Safety Notes and Product Application

Dayton Superior strives to ensure that all products supplied from its manufacturing plants meet or exceed the safety requirements inherent in the proper use of its products. However, the performance of a product can be greatly affected by the manner in which the product is used. It is imperative that the user be instructed in the proper installation and use of the products displayed in this handbook prior to job application. Product production runs are constantly sampled and tested to assure the user a high standard of quality. Samples are tested in Dayton Superior test facility or at independent testing laboratories. The safe working loads listed in this handbook were determined from the results of the testing programs and other sources. The safety factor to be applied to a particular product is a variable dependent on the degree of hazard or risk involved in the application of the product. Job site conditions can often increase the degree of risk. Concentrated loads, such as construction materials stacked on the formwork, unsymmetrical placement of concrete, uplift, impact of machine delivered concrete, use of motorized carts, and formwork height, are examples that produce high risk factors. The user must adjust the safety factors accordingly to accommodate these risks. Dayton Superior publishes the safe working loads and the associated minimum safety factors of its products and strongly advises that the minimum safety factors displayed in the table below not be compromised. When there are unusual job conditions, such as mentioned above, the minimum safety factors must be increased by the user. Refer to the provisions of the American National Standards Institute (ANSI A 10.9), the Occupational Safety and Health Administration (OSHA) Act, Part 1910 and 1926 and the American Concrete Institute (ACI) Recommended Practice for Concrete Formwork (ACI 347) when considering product safety factors. Minimum Safety Factors of Formwork Accessories
Accessory
Form Tie Form Anchor Form Anchor Form Hangers Anchoring Inserts
(Used as Form Ties)

Safety Factor
2.0 to 1 2.0 to 1 3.0 to 1 2.0 to 1 2.0 to 1 All applications.

Type of Construction

Formwork supporting form weight and concrete pressures only. Formwork supporting form weight, concrete, construction live loads and impact. All applications. Precast concrete panels when used as formwork

Dayton Superior Technical Services

Dayton Superior maintains two strategically located technical service departments that are well staffed with trained personnel to service inquiries, take-offs and details for the users of Dayton Superior quality bridge deck accessories. See the back cover for addresses and phone numbers.

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Safe Working Load Considerations
All safe working loads shown in this handbook were established with the following factors considered:
1. All safe working loads shown in this handbook are based on the item being new or in as new condition. The safe working load is considered to be the greatest load that should be applied to a product. 2. All hangers shall have full bearing under the end section and shall be used only on the size beam for which they are manufactured. 3. Hangers must be correctly positioned on top of the beam so that the Coil Bolts or Coil Rods are the proper distance from the edge of the beam flange. This is normally 38" from the beam flange to the centerline of a 12" Coil Bolt or Coil Rod. Improper positioning of the hanger can seriously compromise the hangers safe working load. Refer to the various product application sketches in this handbook. 4. Coil Nuts must have full bearing on hanger end sections. Use caution to ensure that the hangers and related hardware are not subjected to side loading. 5. All Coil Bolts, Coil Rods and related hardware shall be of proper length, diameter and capacity. 6. All Coil Bolts and Coil Rods must fully penetrate and extend through the Coil Nuts a minimum of one diameter (12" for a 12" diameter Coil Bolt or Coil Rod). Note sketch. 7. A qualified person must calculate all hanger and bracket live and dead loads. Refer to American Concrete Institute ACI 347. 8. When hangers and related items are electro-plated or hot-dip zinc galvanized, they must be properly baked to relieve hydrogen embrittlement. Failure to do so may result in a drastic reduction of the products safe working load. 9. Extreme caution must be used when field welding. Welding may reduce material integrity and result in product failure. Dayton Superior recommends the use of a certified welder with a good working knowledge of materials, heat treatment and welding procedures. Since Dayton Superior is not able to control field conditions or workmanship, Dayton Superior DOES NOT guarantee any product altered after leaving the factory. 10. Impact wrenches are not to be used to tighten Coil Bolts or Coil Rods that are part of the bridge deck forming system.
One Bolt Dia. Minimum

The user of Dayton Superior products must evaluate the product application, determine the appropriate safety factor, calculate the applied loads and control all field conditions to prevent application of loads in excess of the products safe working loads.

