The construction industry looks very different today than it did just a few decades ago. Among several aspects, plastic shuttering is one such material. Plastic shutters are reusable and lightweight formwork devices used in concrete construction. Unlike wooden or metal shuttering, plastic shutters are more durable and efficient alternative materials. Plastic permanent formwork systems are transforming how we build with residential, commercial, and large civil infrastructure applications. Let us dive into its benefits, the application of modern construction, and why it stands out.
What is Plastic Shuttering
Plastic shuttering or plastic formwork is a temporary moulding that keeps wet concrete in place until it cures and assumes the desired shape. Traditionally, timber, plywood, or steel is used for shuttering. But plastic shuttering is lightweight, durable, and reusable, making it a better choice than conventional forms.
This plastic formwork system is made of durable, reusable material designed to be easily assembled, utilized, and reused for multiple purposes. It is modular and adaptable to many shapes and sizes, making it appropriate for various construction applications, from small residential buildings to vast, even demanding infrastructure tasks.
The Advantages of Plastic Shuttering for Fast Construction
Durability and Longevity
These plastic shuttering sheets are long-lasting, not damaged, and can be used multiple times. Unlike normal wooden shuttering, which can warp, rot, or become infested by termites, plastic shuttering is immune to environmental damage. It resists extreme weather and repeated use, making it perfect for multiple projects.
Cost-Effectiveness
Although the upfront cost for plastic shuttering sheets can be marginally higher than wood, they are more economical overall due to their durable, reusable construction. These reusable sheets don’t need to be replaced as often, resulting in greater cost savings for any project.
Easy To Handle and Install
The usage of plastic shutters eliminates the risk of damaging metal sheets and makes them easier to handle. This reduces work costs and helps to quicken the installation process. Unlike cutting plywood, plastic shuttering sheets do not cause airborne dust and projectiles, making it easier and safer for carpenters to resize and work with them.
Environmental Benefits
The major benefit of plastic shuttering sheets is that they help with sustainability. By using recycled materials in the manufacturing process, you can decrease the need for brand-new raw materials and, thus, reduce waste. So, they can be an environmentally friendly option for builders applying sustainable practices.
Smooth Finish
Shuttering boards are plaster used to convey a predominantly flat surface onto a piece of concrete. That means less time and labour can be spent on additional finishing work. Plastic sheets have a non-stick surface, which speeds up the demolding process, thus increasing efficiency.
Applications of Plastic Shuttering in Construction
Due to its lightweight and robust nature, plastic shuttering is widely adopted across projects. This versatility allows it to be used in a variety of use cases, including:
1. Residential Construction: Plastic formwork in house and apartment construction gets into walls, floors, and other structural elements, ensuring a smooth finish that requires less plaster.
2. Commercial Structures: Construction becomes more accurate with the use of plastic formwork technology for complicated designs and grand scales, such as those built in office buildings, shopping malls, and stations.
3. Commercial Building: Plastic formwork’s lightweight characteristics simplify transport and installation, thus shortening construction time in commercial spaces like offices and retail outlets.
4. Infrastructure Projects: Plastic formwork is adopted for an array of structures, including bridges, tunnels, drainage ditches, retaining walls, pipe corridors, and culverts, ensuring similar quality and saving resources and time.
5. Water Conservancy Projects: Plastic formwork is suitable for constructing dams and other water management structures. It is resistant to moisture and holds its shape under changing environmental conditions.
Plastic formwork in these applications offers fast construction, low labour, and is environmentally friendly due to its reusable properties.
How to Install Plastic Shuttering: Step-by-Step Guide
Properly installed plastic shuttering is very important for the strength, firmness, and flow of construction. Here are the detailed steps for installing plastic shuttering, ensuring your formwork system is flawless and built to last.
1. Site Preparation
Clean the Area: Make sure there are no stones or any particles within the area to be formed and that the ground is clean so that the formwork has a stable base.
Mark Reference Points: Use chalk lines or laser markers to outline the formwork location for accurate alignment.
2. Assemble Support Structures
Beams and Props: Place adjustable props and beams to support the plastic panels. The spacing of these supports is based on the thickness of the concrete floor slab. Supports for 0.15m thick slabs should have around 200–250mm spacing.
3. Panel Assembly
Position Panels: Arrange the plastic formwork panels over the inserted supports so that the panels interlock with zero gaps (to avoid concrete leakage through gaps)
Installing the Panels: Use the right fasteners (for example, clamps or screws) to attach the panels to the supportive structures securely and hold them tightly.
4. Reinforcement Placement
First, place the reinforcement bars inside the mould as per the construction design and ensure the bars are tied and positioned properly.
5. Concrete Pouring
Release Agent: Before pouring, a release agent is applied to the formwork’s inside surfaces to make removing it easier after curing.
Place Concrete: Carefully add the concrete to the formwork, evenly spreading the mixture. Use vibrating tools where applicable to remove air gaps and create dense, even material.
6. Curing Process
Cure Properly: Cure the concrete for the suggested period (usually 7–14-28 days, depending on conditions and mix).
Keep Moist: While curing, keeping the concrete’s surface moist is essential to prevent cracks and allow maximum strength development.
7. Formwork Removal and Maintenance
- After the concrete has cured enough, remove the plastic formwork so as not to have it damaged by the concrete.
- Clean the panels well to eliminate all traces of concrete.
- Store the cleaned panels in a dry, shady area to prevent them from warping or degrading and to ensure they are ready for the next time.
This will help construction professionals use plastic shuttering effectively and make high-quality concrete structures by reusing the material and saving money.
Conclusion
Plastic shuttering is one of the ideal building materials for the construction industry. It is also much more resistant to environmental damage than other traditional materials. Meanwhile, plastic shuttering is becoming increasingly used as the industry advances towards more environmentally friendly ways. Want to elevate your construction projects to a new height? It is time to welcome plastic shuttering!
Apoorva H P Achar