In construction, shuttering plywood plays a crucial role—it holds wet concrete in place until it sets, directly influencing both the safety of the structure and the finish of the concrete surface. But not all plywood performs equally well, and even good boards can fail if not used properly.
Let’s explore some of the most common problems with shuttering plywood and the steps you can take to avoid them.
1. Delamination or Peeling
The issue:
One of the biggest concerns with low-quality shuttering plywood is delamination—the layers start to separate after just a few uses. This usually happens when the bonding adhesive isn’t strong enough, or when the board hasn’t been manufactured to proper standards.
The solution:
- Choose IS:4990-certified plywood, which ensures strong bonding with phenolic resins.
- Inspect boards before purchase for signs of poor lamination or uneven pressing.
- Store plywood in a dry, covered area to prevent excess moisture absorption.
2. Warping and Bending
The issue:
Plywood sheets often warp or bend when exposed to moisture, temperature variations, or improper stacking. Warped boards make it difficult to achieve a uniform finish and can compromise structural safety.
The solution:
- Opt for plywood made from dense hardwood species with uniform veneers.
- Always store plywood sheets horizontally on a flat surface, with supports underneath.
- Use waterproof coatings or film-faced shuttering plywood for added protection.
3. Poor Reusability
The issue:
One of the reasons contractors prefer quality shuttering plywood is its ability to be reused 15–20 times or more. Cheap alternatives may deteriorate after just 3–5 uses, raising costs in the long run.
The solution:
- Invest in film-coated shuttering plywood (like red shuttering plywood) that provides durability and smooth form release.
- Apply form release oil before pouring concrete to extend the board’s life.
- Handle boards carefully on-site—avoid dropping, dragging, or striking edges.
4. Concrete Sticking to the Surface
The issue:
If concrete sticks to the plywood surface, it not only damages the board but also leaves behind rough concrete finishes that require additional plastering or grinding.
The solution:
- Use film-faced shuttering plywood with smooth coatings that prevent sticking.
- Apply a thin layer of shuttering oil before every pour.
- Clean boards immediately after use to remove any concrete residue.
5. Edge Damage and Core Gaps
The issue:
Edges of plywood are vulnerable to chipping or breaking during handling, especially if the board has hidden core gaps. Damaged edges reduce the strength of the formwork and allow water or slurry to seep in, weakening the plywood further.
The solution:
- Select gap-free plywood manufactured with precision.
- Protect exposed edges with paint or sealant.
- Train workers to handle sheets properly—lifting rather than dragging.
6. Inconsistent Concrete Finish
The issue:
Poor-quality or worn-out shuttering plywood results in uneven concrete surfaces, with marks, ridges, or discoloration. This increases finishing costs and delays the project.
The solution:
- Use high-quality film-coated plywood for smooth, uniform finishes.
- Rotate boards during reuse to ensure wear is evenly distributed.
- Replace damaged boards promptly instead of forcing them into critical pours.
Final Thoughts
Shuttering plywood may be temporary, but its impact on construction quality is permanent. Most of the issues—delamination, warping, poor reuse, sticking concrete, and edge damage—can be avoided by:
The solution:
- Choosing certified, high-quality plywood like IS:4990-compliant red shuttering plywood.
- Storing and handling boards properly to maintain their strength.
- Using form release oils and protective coatings to extend reusability.
By paying attention to these details, contractors and engineers can achieve better finishes, save costs, and ensure safer, more efficient projects.
