Revolutionizing Modular Housing: Lianggong's Third-Gen Tunnel Formwork Dominates Middle East

How Simultaneous Wall-Slab Casting Accelerates Affordable Home Delivery

Breaking the Mold: What Makes Tunnel Formwork Essential for Modern Housing?

Lianggong's tunnel formwork system redefines modular construction through monolithic concrete casting - simultaneously forming walls and floor slabs in 

one continuous pour. Unlike traditional methods requiring separate formwork stages, this system enables:

• 72-hour cycle times per housing unit (vs. 12+ days with conventional systems)

• 0.5mm/m vertical alignment precision across cast surfaces

• 400+ reuse cycles with Q355B steel construction

Core Component Evolution

Proprietary Features Driving Adoption:

• Dual-phase stripping: Wall forms retract first, followed by ceiling components

• Mobility package: Air-cushioned transporters enabling 15-minute unit relocation

• Surface finish control: 3D-printed texture plates eliminating post-cast plastering

Dubai Case Study: 1,200 Units in 98 Days

Project: Nad Al Sheba Affordable Housing Complex
Challenge: Complete 50+ identical units/week in 45°C heat

Lianggong's Solution:

Deployed 12 tunnel formwork sets working in 3 shifts

Implemented "pour-move-pour" sequence with 8-hour cycles

Used phase-change concrete additives preventing rapid moisture loss

Results:

• 63 units completed weekly (26% above target)

• 0.3% concrete waste rate (industry avg: 6-8%)

• 98.4% dimensional compliance across all units

• Economic Advantage: Cost Analysis per Housing Unit

Speed Bonus Calculation:
Early completion incentives ($28,000/day penalty avoidance) + accelerated progress payments

Climate-Smart Engineering: Desert-Proofing Modular Construction

Adaptations for Middle Eastern Conditions:

• Thermal Management System

• Active cooling channels maintaining 22-28°C curing environment

• Ceramic-coated surfaces reflecting 92% solar radiation

• Sand Mitigation Tech

• Positive-pressure seals preventing particle ingress

• Self-cleaning track systems removing abrasive residues

• Cultural Customization

• Pre-set openings for majlis seating niches

• Adjustable module widths accommodating extended families

• Quality Control: From Doha to Riyadh

Three-Stage Inspection Protocol:

1. Pre-Cast Verification

• Laser-scanned alignment (±0.15mm tolerance)

• 250kN/m² pressure testing of all joints

2. Pour Monitoring

• Real-time slump measurement via embedded sensors

• Thermal imaging detecting cold joints

3. Post-Stripping Audit

• 3D photogrammetry comparing as-built vs BIM models

• Schmidt hammer tests verifying 35MPa+ concrete strength

Riyadh Incident Resolution (2023):

Issue: Surface pitting in 14 units

Root Cause: Improper vibration frequency during 48°C pour

Fix: Implemented AI-driven vibration adjustment algorithm

The Road Ahead: What's Next in Tunnel Form Tech

Robotic Rebar Integration

Automatic reinforcement cage installation during form setup

Self-Healing Concrete Interface

Microcapsule technology repairing minor surface defects

Blockchain Tracking

Material traceability from steel mill to jobsite

4D Scheduling Integration

Real-time progress mapping against BIM timelines

Industry Endorsement

"Lianggong's system helped us achieve what local contractors deemed impossible - building quality homes faster than migrant worker camps."
– Khalid Al Maktoum, UAE Ministry of Housing Project Director