Doka has launched Xlife top, the company’s first formwork sheet featuring a core made entirely of recycled plastic. This new solution delivers excellent durability and multiple reuse cycles to radically reduce greenhouse gas emissions (GHG).
Setting its ambitious goal of achieving net zero by 2040, Doka is actively working across diverse product segments to develop a growing portfolio of more climate-friendly solutions for its customers, contributing to the reduction of GHG on construction sites. An important transformation enabler is product design, focusing on material selection, modularity and refurbishment.
One of such efforts has been demonstrated through Doka’s formwork rental model, with formwork being refurbished on demand in dedicated service centres worldwide to significantly extend its lifespan. With the premiere of the Xlife top sheet, Doka is taking this sustainability commitment to the next level.
“Until now, sustainable solutions are often premium or niche products that struggle to reach the mainstream construction market,” said Robert Hauser, CEO of Doka. “With Doka Xlife top, we are breaking that pattern and proving that sustainability and economic viability can go hand in hand, making climate-friendly concrete construction feasible, accessible and practical at scale.”
Closing the loop
The development of Xlife top enables Doka to integrate closed-loop recycling into an industrial-scale solution. The core of the sheets is made of 100% recycled plastic. At the end of their lifecycle, the used Xlife top sheets are taken back by Doka and fully reintroduced into the cycle – that’s the beginning of a new sheet core. “This represents the full realisation of a circular economy,” said Mr Hauser.
When it comes to product carbon footprint (PCF) data, the Xlife top sheet has a significantly smaller PCF in comparison to conventional wood-composite sheets due to usage of recycled plastic and long lifespan.
Apart from its sustainability benefits, Xlife top also offers tangible performance and economic advantages. A standout feature is its silk-matte surface, which is highly scratch-resistant, ensuring consistent concrete quality across multiple uses. Unlike phenolic resin sheets, it does not stain the concrete, and its flush installation in the panel delivers a high-end finish.
The Xlife top surface and advanced composite technology make the sheet more resistant to damage, extending its lifespan substantially beyond conventional formwork sheets. Its robust structure allows fast and easy cleaning, even with high-pressure washers, thus minimising on-site labour time. The new sheet lowers refurbishment costs due to enhanced refurbishment methods including partial sheet replacement.
All Xlife top sheets are designed for seamless integration with the Doka framed formwork systems. Fewer replacements, lower maintenance and reduced concrete refurbishment translate into major cost savings for construction companies.
All images: Doka
