ILPA - Formwork Panels

WHAT ARE FORMWORK PANELS

A formwork panel is a temporary structural element used in construction to contain and shape fresh concrete during the casting and hardening phase. It works as a mould: concrete is poured inside the formwork, which defines its shape until the required mechanical strength is reached.

Timber formwork panels are the most widespread and versatile solution in the construction industry. They are valued for their lightness, workability and adaptability to complex geometries – qualities that make them indispensable in both large-scale infrastructure projects and residential construction.

ILPA has been manufacturing formwork panels since 1978. Over the decades, the company has developed innovative solutions that have redefined industry standards, progressing from traditional three-layer panels to advanced composites with plastic coating and patented perimeter protection.

THE FORMWORK PROCESS

The formwork process is a fundamental phase in the construction of reinforced concrete structures. It consists of several stages:

1. Assembly. The panels are assembled to create the desired shape – whether it is a wall, a column, a slab or a foundation. The precision of the assembly determines the quality of the finished concrete surface.

2. Casting. Fresh concrete is poured inside the formwork. During this phase, the panel must withstand the hydrostatic pressure of the concrete and the mechanical vibrations used to compact the material.

3. Curing. The concrete is left to harden inside the formwork for the time required to reach the structural strength specified by the project design.

4. Stripping. Once the concrete has reached the required strength, the panels are removed. A good panel must allow easy stripping without damaging the concrete surface or the panel itself, so that it can be reused.

Panel quality directly affects the surface finish of the concrete, the working speed on site and the number of reuse cycles achievable – a factor of primary economic and environmental importance.

PANEL TYPES

The formwork panel market offers a range of solutions, each with specific characteristics. The main types are:

Three-layer spruce panel. This is the traditional formwork panel, made of three cross-layered spruce battens. It offers a good quality/price ratio and is suitable for general use. The surface can be treated with melamine to increase resistance to abrasion and weathering. ILPA has been producing this type since 1978 with its Cassero.

Birch plywood. Birch plywood panels with phenolic bonding, used for high mechanical resistance formwork and applications requiring particularly smooth surfaces. ILPA offers this solution in the Other Products section.

Composite panel with plastic coating. This represents the evolution of the traditional panel. A polyolefin coating is applied to the outer surfaces of the timber core, providing greater abrasion resistance, waterproofing and ease of cleaning. ILPA patented this technology in 1994 with STRATO-STOCK® and also offers it in a three-layer spruce version with FIR-STOCK®.

Panel with perimeter protection. The most recent innovation in the sector: the panel edges are protected by high-pressure polyurethane injection, eliminating the most vulnerable point of traditional panels. ILPA patented this technology in 2017 with PUR-STOCK®.

KEY PROPERTIES OF A FORMWORK PANEL

When choosing a formwork panel, construction professionals evaluate several technical properties:

Mechanical resistance. The panel's ability to withstand the pressure of fresh concrete without deforming. It is determined by the quality of the timber, the thickness and the structure of the panel.

Abrasion resistance. The panel surface must resist wear caused by casting, stripping and cleaning. Panels with plastic coating offer significantly superior performance compared to traditional ones.

Nailability. The ability to nail the panel without splintering is essential for on-site assembly. Polyolefin plastic coatings eliminate the splintering problem typical of panels with phenolic film.

Chemical resistance. Contact with concrete (highly alkaline), release oils and weathering agents requires the panel to maintain its characteristics over time.

Number of reuse cycles. A higher-quality panel allows a greater number of use cycles, reducing the cost per pour and the overall environmental impact.

Recyclability. At the end of their life, panels must be disposable or recyclable in a responsible manner. ILPA panels with plastic coating are fully recyclable.

ILPA'S INNOVATION IN THE FORMWORK SECTOR

ILPA is among the companies that have contributed most to innovating traditional formwork panels. The company's philosophy is based on technology transfer between different sectors: applying technologies and materials from other industrial fields to the construction industry.

1994 – STRATO-STOCK®. ILPA patents the first composite formwork panel with polyolefin plastic coating on a birch plywood core. A solution subsequently imitated by all major manufacturers in the sector.

2004 – Xlife Project. In partnership with one of the world's most important industrial groups in the sector, ILPA develops and patents a new generation of composite panels.

2017 – PUR-STOCK®. ILPA patents the first timber formwork panel with perimeter edge protection using high-pressure injected polyurethane, eliminating the most vulnerable point of traditional panels.

Today ILPA collaborates with the most important international partners in the sector, developing solutions that combine the tradition of timber craftsmanship with the most modern coating and protection technologies. The company motto – STRONGER TOGETHER – reflects this philosophy of shared innovation.