Dr Al Isa.
Plastbau systems ease construction process
01 March 2009
SAUDI Arabia-based Plastbau Arabia’s building systems, produced after years of research, design and practical experience, is looking to revolutionise the way buildings are engineered with its innovative construction technique.
Located in Dammam, Plastbau Arabia’s plant produces floor/roof and wall shuttering elements.
The system is essentially based on the use of steel and polystyrene, thus benefiting the national economy by adding value to locally-produced products, while simultaneously reducing the need for imported wooden shuttering material, according to the company.
Commenting on the product, Dr Muhammed S Al Isa, chief executive of Plastbau Arabia, says: “Plastbau forms have been developed following several years of research, design and practical experience. These multipurpose forms are self-supported with metallic strips of galvanised mesh and can replace wooden shuttering in in-situ concrete slab casting as well as conventional hollow blocks to provide a complete integrated mould to cast the slab.”
“The assembly of Plastbau forms is very easy. This apart, installation is fast compared to the wooden shuttering method, and can be done manually with limited manpower and without heavy equipment. The required horizontal and vertical support is minimal,” he adds.
The technology improves the traditional poured concrete system of construction by incorporating thermal and sound insulation through the use of the polystyrene forms.
This advanced insulated concrete form (ICF) system enhances the usual poured cement method of construction.
Also, the forms do not have to be removed, as with wood shuttering, thus affording cost savings as well as a higher quality of construction to the building contractor.
The unique feature of the Plastbau system is that it uses polystyrene blocks as formwork during the construction stage. These same blocks stay on during the life of the building providing excellent thermal insulation.
Due to the modular construction technique and light weight of the panels, the total time taken for construction comes down drastically and makes a very low requirement on manpower, says the company.
Plastbau Arabia’s manufacturing facility includes two main production lines – one for Plastbau eDeck, a structural floor, roof, and ceiling system, and the other for Plastbau eWall, a structural wall, partition, and foundation system.
These products can be manufactured in various lengths, thicknesses and shapes and feature utility holes as per the requirements of the projects.
Structures built with Plastbau eDeck and eWall systems are designed, engineered, and constructed in accordance with applicable governing building codes and regulations.
Therefore, in addition to direct manufacturing and marketing of the Plastbau walls and floors/roofs systems, Plastbau Arabia has also an established engineering support division (ESD).
The Plastbau eDeck is a stay-in-build insulating concrete forming system for joisted concrete floors. Roofs that are built using Plastbau moulds are considered to be lighter than similar roofs built using hollow blocks or precast by 50 per cent, which significantly reduce load on walls, columns and foundations, he says. This, in turn, reduces volume of building materials required.
The moulds manufactured are of two main types – the dry wall version and the plaster version. The first is produced without plastering mesh and can be fixed using screws that attach the moulds directly with metallic strip. In the plaster version, a metal mesh is added to the element in order to have a good bond between the plaster and the element.
“Ceilings that are built using Plastbau eDeck systems are prepared to accommodate several types of finishing materials like cement plastering or gypsum and cement boards fixed directly using mechanical fastening technique on the metallic strip. There is no need for any additional fastening systems, which reduces finishing costs. Mechanical, electrical, HVAC can be easily hanged on the metallic strips,” says Dr Al Isa.
Meanwhile, Plastbau eWall is an insulating wall shuttering pre-assembled, rigid element, that is easy to handle and installed.
Elaborating the advantages of these forms, Dr Al Isa says: “Plastbau eWalls are equipped with basic reinforcement steel. They are internally provided with plastic spacers to guarantee the needed 25-mm thickness concrete coverage for the reinforcement steel.
“The eWalls also provide sound insulation for facilities built using this system,” he says. “Recent studies have showed that the sound reduction rate for eWalls can easily reach 62 db, which is highly desired for sound insulation purposes.”
Plastbau forms for decks and walls provide efficient thermal insulation for buildings. Studies have shown that Plastbau forms enhance thermal insulation by 50 per cent, thus decreasing the load requirements for cooling or heating, while also reducing electrical consumption by 30 to 60 per cent. They also help in reducing wood consumption in the shuttering process, saving natural wood resources, as well as decreasing the volumes of building materials consumed.
From the environmental aspect, Dr Al Isa says: “Plastbau systems are ideal in terms of thermal and sound insulation and quality of air. They also speed the construction process by almost 70 per cent. All these advantages, as well as their aesthetics and durability, makes Plastbau building systems a choice product for residential and commercial buildings.”
Plastbau Arabia is a joint stock company set up in technical partnership with and licensed by Swiss Plastedel Company.
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