Tunnel Mineral Del Monte Highway Project | Mineral del Monte, Hidalgo, Mexico

Expanding Mobility Through Innovation: Mexico’s Tunnel Mineral Del Monte Highway Project

Mineral del Monte, Hidalgo, Mexico

Connecting Communities with Cost-Effective Engineering

The Tunnel Mineral Del Monte project represents a transformative infrastructure investment for Hidalgo, Mexico. This new highway system addresses critical transportation challenges while preserving the region’s mountainous terrain.

Rather than widening existing roadways through extensive excavation, engineers created a 200-meter double-traffic tunnel—one road for each direction. This dual-tunnel design demonstrates how modern engineering can balance development with environmental preservation, reducing travel times and improving safety for thousands of daily commuters.

A Partnership Built on Custom Solutions

When Jaguar Ingenieros Constructores S.A. de C.V. was selected to construct the Tunnel Mineral Del Monte, they knew that using traditional tunnel-forming methods of specialized hydraulic equipment would be a considerable capital investment that could compromise the project’s feasibility.

Working closely with EFCO’s Mexico team, they engineered a hybrid forming solution that combined EFCO’s modular SUPER STUD® and REDI-RADIUS® systems. This solution not only provided a significant cost reduction compared to specialized tunnel systems but also maintained structural integrity and construction efficiency.

Engineering Innovation in Action

The hybrid system leveraged the complementary strengths of both systems. EFCO’s SUPER STUD® system provided the structural backbone—3-meter-tall H-frames that created a high-capacity, load-bearing framework. Eight REDI-RADIUS® panels were then mounted to these SUPER STUD® H-frames to form the tunnel’s distinctive curved horseshoe profile.

The REDI-RADIUS® system brought precision to the curved surfaces. Creating smooth tunnel walls required a specialized interface between the rigid SUPER STUD® structure and the curved REDI-RADIUS® forming surface. EFCO developed customized connector templates to bridge this transition, with custom-shaped pieces installed between the SUPER STUD® H-frames and REDI-RADIUS® panels for seamless integration.

EFCO’s SUPER STUD® clip angles secured wood to the REDI-RADIUS® panels, creating a rigid assembly that maintained the precise 8-meter radius throughout concrete placement. This integration combined the SUPER STUD® strength with REDI-RADIUS® geometric accuracy, efficiently distributing tunnel concrete pressures to create a stable structure.

Moving Formwork Through the Tunnel

Tunnel construction requires forming systems to move quickly and safely between pour locations. EFCO engineered its SUPER STUD® and REDI-RADIUS® systems to function as a mobile forming carriage. The contractor installed steel C-channels as guide rails along the tunnel floor, with Hillman Rollers mounted beneath the SUPER STUD® frame. The frame was rolled along the C-channels, which were anchored to the slab, resulting in fast and safe cycle times between pours.

Adapting to Portal Requirements

At the tunnel portals, both interior and exterior walls required forming. EFCO adapted the system to accommodate double-sided wall forms for the four entrance pours.

This approach eliminated the time-consuming disassembly and reassembly typically associated with conventional forming. While the average cycle time for the entire process was two days, the team managed to complete it in as little as one day, with individual setup and stripping operations averaging just three hours. This efficiency allowed the contractor to maintain a consistent workflow throughout the 200-meter tunnel.

Why Jaguar Ingenieros Constructores Chose EFCO

For the Tunnel Mineral Del Monte project, Jaguar Ingenieros Constructores partnered with EFCO to access specialized tunnel engineering expertise while maintaining the cost flexibility of rental equipment.

EFCO’s team developed a hybrid system using commercial products that met EFCO Quality standards while eliminating capital investment associated with specialized tunnel forms. Unlike traditional tunnel-forming systems designed for specific dimensions, EFCO’s SUPER STUD® and REDI-RADIUS® systems can be configured for a variety of tunnel sizes and profiles using standard, rentable equipment. This adaptability enables contractors to tackle diverse tunnel projects without requiring custom formwork for each application. The field service support maintained consistent performance through 94 pour cycles.

By reducing equipment costs while maintaining production efficiency, EFCO demonstrated how the right formwork partner achieves the Lowest in-Place Concrete Cost (LIPCC) through custom engineering, flexible rental programs, and dedicated field support.