REPORT ON

TUNNEL FORMWORK
SUBMITTED TO:-

PREPARED BY:-

Brig. S.K. Sharma(Retd.)

Nitesh Chowdhry
(12CVU033)
Shivam Sharma
(12CVU043)
Deepanshu Goel
(12CVU017)

INDEX
S.NO
1
2
3
4
5
6
7

TITLE
INTRODUCTION
HISTORY
COMPONENTS
CONSTRUCTIO
N SEQUENCE
ADVANTAGE
SUMMARY
REFERENCES

PAGE NO.
3
5
6
8
9
10
11

INTRODUCTION
Slip forming, is a construction method in which concrete is poured into a
continuously moving form. Slip forming is used for tall structures (such
as bridges, towers, buildings, and dams), as well as horizontal structures,
such as roadways. Slip forming enables continuous, non-interrupted,
cast-in-place "flawless" (i.e. no joints) concrete structures which have
superior performance characteristics to piecewise construction using
discrete form elements. Slip forming relies on the quick-setting
properties of concrete, and requires a balance between quick-setting
capacity and workability. Concrete needs to be workable enough to be
placed into the form and consolidated (via vibration), yet quick-setting
enough to emerge from the form with strength. This strength is needed
because the freshly set concrete must not only permit the form to "slip"
by the concrete without disturbing it, but also support the pressure of the
new concrete as well as resist collapse caused by the vibration of the
compaction machinery.
In Vertical Slip forming the concrete form may be surrounded by a
platform on which workers stand, placing steel reinforcing rods into the
concrete and ensuring a smooth pour. Together, the concrete form and
working platform are raised by means of hydraulic jacks. Generally, the
slip form rises at a rate which permits the concrete to harden by the time
it emerges from the bottom of the form.
In Horizontal Slip forming for pavement and traffic separation walls
concrete is laid down, vibrated, worked, and settled in place while the
form itself slowly moves ahead. This method was initially devised and
utilized in Interstate Highway construction initiated by the Eisenhower
administration during the 1950s.

HISTORY
The slip forming technique was in use by the early 20th century for
building silos and grain elevators. James Macdonald, of Macdonald
Engineering of Chicago was the pioneer in utilizing slip form concrete
for construction. His concept of placing circular bins in clusters was
patented, with photographs and illustrations, contained in a 1907 book,
The Design Of Walls, Bins, And Grain Elevators. In 1910, Macdonald
published a paper Moving Forms for Reinforced Concrete Storage
Bins, describing the use of molds for moving forms, using jacks and
concrete to form a continuous structure without joints or seams. This
paper details the concept and procedure for creating slip form concrete
structures. On May 24, 1917, a patent was issued to James Macdonald of
Chicago, "for a device to move and elevate a concrete form in a vertical
plane".

The technique was introduced to residential and commercial buildings in

the late 1960s. One of Its first uses in high-rise buildings the United
States was on the shear wall supported apartment building at Turk &
Eddy Streets in San Francisco, CA, in 1962, built by the San Francisco
office of Macdonald Engineering. The first notable use of the method in
a residential/retail business was the Skylon Tower in Niagara Falls,
Ontario, which was completed in 1965. Another unusual structure was
the tapered buttress structures for the Sheraton Waikiki Hotel in
Honolulu, Hawaii, in 1969. Another shear wall supported structure was
the Casa Del Mar Condominium on Key Biscayne, Miami, FL in 1970.
From the 1960s, the vertical technique was adapted to mining head
frames, ventilation structures, below grade shaft lining, and coal train
loading silos; theme and communication tower construction; high rise
office building cores; shear wall supported apartment buildings; tapered
stacks and hydro intake structures, etc. It is used for structures which
would otherwise not be possible, such as the separate legs of the Troll
A deep sea oil drilling platform which stands on the sea floor in water
about 1000 feet (300 m) deep.

COMPONENTS OF SLIPFORM
A slipform assembly can only start after the foundations of the walls
have been correctly laid and a starter for the walls laid out in its correct
alignment with all the necessary steel for the walls already in position.
The slipform shuttering is then firmly aligned to this starter with the
means of yokes on each side of the shuttering that help to keep the
panels in position. The yokes are all connected by horizontal
crossbeams. Hydraulic jacks are then installed rigidly to the crossbeams
that can all act simultaneously so that the entire slipform shuttering
moves upwards. The heights of such slipform shuttering will normally
be between 1.1 meters to 1.5 meters in height. The yokes and horizontal
crossbeams are also used to support a working platform that can afford
space for men and materials. The jacks climb using jacking rods that are

