How many times PAC® Shuttering Board be Reused ?

If you are a contractor or builder in India, you know that plywood shuttering is one of the biggest recurring expenses on any construction site. You buy expensive film-faced plywood, and after 5 to 8 uses, it starts swelling, splitting at the edges, and warping due to water absorption.

This is why many contractors are shifting to the PAC® Shuttering Board (Plastic Aluminium Composite). But the biggest question we get from site engineers and purchase managers is: How many times can we actually reuse this plastic centering sheet on-site?

Let us look at the exact numbers, the technical specifications, and the math behind the repetitions of these boards.

Understanding the Repetition Limit of PAC Formwork Board

A PAC® Shuttering Board can be reused between 30 to over 100 times depending on the product grade you choose and how well your team handles the material on-site.

Unlike traditional plywood, which rots when exposed to water, these composite boards are made of high-grade recycled industrial plastics reinforced with aluminium oxide and cross-linked polymer (XLP) metals. This chemical structure prevents water from entering the core, meaning the board does not lose its strength over time.

Rajratan Industries manufactures two distinct grades of shuttering sheets to match different budget and project needs:

1. ECOPRIME Standard (Marble White)

Average Repetitions: 30 to 40 times.

Density: 1100 kg/m³ (Weight is approximately 40 kg per 8×4 feet sheet in 12mm thickness).

Composition: 60% Mix Plastic (Industrial Grade), 25% Aluminium Oxide, and 15% XLP Metals.

Best For: Standard residential projects, low-rise buildings, and contractors who want a budget-friendly entry into plastic centering boards.

Price: ₹80 per sq. ft. for the standard 12mm board (approximately ₹2,560 per sheet).

2. ECOPRIME Premium (Marble Black)

Average Repetitions: 60+ times (easily reaches 100+ repetitions on well-levelled surfaces with proper care).

Density: 1320 kg/m³ (Weight is approximately 45 kg per 8×4 feet sheet in 12mm thickness).

Composition: 52% Mix Plastic, 23% Aluminium Oxide, and 25% XLP Metals. The increased metal component makes the sheet highly dense, stiff, and impact-resistant.

Best For: High-rise commercial buildings, heavy RCC columns, shear walls, and large-scale infrastructure projects.

Price: ₹90 per sq. ft. for the premium 12mm board (approximately ₹2,880 per sheet).

Technical Specifications Comparison

To help you choose the right plastic shuttering sheet for your project, here is a quick comparison of our standard sizes and grades: 

The Math: Plywood vs. Plastic Centering Sheet Cost-Per-Use

The real value of a Rajratan PAC Shuttering Board lies in its cost-per-use, which is significantly lower than traditional plywood despite the higher initial purchase price.

Let us do a simple, honest calculation that every site supervisor can understand.

The Plywood Calculation

Suppose you buy a decent quality film-faced plywood sheet (8×4 feet) for ₹1,600 (approx. ₹50 per sq. ft.).

On average, a plywood sheet lasts for 5 uses before it starts chipping, swelling, or bending.

Cost per use: ₹1,600 ÷ 5 = ₹320 per slab casting.

Once it is damaged, its scrap value is zero. You have to pay labor to discard it.

The ECOPRIME Premium Calculation

You buy an ECOPRIME Premium (Marble Black) sheet for ₹2,880 (₹90 per sq. ft.).

Even if we take a conservative estimate of 60 repetitions:

Cost per use before buyback: ₹2,880 ÷ 60 = ₹48 per slab casting.

But it gets better. Rajratan offers a 40% Buyback Guarantee. When your board is completely worn out after years of use, you can return it to our Indore factory and get a 40% value adjustment (₹1,152) against your next purchase.

Your net material cost is: ₹2,880 – ₹1,152 = ₹1,728.

Actual Cost per use: ₹1,728 ÷ 60 = ₹28.80 per slab casting.

If your site team maintains the boards well and you achieve 100 repetitions, your cost drops to less than ₹18 per use. That is a direct saving of over 90% compared to plywood.

