PLASTBAU Arabia will showcase cast-in-place insulated concrete form (ICF) systems for one-way joisted concrete floors and roofing at The Big 5 this month. The system is described as an extremely versatile product having the highest R-value (up to 50) and extremely lightweight, eliminating the need for cranes.

Due to its easy installation, construction time is reduced by up to 40 per cent, thereby reducing the project cost by up to 30 per cent, the company says, adding that in addition, workers don’t need specific training to work on the product.
“Beauty, strength and durability are just some of the reasons why Plastbau systems are products of choice for commercial and residential buildings. Either as standalones or integrated into other systems, these adapt to a diverse palette of configurations, shapes, and texture,” says a spokesman for the company.
One major gain is import substitution. While Plastbau technology continues to use the typical construction process of poured concrete, in the past Saudi Arabia has had to import plywood for shuttering. The system incorporates a locally-produced shuttering material – polystyrene – to contain the poured concrete. In addition, the polystyrene has high insulating properties for both temperature and noise and is easy to manipulate because it is so light, he says.
“The construction time, and consequently, costs are cut dramatically. The finished building also uses a smaller, more economical air-conditioning system as the insulated walls inhibit the loss of conditioned air to the outside,” he says.
Plastbau’s two renowned systems are the eDeck and eWall systems.
Through the use of Plastbau technology, eWall provides a structural system endowed with the effectiveness of not only concrete, but also a reinforcement cage of extreme robustness, quality control, and exceptional workmanship achievable under factory conditions, the spokesman points out. The seamless integration of the rebar cage into expanded polystyrene (EPS) form is a unique feature that allows the eWall system to achieve economy, performance and lasting durability, he says.
Whether used for load bearing or internal partition, the eWall system is selected for economy and the speed it provides to construction, with services concealed behind the EPS, he adds.
“The eDeck system – built on best ICF principles in accordance with Plastbau technology – is at the leading edge of flooring systems that address virtually every major concern of the concrete building industry. The system consists of a continuous pair of z-metal strips embedded into a core of ICF insulation moulded according to a process patented by Plastedil of Switzerland,” says the spokesman.
In addition, Plastbau also offers the Plastbau Tilt-up Walls and Plastbau Metal systems. The former is a lightweight forming system for creating reinforced concrete walls. This patented system features self-supporting forms that eliminate the need for a casting bed. Its T-beam design reduces concrete consumption by up to 30 per cent while the system requires less reinforcing steel, thus reducing the weight of panels, making them easy to transport. The system is pre-cut in production to exact length for each product with the utilities placed in wall chases before the pour.
The Plastbau Metal system is a lightweight forming system for concrete floors and roofs. Designed for joisted concrete floors, its modern and patent design gives it a superior insulation value, resulting in consumption of much less energy to heat and cool a structure. It does not contain any harmful gases that might affect the ozone layer, therefore, being environment-friendly. The Plastbau Metal system has two versions – drywall and plaster versions.
Plastbau is a joint venture registered in Saudi Arabia under licence and technical agreement with Plastedil of Switzerland. The company has a manufacturing facility in Dammam for the production, fabrication, and processing of the Plastbau Building Systems (PBS). The company also operates an engineering support division with an office in Al Khobar that offers complete engineering, marketing, and training services for customers using pre-engineered PBS products.
Plastedil, based in Switzerland, was established in 1978 to promote the technology invented by Piero Cretti. The company, sole owner of the patented Plastbau technology and brand, is specialised in the design, construction and sale of machines and complete turnkey plants for the manufacture of Plastbau building elements made of EPS.
Plastedil’s technology is based on the continuous moulding of EPS shapes which creates a wide range of innovative, top-quality products. These may be solid or hollow-cored, may have longitudinal cavities and variability of the section height. In order to meet the market demand, Plastedil has developed a series of forms for the casting of concrete (ICFs). These forms are pre-reinforced and heat-insulated.