Cost, Time Efficiency, and Serviceability of Precast Formworks Using

Polypropylene Plastic for Concrete Column: A literature Review

1,[1]
Rodelyn S. Nortez, 2,[2]Reynald P. rubio, 3,[4]Coleen Joyce L. Soriano, 4,[3]Geraldine I. Del Rosario

School of Engineering of Aurora State College of Technology

[1]
[email protected]
[2]
[email protected]
[3]
[email protected] [4][email protected]

ABSTRACT: Precast formwork is usually composed of prefabricated modules that have a metal frame, such
as steel or aluminium. However, we have developed a new method that uses Polypropylene Plastic as the
primary material for constructing the formwork. This new method allows for the application of a desired surface
structure, such as the Polypropylene Plastic which is bolted on the concrete side of the formwork.

In this article, we will compare the cost of plastic precast formworks to traditional formworks made from
various materials. We will also explore how using plastic formwork can save time and money during
construction, and how they can improve efficiency. We will explain the process of using plastic formworks, as
well as their durability and serviceability in the construction industry. One of the main advantages of using
polypropylene plastics for formworks is the speed of construction. These formworks can be quickly pinned,
clipped, or screwed together, making them faster than traditional timber formworks. Additionally, they have
lower life-cycle costs, since the formwork's frame is nearly indestructible, while the covering, typically made of
wood, may need to be replaced after a few uses. However, if the covering is made of hard plastic, the form can
be used up to two thousand times depending on care and applications. Plastic formwork systems are better
equipped to handle heavy weight and require less manpower than traditional timber formwork, making them
more efficient and cost-effective.

Keywords: Precast Formworks, Polypropylene Plastic, bolted, hard plastic

1. Introduction
Concrete is a widely used building material in India that is known for its strength and durability (Bhasin
and Singh, 2019). However, it is important to recognize that the manufacturing and construction sectors are
responsible for 12.4% of energy-related greenhouse gas emissions as of 2013 ("Global Emissions," 2017), and
concrete is a significant contributor to this figure. Despite its many benefits, the use of this material should be
balanced with the need to reduce carbon emissions and mitigate the effects of climate change [1]. However,
formwork systems are an important aspect of modern concrete construction. They play a crucial role in realizing
the desired shape and strength of concrete elements. A comprehensive review of different formwork systems is
essential for understanding their raw materials, flexibility, and fabrication methods [2]. Concrete structures
using fabric formwork is a construction technique that involves using fabric instead of traditional formwork
materials (such as timber or metal) to shape and support concrete structures. This method offers several
advantages, including cost-effectiveness, versatility, and sustainability. It has been researched and explored by
various experts in the field, such as John Orr, Antony Darby, Timothy Ibell, Mark Evernden, and Mike Otlet [3].
It's interesting to note that the evaluation of the change in concrete strength due to plastic formwork is a research topic
that aims to investigate the impact of using plastic formwork on the strength and overall quality of concrete. The main
objective of this research is to document the changes in concrete strength that occur because of using plastic
formwork [4] structures using plastic formwork is a construction technique that involves using plastic instead of
traditional formwork which is timber to shape and support the concrete. This method offers several advantages,
including reduced construction time, improved flexibility in design, and increased sustainability [5]. This assessment
evaluates the lateral force exerted on the vertical connections of precast concrete buildings. The goal of this trial is
monolithic precast concrete structures. Additionally, we will utilize prefabricated formwork made of polypropylene
plastics to shape the concrete [6]. In recent times, macro plastic fibers have emerged as a popular alternative to
traditional steel reinforcement in the construction of concrete footpaths, precast elements, and shotcrete tunnel linings.
This is because they offer the convenience of easy construction, reduced labor time, and lower cost. These fibers can
improve the performance of concrete by reducing drying shrinkage cracks and enhancing the post-cracking
performance of concrete elements. Recycled polypropylene (PP) fibers are an environmentally friendly choice
compared to virgin PP fibers or steel mesh. However, the construction industry has been slow to adopt them due to a
lack of research and understanding of their mechanical properties, alkali resistance, and performance in concrete.

