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November 1, 2005

BRIDGE CONSTRUCTION MANUAL

5-393.200

FALSEWORK AND FORMS 5-393.200 (Note: This section uses English units only)
5-393.201 INTRODUCTION The finished appearance of a concrete structure is dependent to a large extent on the forms and falsework used in the concrete construction. Concrete lines and surfaces will usually reflect the degree of care and skill used in the design and construction of the forms and falsework. Unsatisfactory concrete construction due to faulty form and falsework design or construction is very difficult to correct after the concrete is cast. In an extreme case, the result of a faulty design or careless workmanship on the forms and falsework could lead to their collapse during construction operations, with serious consequences. The Department, by its Specifications, has placed certain restrictions on the design and construction of forms and falsework. These restrictions do not prohibit the Contractor from exercising ingenuity in the construction of form details and the economical selection of materials. The Specifications do provide guidelines for forms and falsework that should be safe and that will result in satisfactory concrete lines and surfaces. A. Definitions and Nomenclature Forms are those members (usually vertical) that are required to maintain plastic concrete in its desired shape until it has set up. Forms resist the fluid pressure of the plastic concrete, the additional fluid pressure generated by mechanical vibration of the concrete and the impact of placing the concrete in the forms. Forms may be stripped when the concrete is set up and its fluid pressure is reduced to zero. Falsework is the supporting framework required to maintain a concrete unit in the desired position (when it cannot be supported directly on the ground, as a footing or on previously cast concrete) until the concrete is strong enough to carry its own dead weight. Falsework must be strong enough to carry its own dead weight, the dead weight of the forms and concrete and the live load of construction crews and their equipment. Sheathing used on the underside of a concrete unit, such as sheathing under deck slabs or pier caps, serves the dual purpose of a form and a falsework member but, for design, is classified as a falsework member, as the dead weight of the concrete plus live load is used in the design loading rather than the fluid concrete pressure. Common terminology for members of a falsework pile bent and for a typical form system are shown on Figure A 5393.201. In addition, the following nomenclature will be used in this manual when referring to form lumber: }regardless of how the piece is positioned Side = wider face Edge = narrower face} Dressed or surfaced lumber - lumber which, to attain smoothness has been planed on a planing machine on either one side (S1S), two sides (S2S), one edge (S1E), two edges (S2E) or a combination thereof (including complete planing S4S) Rough timber - lumber which has not been dressed but has been sawn to the extent of showing saw marks on the full width of each of the 4 faces, also described as full sawn lumber. Sized lumber - lumber, either rough or dressed, which is prepared in standard dimension increments, with a plus and minus tolerance assigned to each size. Nominal dimensions - the cross-section dimensions of the piece in inches as a full sawn piece (dimension prior to surfacing). B. Falsework Requirements Usually the need for falsework is self-evident; however, bridge plans often require the construction of some concrete item at or below ground level which has no footing. Typical of these are: 1. 2. 3. cantilevered wingwalls on the abutments, tie beams between concrete walls or between footings, high abutment side walls (or curtain walls) as on box type abutments.

Judgment must then be exercised as to whether the existing soil can adequately support the weight of the concrete without settlement, or if falsework support is necessary. (Note, the falsework referred to is in addition to that which is used to hold sheathing to shape the lower concrete surface, as on the bottom of most abutment wingwalls.) Wingwalls and tie beams can normally be formed directly on the underlying soil, providing that the soil is stable and well compacted. (Beware of plastic soils that will become unstable with rain.) However, the higher abutment sidewalls will usually require falsework and falsework piling when the underlying material is not rock. Specific falsework requirements are given in Specifications 2401.3B4. For certain structures, the special provisions will contain requirements for falsework plans and construction. These requirements are in addition to those contained in construction specifications and this Manual. Forms must be used on all vertical or battered surfaces except the portions of footings that extend into solid rock. Casting concrete against an earth face will not be permitted (see Specifications 2401.3B). One exception to the above is that