Why Does Rajratan PAC® Shuttering Board Last So Long?

The long service life of a PAC®  Shuttering Board is due to its engineered composite design, which eliminates the organic vulnerabilities of wood and the structural weakness of pure PVC sheets.

Zero Water Absorption: Plywood absorbs water from the concrete slurry. This makes the wood fibers swell and eventually delaminate. PAC is 100% waterproof. It does not absorb a single drop of water, keeping its shape intact.

No Chemical Reaction: Concrete contains alkalis and additives. Our composite material is chemical and acid-resistant. You can even clean the dry concrete off the board using mild acid washes without damaging the surface.

High Surface Hardness: The addition of 23% to 25% aluminium oxide gives the board a tough outer skin. It does not get scratched easily when your team drags steel reinforcement bars (rebar) over the centering platform.

No Delamination: Plywood is made of glued layers. Under heavy load or heat, these layers separate. PAC is a solid, homogenous composite board. There are no layers to separate.

Best Practices to Get 100+ Repetitions on Your Construction Site

To get the absolute maximum life out of your recycled plastic shuttering board, your site team should follow these practical, on-site guidelines:

Support Spacing: Always place your runners (wooden batten or MS pipe) at a distance of 1 foot (12 inches) center-to-center. Since plastic is more flexible than wood, proper support prevents sagging and ensures a flat, smooth concrete finish.

Use the Right Nails: Use 1-inch or 1.5-inch thin wire nails. Do not use very thick nails, as they are unnecessary. The PAC material holds nails tightly, and they can be easily pulled out during de-shuttering without tearing the board.

Smart De-shuttering: Do not let your laborers throw the boards from the upper floors to the ground during stripping. While the boards are highly durable, throwing them from heights onto sharp stones can chip the corners.

Minimal Shuttering Oil: You do not need to drench these boards in oil. A very light coat of shuttering oil or even waste engine oil is enough to ensure the concrete slides off smoothly, leaving a mirror-like finish.

Ordering, Trials, and Logistics Policies

We understand that changing your centering material is a big decision for any contracting firm. That is why we make it easy to test our products before making a large commitment.

Trial Orders: We highly recommend starting with a trial order of 5 to 10 sheets. This allows your site team to cut, nail, hammer, and cast concrete on the board themselves to see the results.

Payment Terms: Our standard billing policy is 30% advance payment to lock the order, and the remaining 70% balance payment before dispatch. We do not offer Cash on Delivery (COD) because we ship through external transport partners.

Logistics: We ship materials all across India through reliable transport networks like VRL Logistics, BRL Logistics, TCI Freight, and ACPL. For small trial loads, the material is sent on a “godown delivery” basis (you can pick it up from the nearest transport hub in your city).

Dealership Queries: If you want to become a dealer for Rajratan PAC products, we require an in-person visit to our factory in Indore, Madhya Pradesh, for a face-to-face meeting. The minimum opening order for a dealership is a full truckload (approx. 600 sheets).

Frequently Asked Questions (FAQ)

Will nailing and hammering repeatedly ruin the plastic centering board?

No, nailing does not ruin the board because the composite material has a self-healing property under pressure. When you pull a nail out, the surrounding plastic and polymer fibers compress back, leaving a clean, tiny pinhole that does not expand or split like wood.

Can we cut these boards on-site using standard wood cutting tools?

Yes, you can easily cut, trim, and size PAC boards using your regular circular hand saws, table saws, or manual hand saws. The material cuts smoothly without leaving jagged edges or causing splinters.

How does the 40% buyback guarantee actually work?

When your PAC boards finally wear out after years of use, you can return the scrap boards to our factory in Indore. We will calculate 40% of the original scrap weight value and deduct that amount directly from your invoice for new replacement boards.

Why don’t you offer Cash on Delivery (COD) for trial orders?

We do not offer COD because all shipments are handled by third-party transport companies who do not collect cash on our behalf. Production starts immediately once the 30% advance is cleared, and the material is dispatched upon receiving the balance.