Hanger Considerations When Suspending Overhang Brackets

Dayton Superior recommends that interlock type hangers, i.e., a C-60 Type 4-A Pres-Steel Hanger, be used to suspend bridge overhang brackets when a finishing machine is supported on the overhang formwork. The user shall install the overhang brackets, hangers and form materials in such a manner that the Coil Bolts or Coil Rods make a 45 5 angle with the top surface of the bridge beam. Qualified personnel must accurately calculate the hanger and overhang bracket spacing so that the applied load passing through the Coil Bolt or Coil Rod is equal to, or less than the safe working load of the hanger. Interior span loads must be calculated to determine the proper hanger spacing. When calculating interior span loads, always add a minimum of 50 pounds per square foot live load to the dead weight of the concrete.

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Safety Concerns
Incorrect use of hangers; insufficient bolt penetration through a coil nut; or altering a hanger in any way can result in premature failure and expose workers to unsafe conditions. Reusable bridge deck forming accessories such as coil bolts, coil rods, etc., are subject to wear, misuse, overloading, corrosion, deformation, alteration and other factors that may affect safe working loads. It is the responsibility of the user to continually inspect reusable accessories for wear and/or misuse and to discard them if wear or misuse is detected. Do not straighten bent forming accessories discard them. Discard any reusable forming accessory that has been subjected to 70% or more of ultimate load of the product. Such items may have been stretched to a point where they have become brittle hard. Dayton Superior recommends that all users of Dayton Superior deck forming products establish a quality control program to monitor and inspect their deck forming accessories. The frequency of inspections is best determined by the user and is dependent on the type of product use, frequency of use, duration of use and the environmental conditions during use. The user of Dayton Superior products must evaluate the product application, determine appropriate safety factor, calculate the applied loads and control all field conditions to prevent application of loads in excess of the products safe working loads.

Vertical Load for Design of Slab Forms

DESIGN LOAD Based on 150 lbs. per Cubic Foot Concrete Slab Thickness, Inches Pounds per Square Foot (See Note 1) 2 75 4 100 6 125 8 150 10 175 12 200 14 225 16 250 18 275 20 300

Pounds per Square Foot 100 125 150 175 200 225 250 275 300 325 (See Note 2) Note 1: Includes weight of concrete and reinforcing steel plus construction live load of 50 psf; weight of formwork not included. Note 2: Includes weight of concrete and reinforcing steel plus construction live load of 75 psf; weight of formwork not included.

The American Concrete Institute publication, Recommended Practice for Concrete Formwork, (ACI 347) recommends that a minimum live load of 50 pounds per square foot (psf) be used in calculating formwork design loads. However, several states require higher live loads. The American Concrete Institute publication, Formwork for Concrete (ACI SP-4) is a good reference for general formwork design, planning, materials, accessories, loading and pressure information, design tables and much more. Available from American Concrete Institute, P.O. Box 9094 Farmington Hills, MI 48333.

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Technical Data Plywood
Data based on information supplied by the American Plywood Association. For plywood used with face grain parallel to spacing, the tabulated spacings may be used with Plyform Class 1, Structural 1, Exterior A-B, Exterior B-B, Exterior B-C or equivalent grades of plywood. For face grain perpendicular to spacing, tabulated spacings are suitable only for use with Plyform Class 1 or Structural 1 grades or their equivalent.
Safe Spacing in Inches of Support for Plywood Sheathing, Continuous Over Three or More Spaces Design Load of Concrete Pounds per Square Foot f = 1,900 psi; Rolling Shear = 72 psi E = 1,500,000 psi Sanded, Face Grain Parallel to Spacing
1 2"

Sanded, Face Grain Perpendicular to Spacing

1 2"

(3 Ply) (5 Ply) (5 Ply) (5 Ply) (3 Ply) (5 Ply) (5 Ply) (5 Ply)

5 8"

3 4"

1"

5 8"

3 4"

1"

75 20" 23" 100 18" 21" 125 16" 20" 150 15" 18" 175 15" 17" 200 14" 17" 225 13" 16" 250 13" 15" 275 12" 15" 300 12" 15" Maximum deflection is l
Support Spacing Joists

26" 24" 23" 21" 20" 19" 18" 17" 17" 17" /360,

31" 10" 14" 29" 9" 13" 27" 8" 12" 26" 8" 11" 25" 7" 10" 24" 7" 10" 23" 7" 10" 23" 7" 10" 22" 6" 9" 22" 6" 9" but not more than

18" 17" 15" 14" 14" 13" 13" 12" 11" 11" 1 16 " .