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the 1 inch radius required at the front face of sidewalks can normally be shaped with a 1 inch radius edger. However, the 3 inch radius required at the front face of 6 inch high curbs must normally be shaped by a form built to the specified radius since hand shaping of this radius is seldom performed satisfactorily. C. Contractor Responsibilities The Contractor is responsible for the design of all falsework and forms and shall submit detailed plans of the proposed falsework and form construction to the Engineer on request (see Specifications 1502 and 2401.3B). In accordance with these Specifications, all working drawings are subject to review and approval or rejection by the Engineer prior to performance of the work involved. When trying new or untried devices or systems for falsework and/or forms and when using materials with unknown strength properties, it is the Contractors responsibility to verify to the Engineers satisfaction the strength and safety of the device or system and the workability of the device or system as related to the desired end product. This verification has in the past been provided in the form of (a) full scale field tests, (b) tests by a reputable testing laboratory, (c) certified design calculations, (d) manufacturers literature, or a combination of the above items. The Contractor is responsible for constructing the falsework and forms in reasonably close conformity with the approved falsework plans. D. Engineer's (Inspector's) Responsibilities When falsework and/or form plans are requested by the Engineer or required by the Contract, these plans should be reviewed for acceptability as to strength, method of construction, safety, potential problems, and ability to produce the desired finished product. Approval to use such plans should be noted as being approved as to type of construction and should also bear a note that such acceptance is conditional to making changes which the Engineer has noted thereon. When evaluating a new or untried device or system, approval (if given) should be given only on a performance basis. Such approval of plans does not relieve the Contractor of responsibility for results obtained by use of the plans (see Specifications 1502 and Specifications 2401.3B). For certain types of structures, a review by the Contractor's engineer is required prior to acceptance of the completed falsework. The inspector should be present during this review and no use of the falsework should be permitted until this engineer has completed the review and authorized use (normally a written certification is provided). Check the material that will be used for forms and falsework for agreement with sizes, shapes and qualities shown on the Contractors plans. If not in conformance with approved plans, the material must be evaluated as to its ability to

function as intended. information.

See Section 5-393.202 for more

A continuing inspection should be made during placement of form and falsework members to assure conformance with approved plans (if used), to assure structural soundness and accuracy, and to minimize the need for last minute corrections. This inspection is discussed in more detail in Section 5-393.208. Concrete pours are to be made in accordance with approved pour sequences. Where approval of pour sequences is not required, pours should be with the form or falsework design and should provide balanced loading to the extent possible. A follow-up inspection during and after concrete placement should be made to assure that the forms and/or falsework function as intended with regard to deflections, tolerances, etc.

November 1, 2005

BRIDGE CONSTRUCTION MANUAL

Figure A 5-393.201

Bridging

Sheathing

Stringers Pile cap Pile cut off

Drift bolts

Pile cap splice point Corbel

Posts or piles

Sway braces

Bolt, nut and washers

TYPICAL FALSEWORK PILE BENT Concrete strike-off elevation

Upper plate

Chamfer strip

Strongback Wood spreader Waler Form bolt (tie bolt) (tie rod) Sheathing or form lining backed with sheathing

Stud

Tie plate (washer)

Tie cone

Lower plate

CROSS SECTION OF VERTICAL FORMS

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Symbols and Units The following symbols and abbreviations will apply to forms and falsework: psi = pounds per square inch psf = pounds per square foot pcf = pounds per cubic foot

Symbol A B h t w d D E I c S r P p R R1 T v V V1 M f H area width of beam depth of beam thickness of web for steel member uniform load per foot of length least dimension of a column diameter

Description

Units in.2 inches inches inches lb/lin.ft inches inches inches psi in.4 inches in.3 inches lb psf lb ft/hour F psi lb lb inch lb psi psi inches

length (center to center of supports for beam spans; unsupported length for columns) modulus of elasticity moment on inertia distance from neutral axis to extreme fiber section modulus least radius of gyration (for steel columns) concentrated load lateral pressure of concrete reaction at beam support rate or pour for concrete concrete temperature in Fahrenheit at time of placement shear stress shearing force the vertical force causing horizontal shear in a timber beam external bending moment stress in member maximum horizontal shear stress in timber beams deflection

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BRIDGE CONSTRUCTION MANUAL

5-393.202 (1)

5-393.202

FORM AND FALSEWORK MATERIALS

Form and falsework materials described below are listed with either an allowable maximum working stress or a basis for determining safe load. Working stresses, when shown, are based on use of sound material for temporary construction. In general, used material is permitted, provided it is in good condition. The material requirements for falsework piling are stated in Specifications 2401.3B. Maximum allowable pile loads are as follows: Size of Dia. At Cut-Off (inches) Timber (tons) Butts smaller than 8 in. are not permitted 8 10 12 14 16 16 20 24 28 32 16 20 24 28 9000 lb per sqare inch of point area (or least crosssectional area of the pile) Steel Friction (tons) Steel Point Bearing (tons)

General requirements for lumber for falsework and forms are specified in Specifications 2401.3B1c. In addition to these general requirements, it is specifically recommended that material used for studs and walers be sized and dressed to at least S2E to provide for true concrete lines. Lumber that must withstand stress should be checked for conformance with the appropriate allowable stresses shown in the table of Allowable Working Stresses for Design of Wood Forms and Falsework in this section. The following notes apply to use of this table: 1. NEW LUMBER -Each piece of graded lumber is stamped. On new material, information as to timber species and grade or stress rating can be obtained from this stamp for use with the allowable stress table in this section of the manual. USED LUMBER -In the event the mill stamp is missing or eradicated, the species and grade or stress rating must either be determined by visual examination or judgement or an assumed identification must be applied. In case of uncertainty, assume Norway Pine common structural grade to be on the safe side. Regardless of whether new or used lumber will be used, a visual check should be made of stressed members with the following consideration in mind:

2.

