Comparison of aluminum and tunnel formwork for high-rise construction

The growing demand for high-rise buildings in India has increased the need for faster and more efficient construction methods. Formwork systems play a key role in construction speed, quality, and cost. Monolithic construction, using advanced formwork like aluminum and tunnel formwork, has become popular due to its durability and efficiency. However, there is limited research comparing these systems in India, particularly in terms of cost, reusability, and selection criteria. This study fills that gap by comparing aluminum and tunnel formwork based on cost, efficiency, and key selection factors. The main objectives include: (1) identifying important factors in choosing formwork, (2) comparing costs, (3) evaluating cost per square meter, (4) analyzing reusability for cost-effectiveness, and (5) assessing time and cost impacts. The research uses a mix of literature review and case studies from high-rise projects in South and West India. Data was collected on shuttering costs, labor efficiency, reusability, and project timelines. Findings show that aluminum formwork is cost-effective for projects with fewer repetitions due to lower initial investment and labor costs. On the other hand, tunnel formwork is better for large-scale projects needing 450–500 repetitions because of its high reusability and faster construction speed, despite higher upfront costs. This research provides valuable insights for construction professionals, developers, and policymakers. By offering a data-driven comparison, it helps stakeholders choose the best formwork system based on project size, cost limits, and repetition needs. The findings can improve cost efficiency, project timelines, and sustainable construction, especially in developing countries like India.