Concrete formworks play an essential role in construction by providing temporary molds to hold freshly placed concrete until it gains the strength to support itself. While traditional formworks made of timber, steel, and aluminum have long been used, plastic formworks are emerging as a practical alternative due to their unique benefits. Plastic formworks offer advantages like increased durability, cost savings, and flexibility, making them increasingly popular in the construction industry. This article explores these benefits, the objectives of using plastic formworks, and compares them with other materials.
Objectives of Plastic Formworks in Concrete Construction
Plastic formworks fulfill three critical objectives in concrete construction:
- Safety: One of the primary functions of formworks is to ensure safety. Formworks must be strong enough to withstand the weight and pressure of fresh concrete. Plastic formworks are designed to meet high safety standards, minimizing the risk of structural failure that could endanger workers or the public.
- Quality: Plastic formworks contribute to achieving the desired shape, accuracy, and surface finish in concrete structures. The smoothness and consistency of plastic help create a high-quality finish on concrete surfaces.
- Economy: Formworks can account for up to 25% of a project’s total cost, making it crucial to find cost-effective solutions. Plastic formworks are more economical over time because they are reusable and require less labor and maintenance.
Advantages of Plastic Formworks in Concrete Construction
Plastic formworks bring numerous benefits to concrete construction, including:
- Cost-Effectiveness: Compared to traditional materials, plastic formworks are more affordable due to their high reusability. Their lightweight nature reduces transportation costs and assembly labor.
- Labor-Friendliness: Plastic formworks are easier to assemble and dismantle than other types, making them labor-efficient. Their lightweight design allows workers to handle and move them with less effort.
- Eco-Friendliness: Plastic formworks are recyclable, helping reduce waste and environmental impact compared to materials like timber, which contributes to deforestation.
- Low Maintenance: Plastic requires minimal upkeep, as it doesn’t corrode or deform. This durability results in significant long-term savings on repairs and replacement costs.
- Versatility: Plastic formworks can adapt to a wide variety of shapes and sizes, accommodating complex architectural designs with ease.
Plastic Formwork System
Plastic formworks are made from specific-grade plastics that prevent adherence of materials, minimizing patching requirements on the concrete surface. Additionally, they resist chemical reactions, making them ideal for concrete construction. The plastic formwork system is designed with parts that fit together perfectly, preventing leakage of water or concrete and ensuring structural integrity.
Compared to traditional formworks, plastic systems require approximately 30% less time for setup and removal. The need for nailing, oiling, and additional leveling is minimized thanks to the built-in leveling system of plastic formworks. Cleaning these formworks is as simple as rinsing with water, and minor damage can be repaired easily using a low-voltage hot air gun. These features make plastic formworks an efficient, user-friendly option for construction.
Comparison of Plastic, Traditional, and Steel Formworks
When evaluating formworks, plastic stands out for its reusability, ease of handling, and overall durability. Here is a summary comparison of the properties of plastic, traditional, and steel formworks:
| Attribute | Plastic Formwork | Traditional Formwork | Steel Formwork |
|---|---|---|---|
| Recyclability | 40% | No | 10% |
| Water Resistance | Yes | No | No |
| Deformation | No | Yes | Yes |
| Ease of Stripping | Easy | Moderate | Difficult |
| Size Flexibility | Customizable | Restricted | Restricted |
| Corrosion Resistance | Excellent | Poor | Poor |
| Reusability | > 100 uses | 8 uses | 100 uses |
Plastic formworks outperform traditional and steel options in key aspects such as recyclability, resistance to water and corrosion, and ease of handling.
Types of Commercially Available Plastic Formworks
Several types of plastic formworks are available for different construction needs, including the Siscon and Nova systems.
- Siscon Plastic Formwork System: This system is known for its versatility and precision, making it suitable for walls, columns, and slabs. Siscon formworks allow for accurate, consistent molding, helping construct complex shapes with high precision.
- Walls: Siscon plastic formworks are often used for walls in boundary structures, retaining walls, flood and storm drains, irrigation channels, and rainwater drainage walls. Their adaptability makes them ideal for various wall types.
- Floors and Slabs: Plastic formworks facilitate the construction of concrete floors and slabs with even surfaces and reliable structural integrity.
- Columns: Plastic formworks are particularly advantageous for column construction. The ease of setup and dismantling significantly reduces installation time and labor costs.
- Nova Plastic Formwork System: Produced from composite plastic, the Nova system is unique for its resilience in both salt and freshwater environments, making it suitable for marine applications. It is highly durable and commonly used for constructing columns and concrete walls in various environments.
Plastic formworks offer a cost-effective, durable, and eco-friendly alternative to traditional materials. Their ease of handling, reusability, and low maintenance needs contribute to significant project savings in terms of labor, time, and material costs. As the construction industry seeks safer, more sustainable, and efficient solutions, plastic formworks are well-positioned to become a standard choice. These systems meet the demands of modern construction projects, supporting the industry’s goals of enhancing safety, improving quality, and achieving economic efficiency.