25" 23" 22" 21" 20" 19" 18" 17" 16" 16"

Plywood

Plywood used the strong way (Face Grain parallel to spacing)

Support = Spacing

Support = Spacing

Support = Spacing

Safe Spacing in Inches of Support for Plywood Sheathing, Single Spacing Design Load of Concrete Pounds per Square Foot f = 1,900 psi; Rolling Shear = 72 psi E = 1,500,000 psi Sanded, Face Grain Parallel to Spacing
1 2"

Sanded, Face Grain Perpendicular to Spacing

1 2"

Support = Spacing

(3 Ply) (5 Ply) (5 Ply) (5 Ply) (3 Ply) (5 Ply) (5 Ply) (5 Ply)

5 8"

3 4"

1"

5 8"

3 4"

1"

Plywood used the weak way (Face Grain perpendicular to spacing)

Plywood Data
Thickness Approximate Weight lbs. 4x8 Sheet
1 2" 5 8" 3 4"

Plies

Minimum Bending Radii Across Parallel Grain to Grain

Square Foot 1.5 1.8 2.2 3.0 3 5 5 5

75 16" 100 14" 125 13" 150 12" 175 12" 200 11" 225 10" 250 10" 275 10" 300 10" Maximum deflection

19" 22" 17" 20" 16" 18" 15" 17" 14" 16" 14" 16" 12" 15" 12" 14" 12" 14" 12" 14" is l /360, but

26" 8" 11" 25" 7" 10" 23" 7" 9" 22" 6" 9" 21" 6" 8" 20" 6" 8" 19" 6" 8" 18" 6" 8" 18" 5" 7" 18" 5" 7" not more than 1 16 ".

15" 13" 12" 12" 11" 11" 10" 10" 9" 9"

21" 19" 18" 17" 16" 15" 14" 14" 14" 13"

1"

48 58 70 96

6 Ft. 8 Ft. 12 Ft.

12 Ft. 16 Ft. 20 Ft.

Plywood

Joists

= Support Spacing

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Technical Data Joists

Spacing of Joists Support Spacing

Safe Spacing, Inches, of Supports for Joists, Continuous Over Three or More Spans Based on use of No. 2 Grade Southern Pine or Douglas Fir-Larch F'b varies with member E' = 1,400,000 psi F'v = 225 psi Uniform Load, Pounds per Nominal Size Lumber, bxh (S4S) 19% Maximum Moisture Content Linear Foot (Equals Design Load, Pounds per 2x4 2x6 2x8 4x2 4x4 Square Foot Times Fb psi Spacing of Joists in feet.) 1625 1440 1310 1790 1625
75 100 125 150 175 200 225 250 275 300 325 350 375 400 450 500 550 600 81" 76" 69" 63" 58" 55" 52" 49" 47" 45" 43" 42" 40" 39" 36" 35" 33" 32" 114" 106" 100" 93" 86" 81" 76" 72" 69" 66" 63" 62" 59" 57" 54" 51" 49" 47" 140" 131" 124" 117" 109" 102" 96" 91" 87" 83" 80" 77" 74" 72" 68" 64" 61" 59" 49" 45" 41" 39" 37" 35" 34" 33" 32" 31" 29" 29" 27" 27" 25" 24" 23" 22" 100" 93" 88" 84" 81" 79" 76" 74" 71" 68" 65" 64" 61" 59" 56" 53" 50" 48"

6x2 1650
57" 52" 48" 45" 43" 41" 40" 38" 37" 36" 35" 34" 33" 32" 30" 29" 27" 26"

Note: F'b and F'v shown above includes a 25% increase because of short term loading conditions. Horizontal shear stress adjustment assumes members have no splits, checks or shakes. Support spacings are governed by bending, shear or deflection. Maximum deflection is l /270 of spacing, but not more than 14". Contact Dayton Superior for Spacing of Joists safe spacings of supports for joist or studs used over two spans.

