Types of Shuttering in Civil Engineering , civil engineering and construction
A complete, SEO-optimized guide covering definition, all types, materials, advantages, disadvantages, installation, safety, and FAQs — everything you need to know.
2. Why is Shuttering Used in Construction?
Shuttering is used for several essential reasons in construction:
- Shape & Form: It gives concrete its intended shape (columns, beams, slabs, walls, arches, etc.) before it hardens.
- Support During Curing: Fresh concrete is weak and self-compacting; shuttering supports it until it reaches the minimum design strength (typically 28-day strength).
- Surface Finish: The type of shuttering material directly affects the surface texture and smoothness of concrete.
- Safety: It prevents accidental collapse or deformation of wet concrete elements.
- Structural Accuracy: Ensures dimensional accuracy and alignment of concrete members as per engineering drawings.
- Protection: Protects concrete from dehydration (especially in hot/dry climates) while it cures.
⚠️ Important
Shuttering must be designed by a qualified engineer for large or complex projects. Improper shuttering is one of the leading causes of construction site accidents.
3. Types of Shuttering – Complete List
There are 8 major types of shuttering used in civil engineering construction. Each has specific applications, advantages, and limitations.
1. Timber Shuttering
The most traditional type. Made from wooden planks and boards. Versatile and easy to shape on-site.
Traditional2. Plywood Shuttering
Uses thick plywood sheets. Provides a smooth concrete surface and is easier to handle than timber.
Smooth Finish3. Steel Shuttering
Made from thin steel plates. Highly durable, reusable 50–200+ times, and ideal for large projects.
High Reuse4. Aluminum Shuttering
Lightweight metal shuttering. Faster to assemble and dismantle. Popular in high-rise residential buildings.
Lightweight5. Plastic / PVC Shuttering
Made from polypropylene or PVC. Lightweight, waterproof, and ideal for repetitive standard shapes.
Waterproof6. Fabric / Flexible Shuttering
Uses woven fabric membranes. Enables complex curved and organic concrete shapes not achievable with rigid forms.
Complex Shapes7. Permanent / Insulated Shuttering
Left in place after concrete cures. Acts as thermal insulation. Used in energy-efficient building systems (ICF).
Permanent8. GFRP Shuttering
Glass Fiber Reinforced Plastic. Extremely durable, corrosion-resistant, and used for architectural finishes.
ArchitecturalTimber Shuttering
Timber shuttering is the oldest and most widely used form of shuttering, especially in developing countries. It consists of timber planks, beams, and battens assembled on-site to create the mould. It is highly versatile since carpenters can cut and shape timber to any desired form.
Uses: Columns, beams, slabs, walls, foundations, and any custom or irregular shape.
✅ Advantages
- Low initial cost
- Easily available anywhere
- Can be shaped to any form
- Simple tools required
- Ideal for small projects
❌ Disadvantages
- Swells/warps with moisture
- Limited reuse (5–10 times only)
- Heavy in large spans
- Not fire-resistant
- Absorbs water from concrete
Plywood Shuttering
Plywood shuttering uses phenol-formaldehyde bonded plywood sheets (typically 12mm–25mm thick). It provides a much smoother concrete surface than ordinary timber. Plywood is often used as the facing material, supported by a timber or steel framework.
Uses: Slabs, walls, columns, beams — anywhere a smooth concrete face is required.
Steel Shuttering
Steel shuttering consists of prefabricated thin steel panels (typically 2–3mm thick) with stiffening ribs. Panels can be bolted together in different configurations. Steel shuttering provides excellent concrete surface quality and is ideal for large-scale infrastructure projects such as bridges, tunnels, and dams.
Uses: Bridges, underpasses, retaining walls, large columns, water tanks, and tunnels.
✅ Key Advantage
Steel shuttering can be reused 50 to 200 or more times, making it highly cost-effective for large projects despite its higher initial cost.
Aluminum Shuttering
Aluminum shuttering (also called aluminium formwork) is increasingly popular for high-rise residential and commercial construction. It is significantly lighter than steel (about one-third the weight) while retaining good strength. Aluminum shuttering systems like Mivan formwork are popular for rapid floor-to-floor construction in apartment buildings.
Uses: Mass housing projects, high-rise apartments, repetitive floor slabs.
Plastic / PVC Shuttering
Plastic shuttering is made from high-density polyethylene (HDPE), polypropylene (PP), or PVC. It is lightweight, waterproof, and does not absorb water. Release agents are often not needed. Plastic panels can be reused 50–100 times and are easy to clean.
Uses: Column heads, small slabs, precast concrete elements, retaining walls, repetitive shapes.
