Have you ever wondered how concrete takes its shape before becoming the strong and sturdy structures you see? It is done through a process called “shuttering.” Without it, building structures would be practically impossible. Why don’t we see what shuttering is, the different types available, and the material used in the process?
Shuttering is a type of framework that builders use to shape and support wet concrete while it hardens. If you pour liquid concrete onto a surface without any barrier, it will only spread around without any particular shape. Shuttering is a temporary mold that holds in shape until it becomes solid and gains strength to support itself. You can remove the shuttering once the concrete becomes hard and the shape is set.
Imagine baking cake without a mould, all you would get is a messy puddle, right? Just like that concrete structures would not lack shape, stability and safety without shuttering. Apart from that, the shuttering also gives concrete the right surface finish and alignment. It is also vital for preventing cracks or deformations in the concrete as it sets.
There are different types of shuttering material used for formwork– each serving a unique purpose based on the shape, size, and requirements of your construction.
One of the oldest and most traditional forms of shuttering, timber shuttering is made from wood. This is a practical option when you require irregularly shaped structures, as wood is easy to cut and shape. However, timber might not be as durable as other types as they are easily affected by moisture, leading to swelling or warping. It is also not very cost-effective because of the frequent need for replacement.
This is an excellent choice if you are looking for durability and reusability. These metal sheets used in shuttering can be reused multiple times, which makes it a cost-effective option for large-scale projects. Steel shuttering is strong, resistant to moisture, and offers a smooth finish to the concrete. But it can also be quite heavy. This weight can make it harder to handle and transport. It can also initially prove to be costly, which is usually worth it in major projects.
Even though it is quite similar to steel, aluminium is lighter in weight which makes it easier to handle. It is also quite durable and reusable. However, aluminium shuttering is not as strong as steel, especially if you have to handle heavy concrete loads. Aluminium is more expensive than timber but less so when compared to steel.
Plywood is a fairly new type of shuttering that has become quickly popular because it offers a balance between strength and cost. It can also be shaped easily to fit various designers. On the downside, plywood shuttering has a limited lifespan because the material can become weak if they are repeatedly exposed to moisture. Plywood shutters are usually used for smaller projects or when the budget is tight.
Plastic shuttering materials are lightweight, easy to clean and resistant to moisture. It can also be used several times making it a cost-effective solution for repeated use. But it is not as strong as steel or aluminium. So it is not suitable for large structures or projects that require heavy-duty support. Also, Read All the different types of pilings.
This is a more modern form of shuttering. It uses special fabric sheets to mould the concrete. The fabric allows air and water to escape while the concrete sets, resulting in a smoother finish. Since fabric is lightweight and flexible, it is a suitable option for unconventional shapes. But It requires specialised knowledge and can be more expensive. It is the same reason why this is not more commonly used.
There are some key steps involved to ensure that the concrete sets correctly and the structure is secure
Clean the area where the concrete needs to be poured
Assemble and position the formwork according to the required shape and dimensions. Make sure that the formwork is stable and well-supported
Apply a releasing agent to the inner surfaces before pouring the concrete to make it easier for you to remove the shuttering from the mould.
Now you can pour the concrete very carefully. Make sure that the concrete fills all the corners and spaces
Give the concrete enough time to cure, set and gain strength depending on the weather and type of structure
When the concrete is hardened sufficiently, you can remove the shuttering carefully