3.

Any reduction in section in or near the middle 1/3 of the length of a beam reduces the capacity to resist bending. Such reduction in section could be a damaged area, large knots, notches, or holes in the upper or lower 1/3 of the section. If such pieces are used for beams, only the sound portion of the section can be considered as effective for calculating stresses. Notches or reduction in beam depth near the support point will reduce the beams capacity to resist horizontal shear. Special calculations are necessary to determine the horizontal shear stress when such pieces are used (see Section 5-393.204). When forms or falsework are constructed of used material which is judged to be not equal in strength to sound material, the allowable stresses in the table should be reduced by an appropriate amount. The allowable stresses and modulus of elasticity (E) values listed in the chart below are in accordance with the recommendations of AASHTO Standard Specifications for Highway Bridges. A 25% stress increase has been included in these values (except E values) in view of the anticipated short time loading. Stresses for species or grades not listed below should be obtained from the Office of Bridges and Structures and conform to AASHTO Specifications.

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ALLOWABLE WORKING STRESSES FOR DESIGN OF WOOD FORMS AND FALSEWORK Max. Allowable Fiber Stress, psi Species and Commercial grade Douglas Fir - larch, No. 1 Southern Pine, No. 1 No. 2 Size Classification 2 to 4 in. thick 4 in. thick Bending 1875 1812 1500 Horizontal Shear 120 112 112 Side Bearing 480 506 506 End* Bearing 1562* 1562* 1250* Modulus of Elasticity, E, psi 1,800,000 1,700,000 1,600,000

*The strength of a wood column is dependent on its /d ratio, which must not exceed 50. The allowable stress in a wood column will be either 1. 2. f = the allowable end bearing stress listed in this section for the wood species used
f = 0.30 E l d
2

d = dimension of least side of column

Use whichever allowable stress value is smallest. The maximum allowable compression stress for Douglas Fir columns and Norway Pine columns (as determined by the above criteria) may be obtained from the graph below.

Douglas Fir-Larch 1500 d 1562 psi

Red Pine 1000 Allowable compressive stress for columns, psi 500 1030 psi
No .1
No .1

Gr ad e Gr ade

10

15

20 R/d

25

30

35

40

3.

For convenience in making calculations involving dimension lumber, a tabulation of standard lumber sizes and their respective properties has been included in Figure A 5-393.202.

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5-393.202 (3)

General requirements for plywood sheathing are specified in The plywood sheathing most Specifications 2401.3B. commonly used is Douglas Fir Associations Exterior Plyform, which is available in two strength varieties known as Class I and Class II. Both Classes are fabricated using exterior glue and have sanded grade B face plies. New panels of plyform can be identified by the following trademark stamped on the panels:

Plywood used the strong way (Face ply grains are perpendicular to supports)

B-B PLYFORM
The data in Figure B 5-393.202 may be used for quickly determining the safe spacing of studs or joists using Plyform Class I or Plyform Class II under two different loading conditions. These charts are recommended by the American Plywood Association. The applicable allowable stress values for bending and horizontal shear are shown for each situation.
When the brand name or grade stamp is visible on the plywood being used, the requirements of Specifications 2401.3B can be quickly verified. When no grade stamp is visible, it is the Contractors responsibility to verify to the satisfaction of the inspector that concrete form grade plywood has been furnished.
When it is determined that form grade plywood has been furnished but the specific Class of plywood is unknown, the following limiting stress values will apply:
In considering the bending strength, shearing strength, or deflection of a panel, only those plies have their grain perpendicular to the supporting joist or stud are assumed to be stressed. The safe span length is therefore dependent not only on whether Class I or Class II Plyform is used but also on whether the grain of the face plies runs across supports (perpendicular to the joist or stud), or parallel to supports (parallel to the joists or stud).