Fabric / Flexible Shuttering
Fabric shuttering uses permeable or impermeable woven fabric membranes as the form. The concrete is pumped or placed against the fabric under pressure. This technique allows the creation of complex doubly-curved and organic forms that would be impossible with rigid shuttering. It is also used in geotechnical applications for sand-filled mattresses and slope protection.
Uses: Architectural concrete, underwater structures, slope protection mattresses, shell structures.
Permanent / Insulating Concrete Formwork (ICF)
Permanent shuttering (Insulating Concrete Formwork or ICF) is not removed after the concrete cures — it remains as part of the structure. It is typically made from expanded polystyrene (EPS) foam blocks or panels. Concrete is poured into the EPS hollow cavity, and the foam acts as both the form and the insulation for the finished wall.
Uses: Energy-efficient homes, passive houses, cold-climate buildings.
GFRP (Glass Fiber Reinforced Plastic) Shuttering
GFRP shuttering uses glass fiber reinforced polymer panels. These are lightweight yet very strong, and they can be molded into complex shapes. They are corrosion-resistant and provide excellent architectural concrete finishes. GFRP shuttering is used in prestigious architectural and infrastructure projects.
Uses: Architectural facades, bridges with complex shapes, column capitals, decorative concrete.
4. Materials Used in Shuttering
The following materials are commonly used to manufacture shuttering panels and systems:
- Timber (Pine, Teak, Sal): Traditional; low cost; locally available
- Plywood (Phenol Bonded): Smooth face; 12mm–25mm thickness; multiple reuses
- Mild Steel (MS): Prefabricated panels; high reuse; heavy but strong
- Aluminum Alloy: Lightweight; high strength; used in Mivan systems
- PVC / HDPE / Polypropylene: Waterproof; lightweight; chemical resistant
- Expanded Polystyrene (EPS): Used for ICF / permanent formwork
- Glass Fiber Reinforced Plastic (GFRP): Complex shapes; corrosion resistant
- Woven Fabric / Geotextile: Permeable; flexible; enables curved forms
- Cardboard / Paper Tubes: Circular column forms; disposable
5. Shuttering Types Comparison Table
| Type | Material | Reuse | Weight | Cost | Surface Finish | Best For |
|---|---|---|---|---|---|---|
| Timber | Wood planks | 5–10× | Medium | Low | Rough | Small projects |
| Plywood | Phenol plywood | 8–20× | Medium | Low–Med | Smooth | Slabs, walls |
| Steel | MS plates | 50–200+ | Heavy | High | Very Smooth | Large infra |
| Aluminum | Al alloy | 200+ | Light | High | Smooth | High-rise, mass housing |
| Plastic / PVC | HDPE / PP | 50–100× | Very Light | Medium | Smooth | Repetitive shapes |
| Fabric | Woven textile | 1–3× | Very Light | Medium | Textured | Curved shapes |
| ICF / Permanent | EPS foam | Permanent | Very Light | Medium–High | N/A | Energy-efficient walls |
| GFRP | Fiberglass | 100+ | Light | Very High | Excellent | Architectural concrete |
6. How to Install Shuttering – Step-by-Step
Installing shuttering correctly is critical to safety and concrete quality. Here is a general step-by-step process:
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Prepare the Site
Clean the surface, set out the dimensions according to structural drawings, and ensure the sub-base or previously cast element is stable and level.
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Erect Props and Falsework
Set up vertical steel or timber props (shores) at designed spacing to support horizontal waling and decking. Plumb and level all props carefully using a spirit level.
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Fix Waling / Joists
Install horizontal runners (walers/joists) across the props to create a stable framework on which the shuttering panels will rest.
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Place Shuttering Panels
Fix the shuttering panels (timber, plywood, steel, etc.) in position. Ensure all panels are firmly connected with no gaps where concrete could leak.
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Apply Release Agent
Apply a suitable mould release agent (oil or chemical) to all surfaces that will be in contact with concrete. This prevents bonding and allows easy stripping.
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Place Reinforcement (Rebar)
Once shuttering for the base/sides is ready, place the steel reinforcement bars (rebar) inside the form with correct cover blocks (spacers).
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Inspect Before Pouring
A qualified engineer or site supervisor must inspect the shuttering for stability, alignment, gaps, proper bracing, and correct cover to reinforcement before any concrete is placed.
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Pour Concrete
Place concrete in layers (max 300–500mm per layer), vibrating each layer to remove air voids. Avoid dropping concrete from excessive heights.
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Cure Concrete
Allow concrete to cure for the required time (see removal times below). Keep concrete moist during curing.
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Strip (De-shutter) the Formwork
Remove props, panels, and decking in the correct sequence as specified by the engineer. Never strip early — this can cause collapse.
