Can a Waterproof PAC® Shuttering Board Really Survive Repeated Concreting?

If you work on a construction site in India, you know that shuttering material goes through demanding conditions. Repeated exposure to wet concrete, cutting, nailing, stripping, cleaning, and handling can gradually affect conventional plywood.

Plywood can absorb moisture, swell, warp, split at the edges, and lose surface quality over repeated use. As the board deteriorates, contractors may need to replace sheets more frequently, increasing material consumption and project costs.

This raises an important question:

Can a waterproof plastic shuttering board withstand repeated concrete casting and everyday construction-site handling?

PAC® Shuttering Board is designed to address this challenge. Made using industrial-grade plastics, aluminium oxide, and XLP metals, PAC® is a plastic-based composite formwork board designed for repeated use and moisture resistance.

In this article, we look at the material, reuse potential, cost-per-use, different grades, and practical considerations for using PAC® Shuttering Board on construction sites.

What Is a PAC® Shuttering Board and Why Is It Waterproof?

A PAC® Shuttering Board is a high-density concrete formwork sheet made using a combination of industrial-grade plastics, aluminium oxide, and XLP metals.

Unlike conventional plywood, PAC® does not contain wood fibres. Its non-porous composition makes it resistant to water absorption, helping prevent common moisture-related problems such as swelling, warping, and rotting.

Traditional plywood contains wood layers that can absorb moisture. With repeated exposure to wet concrete and changing site conditions, this can affect the dimensions and surface condition of the sheet.

PAC® Shuttering Board is designed to maintain its dimensional stability when exposed to wet concrete, making it suitable for repeated formwork applications.

The board is manufactured by processing industrial-grade plastics such as PP, LDPE, and HDPE with reinforcing materials under controlled heat and pressure.

For more information, visit the Rajratan PAC® Shuttering Board website.

The Real Cost Per Use: Plywood vs. Plastic Shuttering Board

The initial purchase price is only one part of the cost of a shuttering board.

A better way to evaluate formwork is to calculate the cost per usable repetition.

Cost per use = Total sheet cost ÷ Number of usable repetitions

PAC® Shuttering Board has a higher upfront cost than conventional plywood, but its designed repetition range can make the effective cost per use lower over its service life.

For an 8 ft × 4 ft sheet, the comparison provided by Rajratan is:

*Buyback is subject to Rajratan’s applicable terms and conditions.

The cost-per-use calculation shows why contractors should evaluate shuttering materials based on their expected service life rather than only their purchase price.

A board that can be used repeatedly may reduce the frequency of replacement and help control material consumption over multiple concrete cycles.

How Different Grades of Rajratan PAC® Shuttering Board Perform on Site

Rajratan offers different PAC® Shuttering Board grades for different repetition and application requirements.

Selecting the appropriate grade and thickness can help contractors match the board to the demands of their project.

1. ECOPRIME Standard — Marble White | 12 mm & 18 mm

ECOPRIME Standard is designed as a cost-effective option for standard residential and commercial construction applications.

• Composition: 60% Mix Plastic, 25% Aluminium Oxide, 15% XLP Metals
• Density: 1100 kg/m³
• Approx. Weight: 40 kg per 8 × 4 ft sheet for 12 mm
• Performance: 30–40 repetitions
• Best Used For: Slab formwork, beam sides, and standard concrete casting
• Indicative Price: ₹80 per sq. ft. for 12 mm

2. ECOPRIME Premium — Marble Black | 12 mm & 18 mm

ECOPRIME Premium is the higher-density PAC® Formwork Board, designed for applications where higher repetition and stiffness are required.

• Composition: 52% Mix Plastic, 23% Aluminium Oxide, 25% XLP Metals
• Density: 1320 kg/m³
• Approx. Weight: 45 kg per 8 × 4 ft sheet for 12 mm
• Performance: 60–100+ repetitions on well-levelled staging surfaces
• Best Used For: Heavy slab casting, columns, shear walls, and systematic formwork systems
• Indicative Price: ₹90 per sq. ft. for 12 mm

3. Heavy-Duty 18 mm Shuttering Board

For applications requiring greater board thickness and structural stiffness, the 18 mm option is designed for heavy-duty formwork requirements.

• Thickness: 18 mm
• Indicative Price: ₹125 per sq. ft.
• Best Used For: Bridge decks, heavy-duty retaining walls, and large column formwork

The appropriate board should always be selected according to the project’s formwork design, support arrangement, loading requirements, and site practices.