CLASS I EXTERIOR
PS 1-66 000

B-B PLYFORM

CLASS II EXTERIOR
PS 1-66 000

Maximum allowable bending stress = Maximum allowable shear stress = Modules of Elasticity = Maximum allowable bearing stress at right angle to the plane of the plywood =

1,500 psi 70 psi 1,600,000 psi

285 psi

Plywood used the weak way (Face ply grains are parallel to supports)

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Plywood section properties, which will be necessary for checking stresses when not using the plyform charts, are tabulated below:

EFFECTIVE SECTION PROPERTIES FOR PLYWOOD (12-IN. WIDTHS)*

Sanded plywood, net thickness, inc.

Number of plies

Effective thickness for shear all grades, using exterior glue

12-in. width, used with face grain perpendicular to supports

12-in. width used with face grain parallel to supports

Area for tension and compression (in.2)

Moment of inertia I (in.4)

Effective section modulus S (in.3)

Rolling shear constant I/Q (in.)

Area for tension and compression (in.2)

Moment of inertia I (in.4)

Effective section modulus S (in.3)

Rolling shear constant I/Q (in.)

1/4 3/8 1/2 5/8 3/4 7/8 1 1 1/8

3 3 5 5 5 7 7 7

0.241 0.305 0.450 0.508 0.567 0.711 0.769 0.825

1.680 1.680 2.400 2.407 2.778 2.837 3.600 3.829

0.013 0.040 0.080 0.133 0.201 0.301 0.431 0.566

0.091 0.181 0.271 0.360 0.456 0.585 0.733 0.855

0.179 0.309 0.436 0.557 0.687 0.704 0.763 0.849

0.600 1.050 1.200 1.457 2.200 2.893 3.323 3.307

0.001 0.004 0.016 0.040 0.088 0.145 0.234 0.334

0.016 0.044 0.096 0.178 0.305 0.413 0.568 0.702

0.215 0.315 0.393 0.531 0.632 0.748

Information from "Plywood Design Specification", American Plywood Association, Tacoma, Washington. Use listed S values in bending calculations, and use I only in deflection calculations.

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5-393.202 (5)

The reuse of plywood sheathing will be dependent on its condition with respect to damage due to prior use, amount of permanent set from prior use, amount of face ply separation, and the nature of the concrete surface being formed (exposed or not exposed, etc.). Plywood that is no longer suitable for its intended purpose must be rejected. Form lining requirements both as to material and usage, are Forms specified in detail in Specifications 2401.3B. incorporating form lining backed by sheathing will be used rarely except in the case of architectural treatment of concrete surfaces. In situations like this, special form lining material requirements will usually be specified in the contract. When angles, channels, wide flange beams, H-piles or other rolled shapes are used in critical portions of the falsework, the section should be identified by making measurements of the depth, width and thickness. These dimensions can then be used to identify the member further by referring to the AISC Steel Construction Manual, where all standard rolled sections are listed along with their dimensions, weights and the necessary design properties. Since this material cannot be visually identified as to grade of steel, the following allowable stress limits should be assumed, unless the Contractor furnishes satisfactory assurance that the steel is of a higher grade. Rolled Steel Shapes (Assume ASTM A36 Steel) Maximum allowable bending stress 25000 psi *Maximum allowable compression stress (columns) =

The increasing use of special devices, (made of material other than wood) for forms and falsework has, in general, resulted in a speed-up of work as well as improved quality of work. However, there is usually a degree of uncertainty about each new device until it is proven in use. A partial listing of devices which have been used both successfully, and in some instances unsuccessfully, is as follows: 1. Wall Form Panels The form panels referred to are the mass produced brand name form sections (constructed either of steel or steel and wood) which are produced in small segments so as to be adaptable to a variety of concrete shapes and a variety of types of construction. Past experience with certain brands of these form panels resulted in the recommendation that form panel construction should not be permitted for concrete exposed to view. The reason for dissatisfaction on the work referred to was as follows: a. b. Objectionable offsets existed at abutting panel edges. There were an excessive number of joints. (The frequency of panel joints should generally be no greater than in conventional plywood-form construction.) After being reused a number of times, permanent set (permanent deflection) in the panels became excessive. Adequate provisions were not made for overall alignment of the form work nor for providing mortartight joints.

c.

d.
KL 16,980 - 0.53 x r
2

L = unsupported length K = 1.0 for pinned ends r = governing radius of gyration


* L must not exceed 120. r

Only a form panel system which adequately overcomes these objections with respect to appearances can be considered for use on concrete surfaces exposed to view. Design of the forms, with respect to size and spacing of members, is normally furnished by the manufacturer either as part of the advertising literature or as a special design for the job along with a safe rate of pour for concrete in the form system. These should be carefully adhered to. 2. Circular Column Forms Specific requirements for circular column forms are stated in Specification 2401.3B. Such forms have been fabricated of steel, fiberglass and paper or other fibers and all have been used with varying degrees of success. Since some circular forms can be damaged through mishandling or improper storage, it is necessary to check the roundness and smoothness when making a judgment as to acceptability of each individual form. The form diameter on any axis should not be more than 1/2 inch under the specified diameter. This requirement is to assure proper cover on the column reinforcement. (Dents in paper tubes are normally not so critical since concrete