installed within the concrete and become a permanent part of the

structure, or can be retrieved if so desired. The design of the working
deck and the yokes and horizontal crossbeams are a very vital part of
efficient slipform construction. It is very important that the entire
structure be such that its rigidity and shape is maintained at all times. It
is quite normal for the two sides of the shuttering to be inclined towards
each other at the top with the correct wall dimension available at the
center. This allows the shuttering to move easily and eliminates any drag
that concrete can cause on the shutters to prevent its free upward
movement. The rigidity of the supporting platform is also essential so
that all parts of the structure move simultaneously. If there is any lag
from one part to the other, this can cause the shuttering to drag and make
it difficult to be pulled up. It is also possible to reduce wall thicknesses
as the construction gains height and arrangements have to be made in the
slipform structure that will enable such reduction at regular intervals.
Once the slipform shutters along with the jacks and support deck are in
position, concreting operations can then commence. Sufficient working
space has to be created on the deck to accommodate reinforcement bar
activity. The bars have to be continually lengthened and placed in
position as per the structural requirements for the wall. The concrete is
poured in layers, and by the time the concrete level has reached the top,
the concrete at a level 300 mm above the bottom of the panel should
have gained the initial set. The rate of pouring of the concrete has to be
adjusted so that this is achieved. The slipform is then moved upwards in
steps of 10 mm to 25 mm and both the concreting and placing of the
reinforcement bars is done continuously till the final height is reached.
All jacks are fitted with brakes that act automatically by mechanical
means and do not allow the jacks to slip on the jack rods.

CONSTRUCTION SEQUENCE
1. The formwork and the access platform are assembled on the ground.
2. The assembly is raised using hydraulic jacks which are mounted on
strategically located steel frames to lift the formwork as the concrete is
poured into the forms.
3. As the formwork rises continuously, continuous concrete and rebar
supply are needed until the operation is finished.

4. As the formwork is raised, reinforcement is held in the correct

position using guides, horizontal reinforcement is tied to the vertical
reinforcement.
5. Concrete is poured into the forms in layers of approximately 200 mm.
The setting rates of concrete are constantly monitored to ensure that it is
matched with the speed at which the forms are raised. The jacks lift the
form approximately 25mm per stroke generally producing a slip-forming
rate of 300 mm per hour
6. Slipforming can be performed on either a continuous basis (i.e. 24
hours per day), or a discontinuous basis (i.e. pouring to a predetermined
height usually within one working day) .
7. Block outs for doors and windows can be formed with either timber
or steel. These are in-stalled as the slipform proceeds and can be stripped
from the trailing decks .
8. Recesses are made to host the connections between the beams, slabs
and the slipform walls.
9. When the formed concrete is exposed from the bottom of the steel
form panels it can be sponged or treated if required .
10. At the end of the operation the formwork is removed using a crane,
the entire process is thoroughly inspected and highly controlled Slip
forming relies on the quick-setting properties of concrete, and requires a
balance between quick-setting capacity and workability. Concrete needs
to be workable enough to be placed into the form and consolidated via
vibration. This strength is needed because the freshly set concrete must
not only permit the form to "slip" passed the concrete without disturbing
it, but also support the pressure of the new concrete as well as resist
collapse caused by the vibration of the compaction machinery.

ADVANTAGES OF SLIPFORM
A major cost of concrete structure construction comes in the form
of the required formwork to retain the concrete while it retains it
necessary shape and gains the necessary strength till it can be
safely de-shuttered and be able to support itself and other imposed
loads.
This greatly reduces the cost of the formwork as well as any time
that may be required to erect and move it for re-erection, which
can result in huge savings in time as well as money.
The continuous operations also allow for an evening-out of the
manpower requirements and also a huge saving in the labor that
may have to be periodically employed during otherwise
intermittent concreting operations.
The reduction in the movement of formwork and workers also
leads to far more safe working conditions that also make it a major
advantage.
The slipform setup provides a safe and protected work
environment for your crew. Relatively little climbing is required,
the work area is compact and unchanging and weather
protection can easily be added to the formwork setup. Enclosed
spaces can be heated during the cold weather periods.
Slipform is never released from the structure during climbing, as is
commonly done with other form systems. It only climbs in small
increments and is continuously connected to the structure at
multiple points, making it a very safe system.

SUMMARY

 Slip form construction is a construction method in which

concrete is poured into a continuously moving form.
There are two types of slip-forms; vertical and horizontal.
Slip-form construction consumes very less time but requires
careful planning of construction process to achieve high production
rates.
Due to continuous concrete pouring in slip-form construction it
produces better concrete joint less and watertight structures.
Slip form systems require a few but highly skilled workforce.
Slip-forming is also used in the construction of tapered structures
involving changing thicknesses in walls, diameters and/or shapes.

REFERENCES
Google.com
Wikipedia
slipformwork.com
concretecenter.com
brighthubengineering.com