PERFORM WITH PRECISION BOX CULVERT TRAVELER CONCRETE CONSTRUCTION PRODUCTS APPLICATION GUIDE

A WORD ABOUT SAFETY High productivity depends on safety; even a minor accident causes job delays and inefficiency, which run up costs. That s why Symons by Dayton Superior, in the design of its systems and products, makes the safety of those people who will be working with and near the equipment one of its primary concerns. Every product is designed with safety in mind, and is tested to be certain that it will perform as intended with appropriate safety allowances. Factory built systems such as these provide predictable strength, minimizing the uncertainty that often surrounds hand made, job shop and job built equipment. As a result, Symons by Dayton Superior products are your best assurance of a safe operation when used properly. To insure proper use, we have published this application guide. We recommend that all construction personnel who will be involved, directly or indirectly, with the use of this product be familiar with the contents of this guide. As a concerned participant in the construction industry, Symons by Dayton Superior also recommends that regular safety meetings be held prior to starting the forming operation, and regularly throughout the concrete placement, form stripping and erection operations. Symons by Dayton Superior personnel will be happy to assist in these meetings with discussion of safe use of the equipment, slide presentations and other formal safety information provided by such organizations as the Scaffolding, Shoring and Forming Institute. In addition to the above meetings, all persons involved with the construction should be familiar and in compliance with applicable governmental regulations, codes and ordinances, as well as the industry safety standards developed and published by each of the following: American Concrete Institute American National Standards Institute The Occupational Safety and Health Administration The Scaffolding, Shoring and Forming Institute Because field conditions vary and are beyond the knowledge and control of Symons by Dayton Superior, safe and proper use of this product is the responsibility of the user.

Max A Form Box Culvert Application Guide 1 I. Introduction The Symons Box Culvert Traveler is an all steel, rentable traveler system intended to work in conjunction with the Max-A-Form, forming systems for Box Culvert Forming. The Traveler is designed to function within a range of heights and widths for traveling the inside form unit intact to the next pour position. The Traveler is highly versatile and very simple in function and operation. Typical applications for the traveler system are, but in no way limited to, the following: Storm Drainage Tunnel Galleries Irrigation Channels 3. Typical Conditions Figure 1 represents a typical culvert section with referenced minimum and maximum dimensions according to type. Figure 2 indicates the various corner conditions attainable using the various form systems Figure 3 represents a typical starter wall detail. The traveler is designed to work with a nominal 6" starter wall at invert, using 2 x 6 lumber to form a 5½" high starter wall is a common technique. However, the starter wall is not a necessity. Job-built or specially manufactured base forms can be used when there is no starter wall. Contact your representative for application. Sewer Canals Utility Tunnels II. System Nomenclature A. Design Criteria 1. The Traveler is divided into three size classifications. The minimum and maximums for these classifications or types are as follows: Type I 5'-0 high x 5'-0 wide to 6'-6" high x 6'-6" wide Type II 6'-6" high x 6'-6" wide to 9'-0" high x 9'-0" wide Type III 9'-0" high x 9'-0" wide to 12'-0" high x 12'-0 wide Note: A 12" upright extension (PC 40274) is available which increases the maximum height of each Type by 1'-0". 2. Maximum Deck Thickness MF 12 Module Fig. 1 Typical Box Section 4'-0" Header Spacing 1' and 4' from each end Type I 24" maximum Type II 21" maximum Type III 18" maximum @ 9'-0 to 10'-0 wide 17" max. @ 10'-1" to 11'-0 wide 16" max. @ 11'-1" to 12'-0 wide Fig. 2 Corner Options Fig. 3 Typical Starter Wall