Handling On-Site Challenges: Nails, Cutting, and Oiling

A major consideration when switching from plywood to a plastic-based formwork board is whether the existing site workflow can still be followed.

PAC® Shuttering Boards are designed to be processed using commonly available construction tools.

Nailing and Screwing

PAC® boards can be nailed and screwed for formwork applications. Proper fixing technique is important to avoid unnecessary damage around fixing points.

The board’s composite structure is designed to provide rigidity and support repeated handling during formwork cycles.

Cutting and Sizing

PAC® Shuttering Boards can be cut to the required dimensions using standard cutting tools, including hand saws and portable electric circular saws.

Because the material is consistent throughout its thickness, cutting does not expose a wood-based layer that can absorb water.

Concrete Release and Cleaning

The smooth, non-porous surface of PAC® can help with concrete release and cleaning.

A suitable release agent should be applied according to the project and site requirements. After de-shuttering, the boards can be cleaned and prepared for subsequent use.

Proper cleaning and handling are important for achieving consistent performance across multiple repetitions.

Addressing Commercial Concerns: Ordering, Logistics, and Payments

Rajratan Industries manufactures PAC® Shuttering Boards from its Indore facility and supplies them across India.

Because switching formwork materials is an operational decision, contractors can evaluate the product through a smaller trial requirement before moving to larger quantities.

Try a Small Batch First

Rajratan recommends starting with a trial order of 5–10 sheets.

A trial allows the site team to evaluate the board under actual working conditions, including:

• Cutting
• Drilling
• Nailing
• De-shuttering
• Concrete release
• Cleaning
• Handling
• Repetition performance

This gives contractors an opportunity to assess the product against their existing construction process before placing a larger order.

Direct Shipping & Logistics

PAC® Shuttering Boards are shipped from the Indore facility to project sites and godowns across India through logistics partners.

For smaller trial orders, godown delivery may be arranged, allowing the customer to collect the material from the nearest transport warehouse.

For larger orders, door delivery to the project site can be arranged depending on the location and logistics requirements.

Indicative delivery timelines provided by Rajratan are approximately 2 days for neighbouring states and 4–5 days for other parts of India, subject to production and transportation conditions.

Payment and Dealership Terms

As per the current commercial terms, Cash on Delivery (COD) is not available.

The standard payment structure is:

30% advance → Production → 70% balance before dispatch

For dealership enquiries, Rajratan requires an in-person visit to its Indore factory. Dealership requirements may include full-truckload commitments, depending on the arrangement.

Customers should confirm current pricing, logistics charges, payment terms, and dealership requirements directly with Rajratan before placing an order.

Frequently Asked Questions

Is the PAC® Shuttering Board completely waterproof?

PAC® Shuttering Board is designed with a non-porous, plastic-based composition that resists water absorption. This helps prevent moisture-related swelling, warping, and rotting associated with conventional wood-based formwork.

How does the 40% buyback guarantee work?

Rajratan offers a 40% buyback/replacement program for eligible PAC® boards. When boards reach the end of their usable life, customers can return eligible old or scrap PAC® material, subject to the applicable terms, and receive an adjustment toward a new purchase.

Customers should confirm the current buyback conditions with Rajratan before ordering.

Will pulling out nails damage the plastic board?

PAC® Shuttering Board is designed for repeated construction-site handling, including nailing and de-shuttering. However, fixing technique and nail placement can affect board life. Proper handling helps minimise damage and supports repeated use.

How many times can PAC® Shuttering Board be reused?

The expected repetition range varies by grade and application.

ECOPRIME Standard: approximately 30–40 repetitions.

ECOPRIME Premium: approximately 60–100+ repetitions under suitable site conditions.

Actual repetition can vary depending on staging, support spacing, stripping methods, handling, cutting, fixing, cleaning, and storage.

What is the delivery time from Indore to other states?

The indicative delivery time provided by Rajratan is approximately 2 days for neighbouring states and 4–5 days for other parts of India. Actual delivery time can vary based on production schedules, destination, transport availability, and order size.

Ready to Test PAC® Shuttering Board on Your Site?

The easiest way to understand how PAC® performs is to test it under your own construction conditions.

For a 5-sheet trial pack or product enquiry, contact:

Rajratan Industries Private Limited
Phone: +91 9685727927
Email: info@rajratan.in
Address: 123–124, First Floor, Shastri Market, Opp. Gandhi Hall, Indore – 452007, Madhya Pradesh

Test the board on your site, compare the repetitions, evaluate the finish, and calculate your actual cost per use.