Nilkamal Formwork

Plastic Formwork
WHY PLASTIC?
Nilkamal
www.nilkamal.com
Columns:
Geoplast
the GEOPLAST formwork system
Walls: Slabs:
round, square or modular wall full and
rectangular panels ribbed slabs
GEOTUB GEOPANEL GEOSKY & SKYRAIL

dia 25 – 100 cm
Sq. 20 to 60 cm
Nilkamal www.nilkamal.com
plastic formwork
why plastic formwork?
why plastic
formwork?
why plastic?
the history: wood formwork
Wood was the material traditionally used to

form concrete.
It has some disadvantages:
it is slow to erect and dismantle;
not more than 20 or 30 usages;
skilled labour required;
suffers moisture;
job-site waste is high;
environmental issues (deforestation).
why plastic?
the history: steel-frame formwork
- Speed of erection and dismantling;
- Lifetime longer than wood;
- The concrete finish superior to wood.
The biggest issues with steel?

Very heavy and expensive
High maintenance cost
High logistic cost

Geoplast Plastic formwork
Geoplast chose a special plastic for its formwork system:

ABS (Acrylonitrile butadiene styrene):
- resistant and tough, very good shock absorbance
- mechanically stable under loads
- very smooth and impervious surface
- temperature tolerant
- recyclable
Geoplast
the GEOPLAST formwork system
Principles common to the Geoplast formwork system:
- Very low weight
- Reusability – 100 pours at least
- Simplicity – “what ain’t there can’t break”
- Few, common accessories –

one single pin/handle works
for all systems
Geoplast
Independent testing
plastic does the job
-0,22
Horizontal displaceme nt at the centerline of the pane l - Northern Side
300
0,05
instrume nts n° 1-2-3-4-5
instrument
measured that
-0,16
250
t=10'
vertical position of the instrument [cm]

t=15'
0,89 instrum ent no.4
200 0,89
0,65 t=30'
150
Geoplast formwork resists 100

instrument 0,95
1,80
1,94
2,22 instrum ent no.3
to a concrete pressure of 72
0,92 1,15 instrument no.
50
2,88 3,02 3,54
kN/m2. -1,00 -0,50 0,00 0,50 1,00 1,50

horizontal displaceme nt [m m]
2,00 2,50 3,00 3,50 4,00
Horizontal displacement at the centreline of the panel - Eastern Side

instruments no. 6-7-8-9-10
300 instrument no. 9 1,30 1,33 1,87

t=10'
vert ical p o sitio n o f th e in stru m en ts [c m ] 250
t=15'
instrument 2,00
200 1,67 2,03
t=30'
150
2,12 2,45 2,74 instrument

100 no.7
instrument
1,03 1,21 instrument
50 no.10 1,42
2,86 3,16 3,65
0
-1,00 -0,50 0,00 0,50 1,00 1,50 2,00 2,50 3,00 3,50 4,00
horizontal displacement [mm ]
Spostamenti orizzontali alla distanza L=135cm dall'angolo

strum enti n° 5-6-7
300
250 t=10'
quota verticale strumento [cm]
t=25'
200
-3,56-3,33
strum ento
-4,11 t=180'
150
-2,74 -1,71
strumento -2,49
100
50 2,96
strumento 5,62 5,21
0
-6,00 -4,00 -2,00 0,00 2,00 4,00 6,00
spostamento orizzontale [m m]
why plastic?
Independent testing
Tensile strenght
Laboratory testing of the handles measured an

average tensile strenght (rupture) of 1,178.2 kg
why plastic?
the ADVANTAGES of plastic
Weight: plastic formwork (Geopanel) weighs 18 kg/m2

wood = ca. 18 kg/m2 (±0%)
aluminium = ca. 30 kg/m2 (+67%)
steel frame + plywood = ca. 40 kg/m2 (+220%)
Speed: plastic formwork does not need heavy equipment, so

it is not necessary to wait for cranes, trucks or other
machinery.
GEOTUB WOOD STEEL
Forming time: 15 to 20 min. 4h 25 min
Stripping time: 5 min. 30 min. 20 min.
Total time: 25 min. max 4h 30 min. 45 min.
Cost: - Long lifetime (lower amortisation per pour)

- lower operating cost (no crane time, less labour)
- lower maintenance cost (less cleaning, no or little oiling,
simple storage).
why plastic? GEOTUB job sites
Port Laoise, Ireland M7 Motorway extension