The values listed above will be sufficient for checking most falsework problems involving rolled steel members. Any additional design considerations (as for steel falsework trusses and other special cases) should conform to the provisions of AASHTO Standard Specifications for Highway Bridges, as required in Specifications 2401.3B. When used material is to be incorporated into the work, the extent of damage (caused by previous usage) and corrosion should be evaluated. If corrosion is determined to have reduced the net thickness of a section, it is allowed to use the section properties of a rolled shape in the AISC manual with thickness dimensions compared to those of the intact material. Additional requirements for structural shapes are given in Specifications 2401.3B.

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pressures during filling will round out the tubes. Flattened or elliptical tubes will not be perfectly round when filled with concrete). Reusable steel forms are susceptible to damage in the form of small dents and kinks. These result in unsightly dimples on the concrete surface. Repair of such forms should normally be requested prior to permitting their use. In addition, abutting panels should be adjusted so as to eliminate offsets at panel joints. If they have been overpoured in the past, the face panels may be stretched. Straight edge for acceptability. Due to the possibility of very fast rates of concrete placement in column forms, the pressure at the bottom of the form can be extremely high. Fasteners for the vertical form-joint on segmental forms (such as on steel or fiberglass column forms) can readily be checked for ability to withstand these pressures. (NOTE: These forms usually provide for a variable number of bolts or pins in this joint.) Since circular paper or fibre forms are commercially mass-produced in several strength grades, the adequacy of their design for a specific case will normally be determined by checking the manufacturers literature. Note carefully whether this literature lists a safe loading or a failure loading (or bursting pressure). When only the bursting pressure is given, a safety factor must be applied to determine a safe load. Normally a safety factor of 2 will be adequate. If paper tubes have become wet prior to use, they should be inspected for weak areas in advance of concrete placement. Paper tubes should also be checked to assure that no conspicuous seam ridges are present on the inside surface since these cause objectionable spiral ridges on the finished concrete surface. 3. Friction Collars For Pier Caps Friction collars for pier caps are steel devices which are clamped around the top of circular concrete columns to support the pier cap falsework and pier cap concrete. Serious failures have resulted because of inattention to the placement of these collars. Since the entire falsework in this case is dependent on the stability of the collar, the tightening of the collars must be properly performed. The collars must be level to assure full bearing on the concrete. Manufacturers literature should be used to determine the necessary bolt tension. In addition, the total applied vertical load must not exceed the safe load specified in the manufacturers literature. Slab Falsework - Interior Bays Several types of slab falsework other than the all-wood type which have been successfully used by contractors are as follows:

a.

Adjustable Steel Posts (See Figure C and D 5393.202, types 4 and 5.) This system basically replaces the wood legs of the wooden "horse" system with adjustable steel posts. These posts are normally supported on wood joists spanning between the bottom flanges of adjacent beams. The strength of the system will normally be controlled by the wood members in the system.

b.

Steel Hangers (See Figure C and D 5-393.202, types 2, 3 and 6.) This is basically a hardware item which is laid transversely across the top flange of the beam to receive a vertical bolt on either side of the flange. The bolt in turn supports the main falsework member. Balanced loading of the two sides of the hanger (simultaneous loading of both bolts) is important in the early stage of falsework construction unless measures are taken to hold the hangers in place. Welding of these hangers to the shear connectors is a permissible method of hold down; however, welding to the beam flange is not permitted. Safe working loads for steel hangers are listed in the manufacturers literature.

c.

Steel Bar Joints (See Figure D 5-393.202, Type 7.) This is a steel falsework beam which can be adjusted to a variety of lengths. Load capacity, allowable spacing and deflection data are available from the manufacturers literature which should be used for checking the system. Such steel bar joists have been used as joists to support longitudinal falsework stringers and also used at closer spacing with the sheathing placed directly on them. In the event the latter system is used, no wood nailer is available to hold down the sheathing and a system of wire ties or some other approved method of hold down is necessary. Precautions must be taken to allow for residual camber in this type of falsework system. The amount of residual camber anticipated after placement of the concrete should be determined (by field tests if necessary) and adequate allowance made in setting stool heights to obtain the specified slab thickness.

d.

4.

