Are you planning a construction project and want strong, reliable, cost-effective shuttering materials? Shuttering plywood might be the perfect solution. Shuttering plywood is a type of plywood used for formwork in construction. But why is it so important in modern construction? Here is a deep dive into its features, benefits, and why it signifies a paradigm shift for builders and engineers alike.
What Is Shuttering Plywood?
Shuttering or formwork is a specific type of plywood used in concrete formwork and construction projects. Its strength, versatility, and cost-effectiveness make it one of the most important materials in the construction industry. It is produced to the stringent building standards. It is likely to conform to IS: 4990, the Indian Standard for concrete shuttering plywood. The plywood sheets are heat and pressure-pressed to reinforce and stabilise it. The phenolic film is pasted on the face of the plywood, which comes in the range of 30 to 120 GSM. The higher the GSM, the better the water resistance as well as the wear resistance.
High-quality plywood contains 5–15% moisture, and it will last longer drying out when used on a construction site. Modulus of elasticity (how much it deforms before breaking) is usually 5000 N/mm² or better, which means it can withstand plenty of pressure when concrete is being poured.
How Shuttering Plywood Is Made
Shuttering plywood is made by adhesive bonding multiple layers of wood veneer with PF (phenol-formaldehyde) resin adhesives. The veneer layers are layered with the orientation of the grain of adjacent layers perpendicular to each other, which provides strength to the plywood.
Its construction process results in shuttering plywood that exhibits cracking, shrinkage, and deformation resistance, making it suitable for moulding and concrete plywood applications. A protective layer is usually placed on the surface, especially for adding to water and moisture resistance.
Certain first-rate shuttering ply products are proposed as termite-resistant and borer-proof for long-run projects, making them sturdy and durable for the buildings. Even so, traditional plywood has serious sustainability drawbacks.
Features of Shuttering Plywood
Shuttering plywood is popular in construction because of its many useful features:
- It stays in shape and is easy to carry because it’s both stable and lightweight
- It is tough and holds up well under heavy loads
- It can act as both a support base and a strong layer to keep structures firm
- You can easily cut and fix it using normal woodworking tools
- It can handle rough handling and doesn’t get damaged easily
- It’s a better choice for the environment compared to many other materials
- It doesn’t get damaged by water, making it great for outdoor use
- It holds up well against scratches, swelling, shrinking, moisture, and even exposure to chemicals
- It also resists damage from pests like termites and fungi
- With proper care, like cleaning and storing it in a dry place, it can be used multiple times
Applications of Plywood Shuttering
Here are the uses of shuttering plywood:
1. Holding Concrete in Buildings
Shuttering plywood is employed to hold wet concrete while it sets. It is applied when casting building components such as foundations, walls, floors, ceilings, and columns.
2. Employed on Large-Scale Works Such as Dams and Bridges
In large building schemes like tunnels, bridges, and dams, shuttering plywood is used to create strong molds (formwork) for casting cement. It assists in manhole and water drain creation as well.
3. Fencing and Temporary Structures
It is an inexpensive option to create temporary structures. It is used for site fencing, safety fencing, hoardings, etc. for short-term builds.
4. Assists in Sound and Heat Control
Shuttering plywood can similarly be a good material in soundproofing and controlling heat in or out. That makes it ideal in spaces where insulation or sound control is required.
Benefits of Plywood Shuttering
There are plenty of advantages to using shutter plywood for construction, and we have only mentioned some here. So first, let’s go through them one by one.
Lightweight
Shuttering plywood is lightweight, which makes it easy to handle and transport. Even though shuttering plywood is lightweight, it is also strong and durable. And this is exactly why engineers select shuttering plywood rather than wood shuttering.
Can Be Reused
Unlike other shuttering materials, shuttering plywood is reusable multiple times. This is precisely why shuttering plywood is so popular. It can save time and money, is almost a one-time investment , and is maintenance-free.
Impressive Resistance
Shuttering plywood has incredible durability against fire, chemicals, and water. It is something you can rely on in any weather. The shuttering plywood won’t shrink or crack like wooden planks in extreme climate conditions.
How Plywood Shuttering Works in Construction
Setting Up the Formwork
Plywood shuttering is used as a temporary mould to shape and hold freshly poured concrete until it sets and gains strength. It is typically supported on a framework of beams or rafters and secured in place using screws, clamps, or toggle fasteners. Proper alignment and levelling are critical to ensure the structure remains stable, leak-proof, and dimensionally accurate. Before pouring the concrete, a form-release agent is applied to the surface of the plywood to prevent the concrete from adhering, allowing for easy removal after curing and preserving the quality of the plywood for reuse.
Concrete Pour and Curing
After constructing the formwork, concrete is prepared and poured into the mould. Vibrators are often employed to eliminate air bubbles and achieve uniform distribution. The plywood holds the freshly poured concrete in place while it cures and slowly gains strength. The curing process takes varying amounts of time, depending on the concrete mix and weather conditions.
Removing and Recovering the Formwork
Once the concrete has cured, the plywood shuttering is gently removed, leaving behind the surface. Plywood is a cheap solution, as it can be washed and cleaned, stored properly, and used for future projects if properly maintained.
Types of Plywood Shuttering
There are various types of shuttering plywood depending on the material, strength, and duration for which it can be used. The following are the types that are widely employed:
Marine Grade Shuttering Plywood
It is produced to withstand wet and salty conditions. It is applicable in coastal regions or near piers where the atmosphere is salty. It’s also utilized in boat and ship building since it won’t get spoiled by water easily.
HIgh-Density Shuttering Plywood
This is stronger and thicker than regular shuttering plywood. Its greater strength means you can use it more frequently around a building site without the ply becoming weakened.
Fire Retardant Shuttering Plywood
The plywood has been treated to resist the spread of fire. It’s used where fire-proofing becomes an issue, e.g., in tunnels, underground buildings, and mines.
Pressure Treated Shuttering Plywood
This kind is also designed to take heavy weights and harsh treatment into consideration. It’s durable and tough; hence, it’s normally used in large projects such as dams, bridges, and other tension-stressed structures.
Conclusion
Shuttering plywood is a construction material and the foundation behind good, durable concrete work. It is durable, reusable, and withstands the most challenging conditions, providing premium results while saving time and money. From small projects to major infrastructure work, the right shuttering plywood will make all the difference. If this resonates with you, it is time to improve your construction procedure. Get started on the right plywood today!
Mithali Konety