2 Max A Form Box Culvert Application Guide III. Field Assembly As always, a thorough shake-out of equipment is recommended prior to commencing assembly. Equipment should be placed as close to assembly area as practical to minimize go-fer time. Max-A-Form is a walerless panel system with built-in tie boxes which, with the attachment of the components discussed in this section, is well suited to culvert forming applications. Generally, with Max-A-Form in this application, panel gangs will be assembled prior to attaching components. This operation is almost totally crane- assembled with the exception of certain components. Refer to specific application drawings for location. This section will show only the attachment of these components to the Max-A-Form panel. A. Attach components With panels laying skin plate down on sleepers, establish location of components on panel. Attach the following components in accordance with Figures. PC 40260 - MF Header Bracket R/H C. Attach Forms Max-A-Form panels may be employed as deck panels. However, due to the limited widths of the Max A Form panels, layouts must be produced to illustrate the corner condition used and to incorporate the proper gap (4" to 8") for installation of the slip plate. Refer to specific application drawings and Symons Technical Services for this condition. Place deck panels in accordance with form layout drawings. This will result in a 4" to 8" gap typically at center of deck, although this gap may occur at any point on the flat area of the deck. The gap is covered using the Deck Slip Plate which is furnished in 3'-0, 4'-0, 6'-0 and 8'-0 lengths. The Slip Plate is secured to the header using two Aluminum Beam Clamps (PC 36502) and ½" x 2½" Bolts (PC 49971) with ½" Nuts (PC 31411) to sandwich the flange on the Slip Plate to the flange on the header. See Figures 5 and 6. Securing the Slip Plate to the header, when using Max A Form as deck panels, is accomplished with the Versiform Clip Rod (PC 33265), Channel Aligner Bracket (PC 33747) and 5 8" Fit-Up Nut (PC 36085). PC 40261 - MF Header Bracket L/H PC 40275 - MF Header Connector PC 40292 - MF Wheel/Jack Bracket - R/H PC 40293 - MF Wheel/Jack Bracket L/H PC 40270 - Wheel Bracket PC 40271 - Jack Bracket PC 40272 - Adjustable Jack PC 40273 - Swivel Wheel B. Raise Side Panels With components installed and bolts fully tightened, Max-A-Form side panels may be raised and braced in vertical position to allow attachment of headers and horizontal adjustable braces. Following completion of these steps the unit is self-standing and aligner angles and deck panels may be installed. Install diagonal braces at prescribed locations and the traveling unit is ready for installation of deck panels. Fig. 5 Fig. 6

Max A Form Box Culvert Application Guide 3 D. Max-A-Form with Steel Ply When using the Max-A-Form panels with Steel-Ply panels at the deck a condition may exist which requires additional support for the Steel-Ply panels at the corners. This depends on the specific corner panel being used and must be addressed when application drawings are being prepared. An example of this is shown in Figure 7. Load conditions at this detail will dictate whether or not additional support is required, refer to specific application drawings for recommendations. Fig. 7 IV. Traveler Operation This section deals with basic setting and stripping procedures and recommendations for the Box Culvert Traveler. Regardless of the form system being used, the setting and stripping operation is identical. It should be noted that prevailing job conditions and contractor preference must always be considered and may require or demand a change in sequence or method. In any case, sound, safe construction practices must always be employed. A. Setting A prerequisite to setting is the casting of an invert or slab. This is accomplished utilizing conventional methods, in most cases with a wood system. The starter wall may be formed using 2 x 6 lumber, which will create a 5½" high starter wall. It is recommended the invert be contructed several pours out before using the Box Traveler in order to take advantage of the efficiency and speed of the system. 1. Move traveler and forms into position at construction joints. It may be necessary to take up on horizontal braces to obtain clearance at starter wall. With traveler still on wheels, extend horizontal braces until form face is just short of contacting starter wall. Do not force against starter wall at this time. Check alignment of deck panels across gap at slip plate. If form/traveler is racked, alignment can be attained by attaching the Diagonal Strut Backet to the OCA on one side to the OCA at the opposing side and actuating the strut to pull forms into alignment. It may be necessary to extend jacks at 2 or 3 uprights to keep one side of traveler stationary. 2. With forms aligned at ends, reinstall Diagonal Strut at proper location and extend lower horizontal struts to place form face against starter wall. 3. Using leading end jacks, trailing end jacks, and an intermediate jack, raise form to proper height. Hydraulic jacks, if available, may be used in lieu of screw jacks and placed beneath wheel or jack brackets for this operation. With form positioned to proper height, remaining jacks may be hand cycled to contact invert slab. Hydraulic jacks, if used, may now be removed. 4. Side forms can now be squared and plumbed using the Diagonal Strut in conjunction with upper horizontal brace. With this unit squared and plumbed, the outside forms of adjoining barrels may be spaced properly off this unit.

4 Max A Form Box Culvert Application Guide 5. Position slip plates at deck panels and secure as discussed in Section III. 6. Check that all jacks are in contact with invert slab, form is in contact with starter wall, and all pin and bolt connections are secure. Unit is ready for tie and bulkhead installation. NOTE 1: If starter wall is not used, setting at lower sections of form becomes more critical. This condition will be included in the application drawings for this specific condition. V. Application Details A. Corner Conditions 1. Figures 8 and 9 show various corner conditions utilizing standard rentable components of the Max A Form and Steel Ply systems with the Box Culvert Traveler and associated components. Non-standard corner details which require special or custom panels can be furnished by Symons. Contact your Symons representative for these situations. NOTE 2: If overhead reshore system is used, refer to Section V for details. B. Stripping 1. Remove ties and bulkheads. 2. Outside forms may be stripped and moved ahead at any time. 3. Loosen nuts at header connection at slots. Do not remove bolts or nuts. 4. Raise all jacks at Wheel andjack Backets to the point they will still clear slab when traveler is lowered to wheels. There is an access hole at each Wheel and Jack Bracket to allow use of a 1¼" socket and extension with ratchet or impact wrench to cycle jacks. 5. Check that all wheels are in the traveling position. 6. Remove pin at upper end of Diagonal Struts and allow strut to lean against form. Fig. 8 7. Beginning at lower leading end horizontal brace, take up on brace to begin collapsing traveler at sides generally 1" clear at each side is sufficient. Next take up on the two (2) upper braces to approximate the same clearance at top of form. Return to next lower brace and do same. Form will begin to lower itself along the walls. Repeat this procedure at all braces until form is completely clear of concrete. Additional clearance, if needed, may be obtained by further take-up on struts. Form and traveler may now be rolled ahead for cleaning and presetting operations. It is important to note that due to the large diameter of the traveler wheels most form and traveler units are able to be hand rolled using 4 to 6 workers. Crane or power tugging devices may be attached if desired, but should be attached to a structurally sound area and rigged to prevent eccentric forces. Fig. 9