Corrugated Steel Forms Corrugated Steel Forms are commercially massproduced corrugated sheet metal forms for the bottom of the slab which require no additional supporting falsework. Each unit spans transversely from beam to beam on the bridge and acts in the capacity of a complete structural entity of falsework and sheathing. These

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BRIDGE CONSTRUCTION MANUAL

5-393.202 (7)

units are galvanized and are normally intended to remain in place at completion of the work. Safe loads and deflections for each size of member are available in the manufacturers literature. Under the current policy, this type of falsework is not permitted unless specifically indicated in the Special Provisions. 5. Slab Overhang Falsework Several types of slab overhang falsework (other than the all-wood type) that have been successfully used by contractors are steel hangers, which have been previously discussed, and Steel Overhang Brackets. 6. Typical application of steel overhang brackets is shown in Figures C and D 5-393.202, Types 3, 4, 5 and 6. Details and design data pertaining to two commonly used overhang brackets (Capitol and Superior) are given in Figures E and F 5-393.202. It is intended that spacing and deflection of these brackets be determined by these details as furnished by the manufacturer. However, several precautions must be observed as described below. Information for the Capitol brackets states that the brackets should be spaced at 6'0" centers. However, experience has shown that the 6'0" spacing must be reduced under certain conditions. For example, when the strike-off rails are placed on top of the coping forms or when a very wide slab overhang is specified in the plans, a much higher load is applied to each bracket unless this spacing is reduced. When installing Capitol brackets, the 2" x 4" member placed in the top horizontal member of the bracket must be firmly seated and the hanger chain must be tight. Poorly aligned concrete surfaces have resulted when seating occurred during concrete placement. The influence lines in Figure F 5-393.202 for checking the Superior brackets may be used with a variety of loading conditions. The actual load in the critical members can be determined by use of this chart and checked against the safe working loads shown on the Figure. A wood filler block is required when using these brackets on prestressed concrete girders. This filler must be varied as necessary to provide a bearing surface on the beam at the end of the top horizontal member and at the end of the diagonal member. The filler should not bear on the vertical member of the Superior bracket. The deflection graphs given for each of these brackets should be used only as a guide since the graphs apply only to the specific loadings pictured on the manufacturers details. 7.

For either bracket, when unusual loading conditions are encountered, a full scale field test is recommended. An overload should be applied to assure that there is a safety factor. Since cantilever brackets tend to rotate the fascia beam (push the bottom flange inward), special bracing precautions, as specified in Specification 2401.3B4, are occasionally necessary. For beams depths of 24 in. or less, the difficulty of obtaining good concrete lines increases when this type of overhang falsework is used and serious consideration should be given to the use of needle beams as shown in Type 1, Figure C 5-393.202. Tubular Steel Scaffolding The basic components of Tubular Steel Scaffolding Shoring as shown by the following picture are end frames of various designs and dimensions which are assembled with diagonal bracing and lock clamps. Vertical adjustments are made by adjustable jacks either at the bottom or top of the frames. Frames are normally fitted either with flat top plates or U-heads for supporting the falsework and forms. These towers are rated by the load carrying capacity of either one leg or of one frame (two legs). The manufacturers rated capacity should not be exceeded. Adequate rigid bracing involving several units of steel shoring should be provided. Full bearing for the base plates should be provided, such as being set in fresh mortar pads when resting on rock-like formations. Mudsills placed on yielding earth should not be permitted for supports.

U-Head or other framing Cross braces Lock for braces End frames joined here

End frames

Adjustable jacks

Void Tubes For Voided Slab Spans Void tubes for voided slab spans are similar to the fibre tubes used for column forms except that galvanized steel tubes are also permitted. The circumferential crushing pressure and straight crushing pressure of these tubes will

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normally be listed in the manufacturers literature. When checking stresses, it is necessary to determine if the manufacturer has listed a safe pressure or a failure pressure. Since stress in the void tube is very high at the tie-down straps, a careful visual inspection is necessary at this location. Wetting of paper tubes can result in isolated weak spots where the waterproof coating has been scratched or damaged and the water has penetrated into the paper or fibre layers. Such pieces should be rejected unless they can be satisfactorily reinforced. Void tubes must be mortar tight. When several lengths of tube are necessary to make up the length of void shown in the Plans, each segment of tube should have sealed ends. Butting tube ends together and taping around the perimeter of the joint will normally not be acceptable since deformation of one of the joined tubes during concrete placement would likely rupture a taped splice. Information pertaining to nails and spikes are located on Figure H and I 5-393.202. General requirements governing bolts or form ties are given in Specifications 2401.3B. One specific provision is that a major portion of the device must remain permanently in the concrete. Several types of commercially available form ties meeting this description are shown below. Normally the manufacturers literature will list the safe load that may be applied. However, when the load capacity is questionable or unknown, laboratory tests will be necessary to determine the safe load.