Green plastic formworks can be used to create on-site concrete structures, such as walls, columns,
foundations, and plinths. These formworks are modular and offer flexibility in construction. Meanwhile, modular
construction is a building method that takes place off-site in a controlled environment, following the same codes and
standards as traditional construction. Although it can be completed in half the time, some may argue that it sacrifices
quality and durability for speed. It's also essential to consider the possible environmental impact of using plastic
formworks compared to traditional construction methods, as well as the additional cost of transportation and
installation of the modular components. The assessment of wood and plastic formworks in the building construction
industry is a crucial topic for development. This research examines the use of wood and plastic materials in
construction and their impact sustainability. It explores the potential benefits and drawbacks of using these formworks
in building projects [7] is an essential component in concrete construction, representing a significant portion of the
total cost required for casting-place projects. [3]. According to Krieger et al., the material and labor costs for can
be as high as 35–60% of the total costs [4]. When it comes to selecting a formwork system for
construction projects, there are various factors that need to be taken into consideration. These include
the ease and cost-effectiveness of transporting the formwork from the factory to the construction site,
the simplicity and cost-effectiveness of putting it together and taking it apart, a high rate of
construction speed in relation to the weight of the formwork, the minimum number of construction
joints required minimal waste generated during the production process, safety, ease of storage,
applicability to high-rise structures, potential for preconstruction, the capability to create non-prismatic
sections and complex shapes, not requiring a highly-trained and skilled workforce, compatibility with
the core material to minimize environmental impact, appropriate specific heat capacity and thermal
conductivity, reusability, and the ability to use fast connectors. Formwork is designed to mold concrete
and guide structural members for increased strength over time. Fresh concrete can be poured into formworks to
create desired shapes on site [[21]. This research focuses on using Polypropylene plastic for Formwork
construction. Formwork is designed to mold concrete and guide structural members for increased strength
over time. This research focuses on using Polypropylene plastic for Formwork construction. This work
transforms flexible-formwork research into the realms of fully optimized form-found structures which satisfy
both strength and serviceability. [12] Geometrically unconstrained formwork allows for mass customization of
concrete components to fit their specific context, boundary conditions, and load cases. [18] In numerous nations,
wood is a precious commodity, particularly in the Middle East where it must often be transported from faraway
lands. In tropical regions, wood tends to degrade quickly, which restricts its usage as formwork material. Even
in North America, where wood is abundant, formwork fabrics are much more cost-effective than formwork
plywood, at roughly one-tenth the cost. Additionally, their lightweight and low volume nature make them an
ideal choice, as they lessen or eliminate the expenses associated with formwork storage and disposal, However,
the latter (polypropylene Fibers) seemed to have caught up with the Steel-Fiber-reinforced specimens in terms of
performance, presumably because polypropylene itself is more sensitive to strain rates than wood and steel. This
stiffening response in a low-modulus Fiber under higher stress rates was apparent in the progressive reduction of
crack opening displacement associated with peak bond stress in a Fiber that underwent impact loading.
However, the latter (polypropylene Fibers) seemed to have caught up with the Steel-Fiber-reinforced specimens
in terms of performance, presumably because polypropylene itself is more sensitive to strain rates than wood
and steel. This stiffening response in a low-modulus Fiber under higher stress rates was apparent in the
progressive reduction of crack opening displacement associated with peak bond stress in a Fiber that underwent
impact loading. [14] is also some advanced technique A cutting-edge method to streamline construction involves
leveraging 3D Printed Formwork for Concrete. This method harnesses the power of 3D printing to fabricate
formwork, which acts as a temporary support structure that keeps concrete in place as it cures and solidifies. In
contrast to conventional formwork techniques, this revolutionary approach boasts numerous advantages,
including greater design flexibility, expedited build times, minimized material waste, and heightened cost
efficiency. A cutting-edge method to streamline construction involves leveraging 3D Printed Formwork for
Concrete. This method harnesses the power of 3D printing to fabricate formwork, which acts as a temporary
support structure that keeps concrete in place as it cures and solidifies. In contrast to conventional formwork
techniques, this revolutionary approach boasts numerous advantages, including greater design flexibility,
expedited build times, minimized material waste, and heightened cost efficiency. [20]

Keywords: Formwork systems, Modern concrete construction Review, Raw materials, M onolithic Precast
Concrete Structure

2.METHODOLOGY

This section outlines the steps taken to collect data from online databases such as Google Scholar, IEEE Digital
Library, and Sci-Hub. This includes searching for papers, studies, journals, and articles that are relevant to the
topic. Only sources that were published within the last ten years were considered.

Process of Acquiring Related Literature

Online Database Keywords used for "Precast Formworks",

searching Polypropylene
PLastic", "Formworks"

Google Scholar/
Googe
Article Found [49]

Elzevier
Article Related and
used [24]

Science Direct

Research Rabbit

This aims to answer the following research questions:

a. What are the characteristics of Polypropylene Plastic?
b. How can Precast Plastic Formwork save cost on the overall construction of concrete columns?
c. How can construction time be saved?
3. DISCUSSION