Max A Form Box Culvert Application Guide 5 2. Some culvert specifications incorporate fillet conditions at the invert corners. In such cases, it may become necessary to move the Wheel or Jack Bracket outward in order to place jack and wheel on flat portion of invert slab. This is the purpose of the Fillet Wheel/Jack Adapter - PC 40269 shown in Figure 12. Not coincidentally, it may also become necessary to relocate Wheel or Jack Bracket downward so that forms and traveler will clear the top of the fillet during stripping and traveling. The Fillet Wheel/Jack Adapter is furnished with hole spacing to accomodate several variations in height. Corner fillets of 6" or less do not require this application. Refer to specific application drawings for exact hole locations and configuration. Fig. 10 Fig. 12 Fig. 11

6 Max A Form Box Culvert Application Guide 3. Figure 13 shows the Fillet Wheel/Jack Adapter used to adjust the dimensional relatioship between the bottom of the forms and the wheel base. Due to the limited panel widths, it is not always possible to maintain the ideal 4" from slab to form bottom. This application allows some adjustability which could eliminate the need for additional fillers or job built fill panels. Refer to specific application drawings for exact hole location and configuration. B. Single Barrel Conduit A single barrel conduit schematic illustration is shown in Figure 14. Squaring and plumbing of the inside form using the Diagonal Strut will provide alignment for outside forms. Fig. 14 C. Multiple Barrel Conduit A multiple barrel conduit schematic illustration is shown in Figure 15. Squaring and plumbing of the inside form at the outboard barrels only will provide alignment for outside forms and adjoining barrels. Fig. 13 In multiple barrel configurations it may be possible to eliminate diagonal struts at inward barrels. However, this is dependent on prevailing job conditions and contractor preference. Fig. 15

Max A Form Box Culvert Application Guide 7 D. Overhead Reshore System Quite often, the specifications of Box Culverts require the deck to be supported or shored for a certain period of time to allow the concrete to gain sufficient strength. Rather than leave the entire form system in place to accomplish this, a reshore system utilizing extra slip plates may be employed. Figure 16 illustrates the basic equipment required for this reshore system. As shown in the illustration, this consists of using 50k taper ties threaded into the welded 1" dia. coil nut on the slip plate. Versiform walers are used as the top supporting member blocked up off the concrete roof at locations directly above the walls. The taper ties are inserted in the slip plates prior to pouring the conduit. When the concrete has attained sufficient strength, the blocking and walers are set in place and the taper ties are secured to the walers. Once in place, the inside form unit, with the slip plate left behind, can be moved. Obviously, this requires additional sets of slip plates. Welded nuts are located on the slip plates at various centers depending on the length of the slip plate. However, the spacing of the overhead support system must be furnished by the construction project engineer or contractor. Each project differs with respect to concrete mix, weather, jobsite conditions and other factors, and only the project engineer or contractor s engineering representative can specify this spacing. Symons Engineering must check loading on the Versiform walers after this spacing has been provided. NOTE: For special items consult your representative for pricing and design analysis. Fig. 16

8 Max A Form Box Culvert Application Guide VI. Wall Ties A. Industry Standards Wall ties must be in compliance with industry standards and safe practices established by the American Concrete Institute, The American National Standards Institute, The Occupational Safety and Health Administration and The Scaffolding, Shoring and Forming Institute. The following note applies to all Wall-tie applications. A 2.0 to 1.0 Safety Factor is required for all form work. Fig. 17 B. Load Capacities Symons project drawings indicate safe load capacities of taper ties and she-bolt assemblies, when both outer unit and inner ties are supplied by Symons. C. Concrete Pressure It is the contractor s responsibility to control concrete mix and placement procedure to assure that the maximum formwork design pressure is not exceeded. Clamps flat washers to walers J-Strongback Rod Clamps D. Tie installation precautions: 1. Be sure that the correct thread size hex nut or cast contour nut is mated to all taper tie or she-bolt out-unit threads. 2. Be sure that the inner ties engage full thread depth in all she-bolts. Full thread engagement is noted as dimension (E) on the illustration of she-bolt capacities and thread dimensions. Fig. 18 3. Be sure that all ties using hex nuts with Cast Bearing Washers or flat washers are installed perpendicular to both form faces. Hex nuts installed on ties not perpendicular to the form face are subject to eccentric loading that can cause tie failure.