In this event, the safe load may be set by determining the cross-sectional area of the member and the yield point of the steel by tension test in the laboratory. The applied load should not exceed 70% of the yield strength of the device. NOTE: the yield point of the steel (psi) is not the same as the yield strength of a particular bar. On portions of the structure exposed to view, form bolts must be so designed that all metal can be removed to a depth of not less than 1 inch from the concrete surface. Tie wires may be used only in locations where they will not extend through surfaces exposed to view in the finished work. The hardware used to secure form bolts against the forms is usually reusable. This hardware is normally designed to be stronger than the portion of the device that remains in the concrete and, therefore, will not be the limiting strength factor in the form tie. Crimp ties or snap ties are wire form ties with a notch or reduced cross-section at the point of break-back. These ties are not reusable. After the concrete is set, the portion of the wire which extends outside of the concrete surface is twisted off and removed. A washer is sometimes welded to the wire at the face of the form to act as a form spreader. On concrete surfaces exposed to view, a cone should be used in place of the washer since satisfactory patching of the shallow depression left by the washer is very difficult. Because these ties do not always break off at the intended point, but sometimes break instead at the face of the concrete, plus the fact that they do not provide a rigid member for support of the workcrew, they are not recommended for use on heavy construction. Their use is primarily restricted to light work such as box culverts, etc.

CONE NUTS AND INSIDE THREADED RODS

Coil bolt

Washer COIL TYPE TIE WITH CONE SPREADER Wedge shaped holder

CRIMPED TIE WITH DISCONNECTING ENDS Nut washer or other locking unit May have hole for nailing to stud

PLAIN TIE WITH SHE-BOLT DISCONNECTING ENDS

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BRIDGE CONSTRUCTION MANUAL

Figure A 5-393.202

DESIGN PROPERTIES FOR AMERICAN STANDARD LUMBER SIZES load NOMINAL SIZE h b b (in.) h (in.) 1 1 1/4 1 1/2 2 4 6 8 10 12 14 4 6 8 10 12 14 4 6 8 10 12 14 16 6 8 10 12 14 16 6 8 10 12 14 16 6 8 10 12 14 16 6 8 10 12 14 16 b (in.) 11 1/4 h (in.) 3/4 1 1 1/4 1 1/2 3 1/2 5 1/2 7 1/4 9 1/4 11 1/4 13 1/4 3 1/2 5 1/2 7 1/4 9 1/4 11 1/4 13 1/4 3 1/2 5 1/2 7 1/4 9 1/4 11 1/4 13 1/4 15 1/4 5 1/2 7 1/4 9 1/4 11 1/4 13 1/4 15 1/4 5 1/2 7 1/4 9 1/4 11 1/4 13 1/4 15 1/4 5 1/2 7 1/4 9 1/4 11 1/4 13 1/4 15 1/4 5 1/2 7 1/4 9 1/4 11 1/4 13 1/4 15 1/4 Area =bxh 8.44 11.25 14.06 16.88 5.25 8.25 10.88 13.88 16.88 19.88 8.75 13.75 18.13 23.13 28.13 33.13 12.25 19.25 25.38 32.38 39.38 46.38 53.38 30.25 39.88 50.88 61.88 72.88 83.88 39.88 52.56 67.06 81.56 96.06 110.56 50.88 67.06 85.56 104.06 133.56 141.06 61.88 81.56 104.06 126.56 149.06 171.56 Weight lb / lin. ft. 2.3 3.1 3.9 4.7 1.5 2.3 3.0 3.9 4.7 5.5 2.4 3.8 5.0 6.4 7.8 9.2 3.4 5.3 7.0 9.0 10.9 12.9 14.8 8.4 11.1 14.1 17.2 20.2 23.3 11.1 14.6 18.6 22.7 26.7 30.7 14.1 18.6 23.8 28.9 34.0 39.2 17.2 22.7 28.9 35.2 41.4 47.7 S4S 0.40 0.94 1.83 3.16 5.36 20.80 47.63 98.93 177.98 290.78 8.93 34.66 79.39 164.89 296.63 484.62 12.51 48.53 111.15 230.84 415.28 678.48 1034.42 76.26 174.66 362.75 652.59 1066.18 1625.51 100.52 230.23 478.17 860.23 1405.41 2142.72 128.25 293.75 610.08 1097.53 1793.11 2733.82 155.98 357.26 741.99 1334.84 2180.82 3324.92 Full Sawn 1.00 1.95 3.38 8.00 10.67 36.00 85.33 166.67 288.00 457.33 16.00 54.00 128.00 250.00 432.00 686.00 21.33 72.00 170.67 333.33 576.00 914.67 1365.33 108.00 256.00 500.00 864.00 1372.00 2048.00 144.00 341.33 666.67 1152.00 1829.33 2730.67 180.00 426.67 833.33 1440.00 2286.67 3413.33 216.00 512.00 1000.00 1728.00 2744.00 4096.00 S4S 1.05 1.88 2.93 4.22 3.06 7.56 13.14 21.39 31.64 43.89 5.10 12.60 21.90 35.65 52.73 73.15 7.15 17.65 30.66 49.91 73.83 102.41 135.66 27.73 48.18 78.43 116.02 160.93 213.18 36.55 63.51 103.39 152.93 212.14 281.01 46.64 81.03 131.91 195.12 270.66 358.53 56.72 98.55 160.43 237.30 329.18 436.05 Full Sawn 2.00 3.13 4.50 8.00 5.33 12.00 21.33 33.33 48.00 65.33 8.00 18.00 32.00 50.00 72.00 98.00 10.67 24.00 42.67 66.67 96.00 130.67 170.67 36.00 64.00 100.00 144.00 196.00 256.00 48.00 85.33 133.33 192.00 261.33 341.33 60.00 106.67 166.67 240.00 326.67 426.67 72.00 128.00 200.00 288.00 392.00 512.00 PROPERTIES OF DRESSED SIZES (S4S) MOMENT OF INERTIA SECTION MODULUS 3 2 4 3 I = bh inches S = bh inches 12 6