120 km of new highway, 45 new bridges, middle of the countryside
dia 900 mm
why plastic?
GEOTUB PANEL Square and rectangular
45° integrated chamfer
why plastic?
GEOTUB PANEL job sites
San Fior, Italy

residential project
Light and handy, the ease of use

is extreme.
One man
20 minutes total time
Excellent temperature
tolerance: -30°C / +70°C
why plastic?
GEOTUB job sites - India
Adani port - Mundra
IVRCL- Bangalore
AHURA - Pune B . G Shirke- Mumbai

why plastic?
The characteristics of GEOPANEL
Technical characteristics:
Panel dimensions:
120 x 60 cm 11 kg weight
smaller compensation panels:

40 x 60 cm 3.68 kg
30 x 60 cm 2.90 kg
25 x 60 cm 2.30 kg
20 x 60 cm 2.25 kg
walls thickness of 10 to 45 cm - thicker walls are

possible under certain conditions (foundations).
Geoplast
Gangform with GEOPANEL
GEOPANEL job sites
3 m high x 12 m long
50 pcs. total
36 m2 surface
Total weight 650 kg
Geoplast
GEOPANEL job sites
San José, Costarica

Industrial building
Geoplast
GEOPANEL job sites - India
Ahura - Pune
Pratibha - Mumbai
Mumbai
Pratibha - Mumbai
Ahura - Pune IVRCL - Mumbai
Geoplast
The GEOSKY slab system
GEOSKY® is a system of plastic

formworks for the realization of
concrete slabs.
Thanks to the sliding wedge on

main beam, this new and
innovative system makes
installation and stripping quick,
reduces casting time and increases
equipment turnaround.
No special panels are needed with
GEOSKY® because it uses the same
panels (Geopanel) needed to pour
walls.
Geoplast
The AVANTAGES of Geosky
Wood and steel slab formwork are the traditional systems.

The are time-proven, but they have some shortcomings:
- main and secondary beams are necessary
- the forming and stripping time is high:
GEOSKY Wood Steel
0,35-0,40 0,9 0,8

h/man/m2 h/man/m2 h/man/m2
(traditional systems)
why plastic?
GEOSKY job sites
Belgorod, Russia
Apartement block.
Quick, easy and safe.

No crane, no sweat.
Buyges
Paris,
France Dakspol
St. Petersburg,
Laing – O’Rourke Russia
London, UK Anemon
Moskow,
M50 Highway Russia
Dublin, Ireland
Da Vinci Mall
Rome,
Italy
Nilkamal
India
Cap Cana project

Dominican Rep.
Fibrex
Abu Dhabi
Waiwera highway
Santiago
New Zealand
Chile
Geoplast
thank you for your attention!


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Plastic Formwork

GEOTUB GEOPANEL GEOSKY & SKYRAIL

Wood was the material traditionally used to

it is slow to erect and dismantle;

not more than 20 or 30 usages;

skilled labour required;

job-site waste is high;

environmental issues (deforestation).

- Speed of erection and dismantling;

- Lifetime longer than wood;

- The concrete finish superior to wood.

The biggest issues with steel?

High maintenance cost

High logistic cost

Geoplast chose a special plastic for its formwork system:

- resistant and tough, very good shock absorbance

- mechanically stable under loads

- very smooth and impervious surface

Principles common to the Geoplast formwork system:

- Very low weight

- Reusability – 100 pours at least

- Simplicity – “what ain’t there can’t break”

- Few, common accessories –

vertical position of the instrument [cm]

Geoplast formwork resists 100

kN/m2. -1,00 -0,50 0,00 0,50 1,00 1,50

Horizontal displacement at the centreline of the panel - Eastern Side

300 instrument no. 9 1,30 1,33 1,87

2,12 2,45 2,74 instrument

2,86 3,16 3,65

Spostamenti orizzontali alla distanza L=135cm dall'angolo

Laboratory testing of the handles measured an

Weight: plastic formwork (Geopanel) weighs 18 kg/m2

Speed: plastic formwork does not need heavy equipment, so

Cost: - Long lifetime (lower amortisation per pour)

Port Laoise, Ireland M7 Motorway extension

45° integrated chamfer

San Fior, Italy

Light and handy, the ease of use

Adani port - Mundra

AHURA - Pune B . G Shirke- Mumbai

smaller compensation panels:

walls thickness of 10 to 45 cm - thicker walls are

Total weight 650 kg

San José, Costarica

Ahura - Pune IVRCL - Mumbai

GEOSKY® is a system of plastic

Thanks to the sliding wedge on

Wood and steel slab formwork are the traditional systems.

- main and secondary beams are necessary

- the forming and stripping time is high:

GEOSKY Wood Steel

0,35-0,40 0,9 0,8

Quick, easy and safe.

Cap Cana project

thank you for your attention!

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