PIONBOX WALL FORMWORK (40 KN)

The PionBox formwork system produced by PIONART is a technically well thought-out product of the highest quality. It consists of frames, corners and a wide range of fixtures.

The basic frame is a welded structure made of perforated flat bars and gusset plates, finished with a sheathing made of Polish-made birch plywood laminated on both sides. The flat bars are cut and perforated with high precision on special automatic punching machines. At the same time, special sockets are cut to connect and position the individual ribs of the structure. These sockets allow solid fillet welds to be made on the assembled structure with the help of welding robots. The assembly method is shown in the graphics below.

The second solution to achieve a rigid structure is specially shaped gusset plates, which meet the flat bars at right angles, allowing welding robots to perform fillet welds. Graphics of such connections are presented below.

PionBox is a lightweight formwork successfully used for concreting: footings, footings and foundation walls, foundation and fence beams, reinforced concrete columns and cores, rims, joists and floor ribs, chambers, manholes and tanks.

A summary of available board dimensions is shown in the tables below:

PionBox standard boards
Board height	Board width
	0,20 m	0,25 m	0,30 m	0,35 m	0,40 m	0,45 m	0,50 m	0,55 m	0,60 m	0,90 m
0,90 m	✔	✔	✔	✔	✔	✔	✔	✔	✔	✔
1,20 m	✔	✔	✔	✔	✔	✔	✔	✔	✔	✔
1,50 m	✔	✔	✔	✔	✔	✔	✔	✔	✔	✔

PionBox PZ universal boards
Board height	Board width
	0,60 m	0,70 m	0,90 m (on special request)
0,90 m	✔	✔	✔
1,20 m	✔	✔	✔
1,50 m	✔	✔	✔

PZ - are integrated boards (board graphic and construction photo - below), which have two or three rows of holes used, respectively, to assemble the formwork for concreting dimensionally any rectangular column (in increments of 5 cm). Completing the system are internal, external, articulating and matching corners, as well as spacers, work platform supports, handrail posts and many fasteners that can alternatively perform mounting functions for the boards and corners.

The basic fasteners are PionBox fasteners, disc nuts of 70 mm diameter and 100 mm diameter, and tie rods of various lengths. They are complemented by PionBox pins with nut and gusset, single pins with gusset, double pins with gusset, block nuts, hex nuts, edge hooks, spring clamps, corner tensioners and adapters for carrying a set of boards.

Our construction department can also design and manufacture custom formwork. In the photos below, we show the formwork for concreting footings for high-voltage electric poles and how to use edge hooks to install the formwork. There are also some photos from the construction sites below.

Arrangement of flat bar notches for cross connection to increase the rigidity of the board

An example of a board with visible connection points of ribs that stiffen the board structure

Visualization of the shaped gusset plate

The way and place of connecting the perimeter flat bars to the ends of the gusset plate at an angle of 90°

Example of PZ plate

Outer corner

Inner corner

Articulated corner

Spacers

Matching corner

Example of using matching corners to create a matching board

Example of using edge hooks

PionBox adapter

Example of using PionBox adapters

Stiffening beams

Working platform support

Working platform post

Example of using a working platform of PionBox formwork

Standard formwork

Example of column formwork using PZ panels.

Special formwork

Example of special formwork for concreting footings for high voltage poles. The formwork was designed and manufactured by our Construction Department to the client's order.

Custom formwork

An example of formwork for filling the places of connection of prefabricated poles and beams with concrete. On the order of a precast concrete manufacturer, the formwork was designed and made by our Construction Department.

Block nut, turnbuckle and plate nut