3.1 Characteristics of Precast Polypropylene Plastic

Polypropylene is a thermoplastic polymer that offers excellent chemical resistance to both dilute and
concentrated acids, alcohols, and bases. In addition, it demonstrates good resistance to aldehydes, esters,
aliphatic hydrocarbons, and ketones. However, it is important to note that its resistance to aromatic and
halogenated hydrocarbons and oxidizing agents is limited.
Polypropylene is widely used in the chemical industry due to its exceptional chemical resistance and durability.
Its effectiveness in resisting a broad range of chemicals makes it a popular choice for manufacturing storage
tanks, pipes, and laboratory equipment.
It is important to note that while polypropylene is highly resistant to many chemicals, it may not be suitable for
use with certain solvents and compounds. Therefore, it is recommended to consult with a professional to
determine the appropriate materials for a given application [9].
Polypropylene, a downstream petrochemical product derived from propylene, has excellent chemical resistance,
low density, and high temperature resistance. It can be processed using various converting methods, making it
ideal for items used in clinical environments, such as trays, bottles, and instrument jars. The polymer is
produced through addition polymerization, and its properties vary according to process conditions and
molecular weight [9].

3.2 Cost Effectiveness of Polypropylene Plastic for Formworks

The proper design of formwork is a crucial factor in ensuring that the desired construction requirements are met.
Moreover, the selection of the appropriate formwork material can significantly impact the mechanical and
durability properties of the near-surface concrete [8]. Revolutionize your construction process with the
controlled permeable formwork system. Our innovative solution utilizes a non-woven polypropylene fiber fabric
liner that is seamlessly attached to conventional formwork. Experience increased efficiency and cost savings
with this cutting-edge technology [10].
3.3. Time Efficiency of Precast Polypropylene Plastic

Fabric formwork is a popular construction technique that uses synthetic fiber textile sheets made of materials
such as nylon, polyester, and polypropylene. These sheets are often porous and flexible and can be easily
molded into intricate shapes. Fabric formwork is a valuable tool that allows architects and engineers to achieve
complex geometries in construction projects. This method not only reduces construction time but also offers a
cost-effective and environmentally friendly alternative to traditional building methods [2].

4.Research Gap
This section shows the challenges and limitations that this study faced during the evaluation of related literatures.
The development of this Precast formworks is suggested by construction industries to make the construction made in less
time but has posed many challenges and this article titled "Decision Making on the Optimized Choice of Pneumatic
Formwork Textile for Foam-Filled Structural Composite Panels" outlines a process for selecting the most appropriate
pneumatic formwork for concrete molding. The objective of this method is to optimize the selection of formwork textiles to
ensure the efficient and effective construction of concrete. The article emphasizes the significance of this process in
ensuring the quality and durability of the final product [22]. The other topic is skelETHon Formwork: 3D Printed Plastic
Formwork for Load-Bearing Concrete Structure which only focuses on making a boat with the used of plastic
that shapes into a skeleton that has a capacity of only two people.
However, as suggested to achieve cost-effective and environmentally friendly construction of freeform structures,
an innovative formwork system is necessary. Polypropylene plastic is a promising material for this purpose, allowing for
flexible and recyclable formwork that can accommodate custom designs but its better if it made up of recycled waste
materials for us to help the environment. However, more research is needed to improve the interface quality when using
sand molds for concrete casting. While Sitnikov (2019) has explored the use of ice formwork for casting, its low
temperature requirement limits its application to specialized frost-resistant high-performance concrete mixes.
5.CONCLUSION

Formwork refers to the casing in which the casting material, usually concrete, is poured to obtain the desired
structural shape. In the construction industry, formwork is like a mold used to cast concrete members in different
shapes and sizes. Various materials such as timber, steel, aluminum, and plastic are used for formwork. Shuttering is
another term used synonymously with formwork. It is important that formwork has sufficient strength to carry the
dead and live loads during casting and until the concrete gains some percentage of its design strength [13]
Polypropylene is a type of Fiber that is produced from homopolymer polypropylene resin. It has a low modulus of
elasticity and a low melting point, which may limit its use in autoclaved precast concrete products. However, its low
melting point can be beneficial in producing refractory products or products with high fire resistance. This is because
the Fiber is expected to melt and create a system of relief channels, which can help to dissipate internal pressure [11]
and can be used easily for making formworks to mold some concrete for structure constructions.

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[20] https://www.google.com/url?
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[21]https://www.bing.com/ck/a?!&&p=1853470e69a7194fJmltdHM9MTY5ODYyNDAwMCZpZ3VpZD0xNWFiM
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[11]researchrepository.rmit.edu.au/esploro/outputs/doctoral/An-innovative-formwork-system-basedon/
9922204812501341[1]

[22]

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[23]Fiber-reinforced concrete in precast concrete application. Research leads to innovative products |

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[24] (PDF) Concrete structures using fabric formwork (researchgate.net)