Shuttering plywood is a major investment for any contractor, builder, or construction company. While the quality of plywood matters, its lifespan depends equally on how it is stored, handled, and maintained at the site. With the right practices, you can easily extend the life of each board and achieve more repetitions, reducing your overall project cost.
At Deepak Lamination, we work closely with builders and understand the real challenges faced at sites. This guide covers practical tips you can apply immediately.
Why Proper Maintenance Matters
Even high-quality shuttering plywood can fail early if:
- The boards are exposed to sun and rain
- Edges are not sealed
- They are dragged on rough surfaces
- They are cleaned improperly
Good practices reduce chances of:
- Delamination
- Surface cracks
- Swelling
- Resin washout
- Reduced load-bearing capacity
1. Storage Practices for Longer Life
1.1 Keep Sheets on a Flat, Elevated Platform
Never keep shuttering plywood directly on the ground.
Use:
- Wooden battens
- Steel frames
- Pallets
This prevents moisture absorption from soil, which is the leading cause of swelling.
1.2 Always Cover with Waterproof Tarpaulin
Boards should be protected from:
- Rain
- Dew
- Direct sunlight
Excess heat causes surface film to weaken, while water increases chances of delamination.
1.3 Arrange Sheets Vertically or in Stable Stacks
- Stack boards evenly
- Keep heavier boards at the bottom
- Avoid bending or warping due to uneven pressure
If stored vertically, ensure support on both sides.
2. Handling Practices That Prevent Damage
2.1 Never Drag the Boards
Dragging scratches the surface film and weakens the panels.
Always:
- Lift manually
- Use two people for large sheets
- Use forklifts with rubber padding
2.2 Transport Carefully
During loading and unloading:
- Use edge protectors
- Avoid throwing or dropping boards
- Ensure trucks have proper side support
2.3 Seal Edges Before First Use
Before using the sheet:
- Apply waterproof paint
- Use PU paint or oil-based coating
- Re-apply after every 2–3 uses
Edge sealing can increase the life by 20–30%.
3. Maintenance During Concrete Work
3.1 Apply Shuttering Oil the Right Way
Always apply a thin, uniform layer.
Why?
- Increases the number of repetitions
- Prevents concrete from sticking to the board
- Reduces cleaning effort
Avoid over-use since excess oil weakens adhesion during pouring.
3.2 Use Proper Support Distance
Incorrect spacing causes bending and permanent damage.
Follow manufacturer guidelines for:
- Beam spacing
- Props
- Joist distance
A well-supported board lasts 2–3 times longer.
3.3 Avoid Hitting the Panels with Heavy Tools
During compaction and shutter removal:
- Don’t hammer directly on the surface
- Use crowbars only at the corners
- Provide cushioning if needed
4. Post-Use Care to Increase Repetitions
4.1 Clean Immediately After Use
Once the slab is removed:
- Clean using a soft brush
- Remove cement slurry
- Avoid sharp metal tools
The longer concrete stays on the surface, the more damage it causes during scraping.
4.2 Re-seal Edges Regularly
Check for:
- Cracks
- Chips
- Exposed core
Apply fresh coating to prevent water from entering the panel.
4.3 Dry the Boards Before Next Use
Never reuse wet boards directly.
Moisture inside the core weakens resin bonds.
Dry the boards:
- Under shade
- In good ventilation
- Avoid direct afternoon sun
4.4 Store Again Properly After Use
Repeat the same storage method:
- Elevated platform
- Tarpaulin cover
- Even stacks
Good end-of-day storage ensures each board stays intact for the next cycle.
4.5 Apply Release Oil / Formwork Oil
Once the sheet is dry, apply a thin, even coat of shuttering oil on the surface and edges.
This helps:
- Prevent concrete from sticking
- Reduce surface wear
- Increase the number of repetitions
- Maintain smoothness and water resistance
✔ Repair Minor Damages
Fill dents or edge chips with sealant or putty to avoid further breakage.
5. How Many Repetitions Can Good Maintenance Achieve?
With proper care:
- Standard shuttering plywood: 10–15 repetitions
- Densified film-faced plywood: 20–30 repetitions
- Premium quality (Deepak Lamination): even higher under ideal handling
Actual repetitions depend on:
- Concrete pressure
- Weather exposure
- Handling quality
- Surface care
Conclusion
Shuttering plywood is not just a consumable—it’s an asset when treated correctly. With proper storage, careful handling, and regular maintenance, you can significantly extend its life, reduce wastage, and lower your construction cost per slab.
At Deepak Lamination, we manufacture high-strength shuttering plywood designed for durability and maximum repetitions. For bulk inquiries or dealer opportunities, feel free to contact us.