7. Advantages of Shuttering
✅ Advantages
- Gives concrete its precise design shape
- Enables construction of complex structural forms
- Provides smooth or textured surface finishes
- Supports concrete during curing period
- Improves quality and accuracy of concrete work
- Reusable types (steel, aluminum) reduce long-term cost
- Accelerates construction speed in modular systems
- Permanent ICF shuttering adds thermal insulation
- Protects concrete from dehydration in hot climates
- Enables safety in elevated concrete pours
❌ Disadvantages
- Adds significant cost to construction (15–25% of cost)
- Requires skilled labour to erect and dismantle
- Time-consuming to set up and remove
- Risk of collapse if improperly designed
- Timber types swell, warp, and rot
- Steel shuttering is heavy and requires cranes
- Wastage of timber shuttering adds to cost
- Leakage at joints reduces concrete quality
- High storage requirements for large systems
- Difficult to use for complex shapes (rigid types)
8. Key Disadvantages of Shuttering – Detailed
While shuttering is essential, the following disadvantages must be carefully managed:
❌ Cost Impact
Shuttering and formwork typically account for 35–60% of the cost of concrete structural elements, and 15–25% of total project cost. This is a major factor in project budgeting, especially for complex structures.
- Labour Intensive: Skilled carpenters and form-setters are required, adding to labour costs.
- Time Delay: Setting up and dismantling formwork adds to the overall project schedule.
- Safety Risk: Formwork failure is a major cause of construction fatalities globally.
- Material Wastage: Timber shuttering has limited reuse, contributing to waste and deforestation.
- Storage: Large panels require significant storage space on-site.
- Surface Defects: Poorly made or poorly maintained shuttering results in honeycombing, blow-holes, and surface defects in concrete.
9. Is Shuttering Safe? – Safety Guidelines
Yes, shuttering is safe when properly designed, installed, and inspected. However, formwork and shuttering collapses are among the most common causes of serious injuries and fatalities on construction sites worldwide.
Engineering Design
Always have shuttering designed by a qualified structural engineer for large or complex pours.
Pre-Pour Inspection
Inspect all panels, props, and connections before any concrete is placed.
Secure All Connections
Ensure all bolts, wedges, ties, and clamps are tightened and no panels are loose.
Check Plumb & Level
Verify vertical alignment and horizontal level of all shuttering before concrete pouring.
Load Calculations
Design must account for dead load, live load, wind load, and concrete pressure.
Exclusion Zone
Keep non-essential workers away from the pour area during concrete placement.
Don’t Strip Early
Never remove shuttering before concrete achieves the minimum design strength.
Maintain Equipment
Regularly inspect and maintain props, panels, and accessories for damage or corrosion.
⚠️ Warning
In many countries, including India, the UK, and the USA, shuttering design and supervision is regulated under construction safety codes (e.g., IS 14687 in India, BS 5975 in UK, ACI 347 in USA). Non-compliance can result in legal liability.
10. When to Remove Shuttering? (De-shuttering Time)
The time to remove shuttering depends on the type of concrete member, concrete grade, temperature, and cement type used. Standard guidelines (as per IS 456:2000) are:
| Concrete Member | Minimum Removal Time | Remarks |
|---|---|---|
| Vertical surfaces (walls, columns) | 16–24 hours | Depending on temperature |
| Slabs (spanning up to 4.5m) | 3 days | Soffit form only |
| Slabs (spanning over 4.5m) | 7 days | Props may need re-propping |
| Beams (spanning up to 6m) | 14 days | Bottom form removal |
| Beams (spanning over 6m) | 21 days | Full strength needed |
| Props for arches | 14–28 days | Depends on span |
Note: In cold weather (below 10°C), extend removal times. With rapid-hardening cement, times can be reduced, but always confirm with concrete cube test results (minimum 2/3 of design strength).
11. Uses of Shuttering in Construction
Shuttering is used in virtually all concrete construction works, including:
Buildings
Columns, beams, slabs, walls, staircases, lift cores, and foundations in residential and commercial buildings.
Bridges
Bridge decks, piers, abutments, box girders, and arch ribs in road and railway bridges.
Tunnels & Underground
Tunnel linings, underground metro stations, cut-and-cover structures, and retaining walls.
Water Structures
Dams, water tanks, reservoirs, water treatment plants, and cooling towers.
Roads & Pavements
Road edge forms, kerb and gutter forms, and concrete pavement slab edge shuttering.
Industrial
Precast yards, industrial floors, silos, bunkers, machine foundations, and pile caps.
12. Cost of Shuttering in Construction
The cost of shuttering is a significant part of any concrete construction budget. Here is a general overview:
| Shuttering Type | Initial Cost | Cost Per Use | Reuse Benefit |
|---|---|---|---|
| Timber | Low | High (limited reuse) | Poor |
| Plywood | Low–Med | Medium | Moderate |
| Steel | High | Very Low | Excellent |
| Aluminum | Very High | Very Low | Excellent |
| Plastic / PVC | Medium | Low | Good |
| ICF / Permanent | Medium–High | N/A (permanent) | Adds insulation value |
💰 Cost Insight
In large projects, switching from timber to steel or aluminum shuttering can reduce overall formwork costs by 30–50% over the project life, even though the initial investment is higher.