Max A Form Box Culvert Application Guide 9 E. Non-Perpendicular Ties Batter Plate Castings, with mating Cast Contour Nuts, should be installed to support ties that are not perpendicular to the form face (Figure 20). F. Initial impact release of embedded taper ties: 1. Taper-tie Hammering Caps (Figure 19) are available in two sizes: 1" contour thread, or 1¼" contour thread. 2. The correct diameter and thread-type Hammering Cap must be utilized during initial impact release of embedded taper ties. 3. The Hammering Cap is positioned at the smaller diameter end of the taper tie. The protruding end of the Hammering Cap is then struck with an 8 lb. or heavier sledge-hammer. All mushrooming type impact damage is accumulated at the end of the Hammering Cap, rather than the butt end of the taper tie so as not to damage tie threads. Fig. 20 96K Taper Tie or 85K She-Bolt Contour Threaded Nut Fig. 21 Fig. 19

10 Max A Form Box Culvert Application Guide

Safety Information Improper Use of Concrete Forms and Shores Can Cause Severe Injury or Death Read, understand and follow the information and instructions in this publication before using any of the Dayton Superior concrete accessories displayed herein. When in doubt about the proper use or installation of any Dayton Superior concrete accessory, immediately contact the nearest Dayton Superior Service Center or Technical Service Department for clarification. Dayton Superior products are intended for use by trained, qualified and experienced workmen only. Misuse or lack of supervision and/or inspection can contribute to serious accidents or deaths. Any application other than those shown in this publication should be carefully tested before use. The user of Dayton Superior products must evaluate the product application, determine the safe working load and control all field conditions to prevent applications of loads in excess of a product s safe working load. Safety factors shown in this publication are approximate minimum values. The data used to develop safe working loads for products displayed in this publication are a combination of actual testing and/or other industry sources. Recommended safe working loads given for the products in this publication must never be exceeded. Worn Working Parts For safety, concrete forms must be properly used and maintained. Concrete products shown in this publication may be subject to wear, overloading, corrosion, deformation, intentional alteration and other factors that may affect the device s performance. All reusable products must be inspected regularly by the user to determine if they may be used at the rated safe working load or should be removed from service. The frequency of inspections depends upon factors such as (but not limited to) the amount of use, period of service and environment. It is the responsibility of the user to schedule inspections for wear and remove the hardware from service when wear is noted. Shop or Field Modification Welding can compromise a product s safe working load value and cause hazardous situations. Knowledge of materials, heat treating and welding procedures is necessary for proper welding. Consult a local welding supply dealer for assistance in determining required welding procedures. Since Dayton Superior cannot control workmanship or conditions in which modifications are done, Dayton Superior cannot be responsible for any product altered in the field. Interchangeability Many concrete products that Dayton Superior manufactures are designed as part of a system. Dayton Superior strongly discourages efforts to interchange products supplied by other manufacturers with components supplied by Dayton Superior. When used properly, and in accordance with published instructions, Dayton Superior products have proven to be among the best designed and safest in the industry. Used improperly or with incompatible components supplied by other manufacturers, Dayton Superior products or systems may be rendered unsafe. Installation WARNING 1. Dayton Superior Corporation products shall be installed and used only as indicated on the Dayton Superior Corporation installation guidelines and training materials. 2. Dayton Superior Corporation products must never be used for a purpose other than the purpose for which they were designed or in a manner that exceeds specific load ratings. 3. All instructions are to be completely followed to ensure proper and safe installation and performance 4. Any improper misuse, misapplication, installation, or other failure to follow Dayton Superior Corporation s instruction may cause product malfunction, property damage, serious bodily injury and death. THE CUSTOMER IS RESPONSIBLE FOR THE FOLLOWING: 1. Conformance to all governing codes 2. Use of appropriate industry standard hardware 3. The integrity of structures to which the products are attached, including their capability to safely accept the loads imposed, as evaluated by a qualified engineer. SAFETY INSTRUCTIONS: All governing codes and regulations and those required by the job site must be observed. Always use appropriate safety equipment Design Changes Dayton Superior reserves the right to change product designs, rated loads and product dimensions at any time without prior notice. Note: See Safety Notes and Safety Factor Information.