Support Spacing

Safe Spacing, Inches, of Supports for Joists, Single Span Based on use of No. 2 Grade Southern Pine or Douglas Fir-Larch Uniform Load, Pounds per Linear Foot (Equals Design Load, Pounds per Square Foot Times Spacing of Joists in feet.)
75 100 125 150 175 200 225 250 275 300 325 350 375 400 450 500 550 600

F'b varies with member E' = 1,400,000 psi F'v = 225 psi Nominal Size Lumber, bxh (S4S) 19% Maximum Moisture Content 2x4 1625
69" 64" 59" 56" 52" 49" 46" 44" 42" 40" 38" 37" 36" 35" 33" 31" 29" 28"

2x6 1440
97" 91" 86" 82" 77" 72" 68" 65" 62" 59" 57" 55" 53" 51" 48" 46" 44" 42"

2x8 Fb psi 1310

120" 111" 105" 101" 97" 91" 86" 81" 78" 74" 71" 69" 66" 64" 61" 58" 55" 52"

4x2 1790
40" 36" 34" 32" 30" 29" 28" 27" 26" 25" 24" 24" 23" 23" 22" 21" 20" 19"

4x4 1625
86" 80" 75" 72" 69" 67" 64" 62" 60" 59" 57" 56" 54" 53" 50" 47" 45" 43"

6x2 1650
46" 42" 39" 37" 35" 33" 32" 31" 30" 29" 28" 28" 27" 27" 25" 25" 24" 23"

Note: F'b and F'v shown above includes a 25% increase because of short term loading conditions. Horizontal shear stress adjustment assumes members have no splits, checks or shakes. Support spacings are governed by bending, shear or deflection. Maximum deflection is l /270 of spacing, but not more than 14". Contact Dayton Superior for safe spacings of supports for joist or studs used over two spans.
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Technical Data Ledgers
Supports

rt Suppo g Spacin

Spacing of Ledgers

Safe Spacing, Inches, of Supports for Double Ledgers, Single Span Based on use of No. 2 Grade Southern Pine or Douglas Fir-Larch
Uniform Load, Pounds per Linear Foot (Equals Design Load, Pounds per Square Foot, Times Spacing of Ledgers in feet.)
600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 3200 3400 3600 3800 4000

F'b varies with member 2x4 1625

40" 35" 31" 28" 26" 24" 23" 22" 21" 20" 19" 18" 18" 17" 17" 16" 16" 15"

E' = 1,400,000 psi

F'v = 225 psi 2x12 1090

105" 91" 81" 74" 69" 64" 61" 58" 55" 53" 50" 49" 47" 45" 44" 43" 42" 41"

Nominal Size Lumber, bxh S4S 19% Maximum Moisture Content 2x6 2x8 2x10 Fb psi 1440
59" 51" 46" 42" 39" 36" 34" 32" 31" 30" 28" 27" 26" 26" 25" 24" 23" 23"

1310
74" 64" 58" 52" 49" 45" 43" 41" 39" 37" 36" 34" 33" 32" 31" 30" 29" 29"

1150
89" 77" 69" 63" 58" 54" 51" 49" 46" 44" 43" 41" 40" 38" 37" 36" 35" 34"

Note: F'b and F'v shown above includes a 25% increase because of short term loading conditions. Horizontal shear stress adjustment assumes members have no splits, checks or shakes. Support spacings are governed by bending, shear or deflection. Maximum deflection is l /270 of spacing, but not more than 14". Contact Dayton Superior for safe spacings of supports for joist or studs used over two spans.

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Technical Data Lumber

XX = Neutral Axis

X b

Lumber Properties
Nominal Size in Inches, bxh American Standard Sizes in Inches, bxh S4S* 19% Maximum Moisture 312
3 4

Area of section A = bh, sq. in. Rough S4S 2.62 4.12 5.44 6.94 8.44 5.25 8.25 10.87 13.87 16.87 5.25 8.25 10.87 13.87 16.87 8.75 13.75 18.12 23.12 28.12 12.25 19.25 25.38 32.38 13.75 19.25 30.25 41.25 56.25