14. Frequently Asked Questions (FAQ)
Shuttering (also called formwork) is a temporary or permanent mould constructed to hold and shape fresh concrete until it gains enough strength to support itself. It is made from materials such as timber, plywood, steel, aluminum, or plastic, and is used in the construction of columns, beams, slabs, walls, and virtually all reinforced concrete elements.
The 8 main types of shuttering are: (1) Timber Shuttering, (2) Plywood Shuttering, (3) Steel Shuttering, (4) Aluminum Shuttering, (5) Plastic/PVC Shuttering, (6) Fabric/Flexible Shuttering, (7) Permanent/ICF Shuttering, and (8) GFRP (Glass Fiber Reinforced Plastic) Shuttering. Each type is suited to specific applications, budgets, and project scales.
The best type of shuttering depends on the project:
• Steel shuttering is best for large infrastructure (bridges, dams, tunnels) due to high reuse and strength.
• Aluminum shuttering (Mivan) is best for mass housing and high-rise repetitive floor construction.
• Timber/plywood is best for small, custom, or irregular shapes at low cost.
• Plastic shuttering is ideal for repetitive precast elements.
• ICF is best for energy-efficient residential construction.
Shuttering refers specifically to the contact surface or mould that directly touches the fresh concrete. Formwork refers to the complete system, which includes the shuttering (mould face), the supporting framework (joists, walers), and the falsework (props, scaffolding). In everyday use, both terms are often used interchangeably. “Shuttering” is more common in the UK/India, while “formwork” is more common internationally.
Yes, shuttering is safe when properly designed, erected, and inspected by qualified engineers. Key safety requirements include: engineering design for loads, correct propping, inspection before pouring, avoiding overloading, and following prescribed de-shuttering times. Formwork collapse is a serious construction hazard — shortcuts or improper erection are the leading causes of shuttering-related accidents.
As per IS 456:2000:
• Vertical elements (columns, walls): 16–24 hours
• Slabs up to 4.5m span: 3 days
• Slabs over 4.5m span: 7 days
• Beams up to 6m: 14 days
• Beams over 6m: 21 days
These times assume normal Portland cement and ambient temperature above 15°C. Always confirm with concrete strength test results.
Shuttering materials include: timber, plywood, mild steel (MS), aluminum alloy, PVC/HDPE/polypropylene, expanded polystyrene (EPS), glass fiber reinforced plastic (GFRP), woven fabric/geotextiles, and cardboard tubes (for circular columns). The choice depends on project type, required surface finish, budget, and number of reuses required.
Yes, shuttering can be reused depending on the material: Timber can be reused 5–10 times; plywood 8–20 times; PVC/plastic 50–100 times; steel 50–200+ times; and aluminum 200+ times. Proper cleaning, maintenance, and storage after each use maximizes the reuse potential.
Mivan shuttering is a proprietary aluminum formwork system developed by Mivan Company Ltd. of Europe. It is widely used for mass housing projects in India (under PMAY and state housing schemes) and other Asian countries. It enables rapid, monolithic construction of entire concrete structures — walls, slabs, columns, and beams all cast together — achieving floor-to-floor cycles as fast as 4–7 days. It produces very smooth concrete surfaces that require minimal plastering.
Shuttering costs vary by region, type, and project scale. As a rough guide in India (2025–2026): Timber shuttering ₹150–₹250/sqft of contact area; Plywood shuttering ₹120–₹200/sqft; Steel shuttering rental ₹40–₹90/sqft/month; Aluminum formwork (Mivan) purchase ₹800–₹1,200/sqft (for 250+ uses over project life). Always obtain local market quotes as prices vary significantly.
Permanent shuttering (Insulating Concrete Formwork / ICF) uses expanded polystyrene (EPS) foam blocks as the mould. Unlike traditional shuttering, it is not removed after concrete sets. The EPS blocks remain permanently as part of the wall, providing high thermal insulation (R-values of R-22 to R-45), soundproofing, and moisture resistance. ICF construction is popular in North America, Europe, and increasingly in India for energy-efficient homes.
Quality shuttering must: (1) be strong enough to support concrete weight without deformation; (2) be watertight with no leakage at joints; (3) be accurately set to dimension; (4) have a smooth surface (if smooth concrete is required); (5) be treated with release agent to prevent concrete bonding; (6) allow easy stripping without damaging concrete; (7) be inspected before every concrete pour. In India, IS 14687:1999 provides guidelines for formwork.