERTF system can be reused for several projects with minimum cost due to its modular nature. Standard size vertical, horizontal and back panels are used with extension filler panels to fit different spans and floor heights easily.

Easy adjustment with telescopic push-pull props: Standard push pull props can be used at every tunnel dimension due to its telescopic nature. ERTF push pull props make it very easy to adjust vertical and horizontal leveling. Lift up the control arm and move the horizontal panel until it is leveled. Once the arm is locked tunnel is adjusted properly.

Easy stripping with rollers : ERTF Half tunnels can easily be moved and stripped out by the help of rollers used instead of wheels. Rollers are located under vertical panels.

Elevated bottom tie-rod level for higher kicker concrete: High kickers make it easier to adjust tunnel heights which eliminate leveling mistakes of the foundation.

Telescopic extension tunnel legs for non-typical floors: ERTF tunnel form can be used at non-typical floors with higher floor levels by the help of telescopic extension legs mounted on the inner vertical panels. Such floors can be cast in two steps easily by elevating tunnel forms on the legs for the second step (optional).

Stripping platform extension leg for non-typical floors: ERTF stripping platforms can be easily used at non-typical floors with higher floor levels by the help of extended triangle leg of the platform (optional).

DAILY CYCLE

Main feature of tunnel form system is to transform building construction almost into an industrial production line by systemizing daily works into repetitive activities like a factory production which eventually provides highest efficiency on site with daily cycle.

In order to optimise the volume of formwork, equipment & workforce overall structure is divided into a number of more or less similar construction phases, size most of the times  corresponding to daily work to cast concrete. To maximise efficiency, it is important that the phases done everyday are similar. Repetition saves a lot of time on site, as the workers know precisely what they have to do at any time of the day.

To catch daily cycle and fast project completion, MESA IMALAT always studies complete set of construction drawings and provides formwork solution in advance before the concrete works start at site. Thus any loss of time spent to find on-site solutions are eliminated by tunnel form system.

The following items should also be considered for an efficient implementation of tunnel form system;

• Steel wire mesh should be preferred as structural reinforcement. All rebar works should be done at steel prefabrication area in advance to speed up installation.

• Usage of suitable crane is crucial. Tower crane should be used for structures with certain height and floor area.

A formwork team of 12 workers is enough to run one set of ERTF tunnel form (roughly 1000m2) which is enough to cast one floor of 300m2 with two days cycle easily.

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TRTF - Classic Tunnel Formwork System
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TRTF Classic Tunnel Form is the simpler system. It is light weight and therefore the initial investment is less when compared to other types of tunnel forms. However this non-modular system is more suitable and economical for projects which consists of buildings with similar floor layouts

Tunnel Form System has many advantages in comparison with the conventional construction systems. Tunnel Form System reduces the costs of construction and shortens the construction period.

The availability of using the formworks for hundred times reduces investment and thus the cost of construction.

Tunnel Form System maximizes construction quality. Smooth surfaces are obtained with tunnel form in each concreting although it is used again and again. These smooth surfaces do not require plaster; dimensions are perfect and precise.  

DAILY CYCLE

Main feature of tunnel form system is to transform building construction almost into an industrial production line by systemizing daily works into repetitive activities like a factory production which eventually provides highest efficiency on site with daily cycle.

In order to optimise the volume of formwork, equipment & workforce overall structure is divided into a number of more or less similar construction phases, size most of the times  corresponding to daily work to cast concrete. To maximise efficiency, it is important that the phases done everyday are similar. Repetition saves a lot of time on site, as the workers know precisely what they have to do at any time of the day.

To catch daily cycle and fast project completion, MESA IMALAT always studies complete set of construction drawings and provides formwork solution in advance before the concrete works start at site. Thus any loss of time spent to find on-site solutions are  eliminated by tunnel form system.

The following items should also be considered for an efficient implementation of tunnel form system;

• Steel wire mesh should be preferred as structural reinforcement. All rebar works should be done at steel prefabrication area in advance to speed up installation.

• Usage of suitable crane is crucial. Tower crane should be used for structures with certain height and floor area.

A formwork team of 16 workers is enough to run one set of ERTF tunnel form (roughly 1000m2) which is enough to cast one floor of 300m2 with two days cycle easily.

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NLTF - Modular Tunnel Formwork System
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NLTF Modular Tunnel Form is designed to serve as both half-tunnel and full-tunnel system. It has expanded span & height modularity. It's unique design enables the system to serve for large spans without using any table form at the mid-span.

Advantages:

  • No separate production of walls and slabs, so no need for horizontal working space.
  • Backwalls are easily integrated in the production cycle.
  • Safety on site is easy to achieve.
  • Prefabricated elements can easily be poured in.
  • Only a small site needed as there is only a small stock necessary (reinforcement and prefab elements).
  • The end deckpanels can be shifted on the bearing beams, so a tapered bay can be realized in a very economical way.
  • With the special rooflock the tunnel can be stripped as a halftunnel or as a fulltunnel.
  • The joint in the deck between the two halftunnels is reduced to almost zero.
  • All bolts and jacks have the same size so only one tool necessary.
  • The vertical panel jacks are easily to replace.
  • The bottom profile of the vertical panel gives an easy view on the kickerline.
  • By use of massive angle-profiles at the deck joint reduces repairs between projects.
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HRTF - Modular Tunnel Formwork System
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HRTF Modular Tunnel Form System is designed to serve for the requirements of projects in United States.

This robust modular system can be used for different building types from single family housing to highrise condominiums.