Conservative Utilization of Material Used for Temporary Formwork in the

Construction Industry in Malaysia

Low Ka Siong, Ho Shui Chuan

Reinforced concrete is apparently the most common structural element used in the built
environment in Malaysia, as a consequence of its remarkable strength and durability, its
versatility and insulating properties. Concrete structures are also cheaper and less
complicated to construct, therefore nominating concrete as the top construction material
choice not just in Malaysia, but worldwide (Meyer, n.d.). To cast concrete elements of a
structure (columns, beams and slabs), a mould or temporary formwork is needed where wet
concrete is poured into it and cured to achieve its strength. Formwork, depending on its type,
may cost up to 35% to 60% of the total cost of a concrete structure project (Ling and Leo,
2000). This critically implies that the type and design of a formwork system implemented in a
construction project majorly affects construction costs.

To avoid misinterpretation of definitions, the types of formwork stated within this case study
are generally categorised into two, namely, conventional formwork and formwork system.
Conventional formwork is usually fabricated on site, although prefabrication is also practised,
using timber and plywood as primary materials. Timber and plywood are transported to
construction sites to be sawn into specified dimensions to act as moulds for the designed
concrete elements. Conventional formwork are sometimes referred to as traditional formwork
or timber formwork. On the other hand, formwork systems (also known as engineered
formwork systems, steel formworks, Mivan formworks and aluminium formworks) are
mainly made of steel or aluminium, thus are most likely prefabricated to specification by
manufacturers. Due to controlled environments of prefabricating factories, formwork systems
are more likely to produce better quality concrete elements, besides having higher strength to
withstand wet concrete loads (UKEssays, 2015). Conventional formworks, however, deflect
and warp rather easily when carry loads for a long period or exposed to water. Formwork
system also has the upper hand when dealing with construction speed, after-use-value,
reusability and recyclability. Although formwork system induces a higher construction cost
initially, its superior reusability will prove worthy of its implementation, ultimately inducing
less construction cost and aid sustainable development as compared to conventional
formwork.
In spite of the superiority of formwork system over conventional formwork in terms of
sustainable construction, majority of Malaysian contractors are still accustomed to
implementing conventional formwork in a concrete construction project. A survey by Taher
Ahmed et al. (2012) found that only 50% of construction experts in Malaysia were
unanimous that sustainability of a construction project is influenced by type of formwork
used. Whereas in some developed countries, a study found that contractors in France and
Germany have mostly advanced to implementing formwork systems and proprietary forms in
building concrete structures, almost entirely avoiding conventional formwork (Proverbs, Holt
and Olomolaiye, 1999). This leads to the questioning of how conventional formwork waste
materials in Malaysia are dealt with. Instead of practising proper waste management system
by sorting out recyclable timber (and plywood) before disposal, most Malaysian contractors
are less inclined and unmotivated to put valuable resources and time into recycling timber.
Thus usually resort to the purchase of new materials and illegal burial or burning of waste
wood. This irresponsible practice has drastically deteriorated the environment by pollution,
expansion of landfills (legal and illegal) and increased deforestation. These issues are evident
but information on construction waste amount and composition are limited in Malaysia to
prove the issue (Siti and Wan Akmal, 2013).

At this point, it is pertinent to explore on sustainable ways of using formworks of any type
and methods to promote it. Besides the obvious need for contractors to improve record
keeping and management of construction waste, there is also an urgent need for life cycle
thinking to be instilled in construction experts’ minds. As a positive result, the basics of
waste hierarchy, which are the three R’s (Reduce, Reuse and Recycle), can eventually
become the staple of future constructions’ waste managements.

As the most efficient and cheapest way to lessen construction waste (Hansen, Christopher and
Verbuecheln, 2002), “Reduce” should be the first initiative by promoting design
standardizations in concrete structures. Standardization of concrete elements in a construction
indicates the usage of identical or repetitive elements in a structure’s design, which are
common in designs of tall buildings (Jalayerian, 2015). Consequently, less materials are
required to fabricate formworks when only few formworks are sufficient to build many
identical elements of a structure. An alternative ingenious way to reduce usage of formwork
materials is to encourage the use of prefabricated concrete elements instead of cast in-situ
elements in constructions, which eliminates the need for formworks on site.
The importance of standardization in structure designs is again emphasised due to its ability
to promote the “Reuse” of formworks in construction of repetitive concrete elements.
However, it should be highlighted that reusability of formworks are highly dependent on
multiple factors such as materials used for fabrication of formwork; workmen who deal with
the formwork; design of the completed structure; design, fabrication and stripping of the
formwork; and site management issues (Ling and Leo, 2000). A survey conducted by Ling
and Leo (2000) among formwork contractors in Singapore concluded that working attitudes
of workmen, efficiency of workmen, and formwork stripping process, are the three biggest
factors of conventional formworks reusability. This informs the construction industry the
significance for contractors to provide workmen with better training and education to
improve the handling of formwork materials in order to boost their reusability.

Then there comes a stage where formworks are used and reused to their limits, which is
where the “Recycling” of formwork should be practised in place of disposal or incineration.
One popular product that timber and plywood of conventional formworks can be recycled
into is “recycled plastic plywood” (RPP), which can be used as structural elements like
timber flooring or fencing; or used as concrete forms. RPP is manufactured by combining
crushed waste wood with crushed waste plastic, which are then heated, cooled, and cut to
specification (Nett21.gec.jp, 2011). Despite RPP being only 3-5% more expensive than
normal plywood, it is highly worthy due to its better durability, termite resistance, and lower
maintenance needs (Scheid, 2015). In the implementation of RPP as concrete form, feedbacks
have proven that RPP as formwork can be reused up to 30 to 200 times, besides improving
the stripping process of formwork (Sindawood.com, n.d.). Last but certainly not least, RPP is
recyclable, thus closing the loop of resource use and immensely reduce the need for
extraction of raw material (Nett21.gec.jp, 2011).

To sum up, there are numerous methods and ideas to conserve the materials of concrete
formwork, especially conventional formwork. Conservation of materials of formwork
systems was not thoroughly discussed due to its higher reusability and recyclability as
compared to conventional formwork. However, more innovations need to be explored in the
recycling of conventional formwork materials due to its limited solutions. Lastly, all of these
sustainable solutions will be for naught, if the people involved in the construction industry
remain ignorant of sustainable construction and do not grasp the importance of life cycle
thinking.
References

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