Moment of Inertia, in.4 bh3 I = 12 Rough 0.20 0.31 0.41 0.52 0.63 1.30 2.01 2.64 3.35 4.07 6.45 24.10 54.32 111.58 199.31 10.42 38.93 87.74 180.24 321.96 14.39 53.76 121.17 248.91 8.48 22.33 83.43 207.81 281.69 S4S 0.12 0.19 0.25 0.32 0.39 0.98 1.55 2.04 2.60 3.16 5.36 20.80 47.63 98.93 177.97 8.93 34.66 79.39 164.89 296.63 12.50 48.53 111.15 230.84 7.16 19.65 76.26 193.36 263.67

Section Modulus, in.3 bh2 S= 6 Rough 0.46 0.72 0.94 1.20 1.45 1.60 2.48 3.25 4.13 5.01 3.56 8.57 14.73 23.80 35.04 5.75 13.84 23.80 38.45 56.61 7.94 19.12 32.86 53.10 6.46 12.32 29.66 54.51 73.89 S4S 0.33 0.52 0.68 0.87 1.05 1.31 2.06 2.72 3.47 4.21 3.06 7.56 13.14 21.39 31.64 5.10 12.60 21.90 35.65 52.73 7.15 17.65 30.66 49.91 5.73 11.23 27.73 51.56 70.31

Board Feet per Linear Foot of Piece

1 3 1 2 2 3 5 8

4x1 x 3.17 6x1 512 x 34 4.92 8x1 714 x 34 6.45 10x1 914 x 34 8.20 12x1 1114 x 34 9.95 4x2 312 x 112 5.89 6x2 512 x 112 9.14 8x2 714 x 112 11.98 10x2 914 x 112 15.23 12x2 1114 x 112 18.48 2x4 112 x 312 5.89 2x6 112 x 512 9.14 2x8 112 x 714 11.98 2x10 112 x 914 15.23 2x12 112 x 1114 18.48 3x4 212 x 312 9.25 3x6 212 x 512 14.77 3x8 212 x 714 19.36 3x10 212 x 914 24.61 3x12 212 x 1114 29.86 4x4 312 x 312 13.14 4x6 312 x 512 20.39 4x8 312 x 714 26.73 4x10 312 x 914 33.98 6x3 512 x 212 14.77 6x4 512 x 312 20.39 6x6 512 x 512 31.64 6x8 512 x 712 42.89 8x8 712 x 712 58.14 *Roughdry sizes are 18" larger, both dimensions.

1
2 3

1 112 123 2
2 3

1 113 123 2 1 112 2 212 3 113 2 223 313 112 2 3 4 513

Properties of American Standard Board, Plank Dimension and Timber Sizes Commonly used for Formwork Construction. Based on data supplied by the National Forest Products Association.

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Representative Working Stress Values (PSI) for Lumber at 19 Percent Moisture Content, Continuing or Prolonged Reuse
LUMBER SPECIES AND GRADE PROPERTIES Extreme Compression _ Compression || Horizontal Fiber To Grain To Grain Shear Bending
225-2025 1385 825 275-2250 1350 1000 275-1875 1310 1000 250-2100 1275 975 275-2050 1300 1000 85%** 25% 425-650 650 425 625 625 625 425 425 425 405 405 405 565 565 565 67% 0% 475-2250 1425 925 900-2550 2025 1650 750-2100 1725 1400 850-2250 1950 1550 950-1800 1650 1700 80% 25% 160

Modules of Elasticity
800,000-1,400,000 1,200,000 900,000 1,300,000-1,900,000 1,600,000 1,500,000 1,100,000-1,500,000 1,400,000 1,300,000 1,100,000-1,600,000 1,300,000 1,300,000 1,100,000-1,600,000 1,400,000 1,300,000 90% 0%

REDWOOD Range, all grades No. 2, 4x4 and smaller Constr., 4x4 and smaller DOUGLAS FIR-LARCH Range, all grades No. 2, 4x4 and smaller Constr., 4x4 and smaller SPRUCE-PINE-FIR Range, all grades No. 2, 4x4 and smaller Constr., 4x4 and smaller HEM-FIR Range, all grades No. 2, 4x4 and smaller Constr., 4x4 and smaller SOUTHERN PINE Range, all grades No. 2, 4x4 and smaller Constr., 4x4 and smaller ADJUSTMENT FOR MOISTURE CONTENT GREATER THAN 19 PERCENT: Use percentage shown (also applies to wood used wet) INCREASE FOR LOAD DURATION OF 7 DAYS OR LESS

190

140

150

180 97%* 25%

Note: Derived from National Design Specifications for Wood Construction. Horizontal Shear Stress adjustment assumes members have no splits checks or shakes.

