Airplast

Formwork for the construction of lightweight unidirectional slabs

Airplast is a modular formwork made of recycled polypropylene (PP), developed as an advanced alternative to polystyrene for the lightweighting of precast predalles slabs.
 
Drawing on Geoplast’s many years of experience in structural lightweighting systems, Airplast is designed to be integrated directly in the precast plant onto fresh concrete, ensuring precision, stability, and production continuity.
 
The system anchors perfectly to the slab thanks to its support feet and integrated alignment system, ensuring consistent rib geometry and high quality of the finished element.
 
Made of recycled polypropylene, Airplast does not absorb water, does not release moisture over time, and does not require venting in the event of fire, allowing the slab to achieve the required REI fire-resistance performance.
 
Lightweight, walkable, and modular, Airplast optimizes production processes, reduces storage costs, and improves the overall reliability of the predalles system.

Advantages

  • STRUCTURAL LIGHTWEIGHTING AND GEOMETRIC PRECISION
  • Airplast reduces the self-weight of predalles slabs while maintaining constant and controlled rib geometry. The regular spacing ensures reliable structural performance and uniform load distribution.
  • STABILITY AND SAFETY DURING CASTING
  • Thanks to its support cones and rigid structure, Airplast is fully walkable and stable throughout all production phases and during the completion pour, improving operational safety in the precast plant.
  • NO WATER ABSORPTION
  • Recycled polypropylene does not absorb water from the concrete, preventing infiltration phenomena. This ensures the correct water/cement ratio and higher quality of the final concrete pour.
  • HIGH RESISTANCE AND LONG-TERM REUSE
  • Geopanel delivers high structural resistance of 60 kn/m2 and can be reused over 100 times, offering long-term durability and significant savings compared to traditional formwork.
  • OPTIMIZATION OF THE PRODUCTION PROCESS
  • The integrated alignment system allows fast and precise installation directly in the precast plant, reducing processing times and increasing the productivity of prefabrication lines.
  • MODULARITY AND ADAPTABILITY
  • Airplast elements can be easily cut and adapted to different predalles slab dimensions, offering great design and production flexibility without material waste.
  • CREATION OF DISTRIBUTION BEAMS
  • Closed side walls allow the easy formation of distribution beams, improving the structural behavior of the slab and simplifying the design process.
  • FIRE SAFETY
  • The air contained inside the formwork does not pose a risk in the event of fire: Airplast does not require additional venting to achieve the slab’s REI fire-resistance rating.
  • REDUCTION OF LOGISTICS COSTS
  • The light weight and compactness of the elements reduce storage and handling costs, making Airplast an efficient solution also from a logistical standpoint.
  • CERTIFIED SUSTAINABILITY
  • Airplast is made from 100% recycled polypropylene and complies with sustainable building criteria. The system is EPD certified and contributes to the achievement of up to 12 LEED credits, reducing the overall environmental impact of the slab.

Solutions

  • Void formers for precast slabs
  • Slabs for commercial buildings
  • Slabs for school buildings
  • One-way slabs for parking structures

Projects

Faq

Why is AIRPLAST better than polystyrene?

AIRPLAST formwork is far more resistant than polystyrene and does not break in the corners. Moreover, it is impermeable, thus it does not hold water and does not release it over time.

Is any ventilation system necessary, as with polystyrene?

AIRPLAST formwork does not contain any harmful gas like styrene, thus it does not require any ventilation system, which is otherwise necessary according to VV.FF regulations, when using lightening system in polystyrene because it tends to explode, causing collateral damage, when under pressure.

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