*When (Fb)(Cf) < 1150 psi, Cm =1.0 = **When (Fc)(Cf) < 750 psi, Cm =1.0 =

Formulas Used to Calculate Safe Support Spacings of Joists and Ledgers

10

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Technical Data Welding of Half Hangers

Several styles of Half Hangers are manufactured by Dayton Superior for use in special cases requiring one-sided forming. Half Hangers may generally be welded to structural steel beams or rebar stirrups, however, preheat and other quality control procedures may be required in order to develop a sound weld. It is recommended that the user contact his local welding supply dealer for assistance in determining the required welding procedures.
Half Hanger A
1 2" Minimum

Fillet Weld Both Sides of Strut Wire

Warning: Since welding may alter the wire strut or rebar stirrup, the charts shown below should only be used as a general guide in determining the approximate strength of the welded connection. Field tests should be performed on installed Half Hangers so that actual safe working loads may be established, since actual safe working loads may be less than the maximum safe working loads shown in this handbook. Failure to perform field tests may result in premature and unexpected failures. h Fillet Weld Size
/" / " 1/ 4" 5/ 16" 3/ 8" 7/ 16"
1 8 3 16

Structural Steel Beam

Safe Working Load Per Linear Inch of Weld

1,500 2,300 3,100 3,900 4,700 5,500 lbs. lbs. lbs. lbs. lbs. lbs.

Fillet Weld

Half Hanger Strut Wire h

Section A
Flare-V-Groove Weld Half Hanger B Rebar Stirrup

on each side of the strut wire. Minimum length of weld is 4 h. The user should add 14" to the weld length for starting and stopping the arc. S.W.L. provides a factor of safety of approximately 2 to 1.

Note: Place half the required length of weld

Rebar Stirrups Flare-V-Groove Weld Half Hanger Strut Wire y x

1 8"

lw
Note: For additional details on welding Pres-Steel Hangers to Rebar stirrups, contact Dayton Superior Technical Service Department.

Section B

Safe Working Load Per Weld

Rebar Stirrup Size #4 #5 #6 w Weld Length
1 2 5 8

.375" Diameter Strut (x = 3/16" Min.) Y Minimum

14

.440" Diameter Strut (x = 7/32" Min.) Grade 40 Stirrup 1,600 lbs. 2,000 lbs. 2,400 lbs. Grade 60 Stirrup 2,100 lbs. 2,600 lbs. 3,100 lbs.

Grade 40 Stirrup 1,350 lbs. 1,700 lbs. 2,050 lbs.

Grade 60 Stirrup 1,800 lbs. 2,200 lbs. 2,650 lbs.

/"

/"

/" 3/ 4"

5 16

/ " 3/8"

Note: Values are based on the use of E70 series electrodes for welding to Grade 40 stirrups and E90 series Electrodes for Grade 60 stirrups. S.W.L. provides a factor of safety of approximately 2 to 1. Reference: Structural Welding Code Reinforcing Steel, American Welding Society, Miami, Florida Standard Specifications for Highway Bridges, American Association of State Highway and Transportation Officials, Washington, D.C. P .C.I. Design Handbook, Edition 4, Chicago, IL. 4-07 11

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Exterior Hangers Spaced at Different Centers from Interior Hangers
X/2 Centers Bridge Overhang Brackets

Exterior Hangers

Exterior Beam

Special Set of Ledgers

Joists and Plywood Omitted For Clarity

Double Ledgers Interior Beam Interior Hangers X Centers

Partial Plan View

Bridge Overhang Brackets and Exterior Hangers at X2 Centers

Double 2X Ledgers at X Centers

Double 2X Ledgers at X Centers Bolt Runs Through Center of Double 2X Ledger

Special Set of Ledgers Parallel to Exterior Beam Bolt Runs Through Center of Span Between Ledgers

Section View A

Section View B

These sketches illustrate one method of supporting the bridge deck formwork when exterior hangers are to be spaced at different centers from the interior hangers. This method requires an additional set of special ledgers which runs parallel to the exterior beam and supports the joist carrying ledgers.

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Notes & Sketches

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