1 1/2

2 1/2

3 1/2

5 1/2

7 1/4

9 1/4

11 1/4

Figure B 5-393.202

BRIDGE CONSTRUCTION MANUAL

November 1, 2005

PLYWOOD SHEATHING FOR CONCRETE FORMS PLYFORM CLASS I FACE GRAIN ACROSS SUPPORTS

FACE GRAIN PARALLEL TO SUPPORTS Panels continuous across two or more spans Shear stress of 70 psi Flexure stress of 1700 psi Average panel deflection of 1/270th of span 1-1/8 600 400 200 0 0 8 12 16 20 24 Stud or joist spacing, inches. (center to center) 1 7/8 3/4 5/8 1/2

1400 1200
CONCRETE PRESSURE, psf

Panels continuous across two or more spans


CONCRETE PRESSURE, psf

1400 1200 1000 800

Shear stress of 75 psi Flexure stress of 2000 psi Average panel deflection of 1/270th of span

1000 800 600 400 200 0 0

8 12 16 20 24 Stud or joist spacing, inches. (center to center)

32

1-1/8 1 7/8 3/4 5/8 1/2

PLYFORM CLASS II FACE GRAIN ACROSS SUPPORTS 1400 1200


CONCRETE PRESSURE, psf

FACE GRAIN PARALLEL TO SUPPORTS 1400 1200


CONCRETE PRESSURE, psf

Panels continuous across two or more spans Shear stress of 70 psi Flexure stress of 1500 psi Average panel deflection of 1/270th of span

1000 800 600 400 200

1000 800 600 400 200 0 0

Panels continuous across two or more spans Shear stress of 70 psi Flexure stress of 1500 psi Average panel deflection of 1/270th of span

0 0 8 12 16 20 24 Stud or joist spacing, inches. (center to center) 32

1-1/8 1 7/8 3/4 5/8 1/2

8 12 16 20 24 Stud or joist spacing, inches. (center to center)

1-1/8 1 7/8 3/4 5/8 1/2

November 1, 2005

BRIDGE CONSTRUCTION MANUAL

Figure C 5-393.202

TYPICAL SLAB FALSEWORK DETAILS Sheathing Filler on top of each joist

Stringers

Joist Joist Posts under each joist Walk Runner Cleat (preferably on both sides of each post) Wedges Needle beam TYPE 1 Sheathing Posts under each joist Supporting bolts for needle beam

Joist Borg hanger Bolt thru web Wood overhang bracket with hanger support Add struts as necessary

TYPE 2 Hanger Stringers Hanger

Steel overhang bracket with hanger support

Add struts as necessary

TYPE 3 Stringers

Bolt thru web Steel overhang bracket supported by bolt thru beam web Adjustable steel posts Add wedges when strutting of fascia is necessary (both ends) TYPE 4

Figure D 5-393.202

BRIDGE CONSTRUCTION MANUAL

November 1, 2005

Sheathing

Stringer

Sheathing

Joist Bolt anchorage Adjustable steel posts Steel overhang bracket supported by bolt in beam web Support for steel posts TYPE 5

Sheathing

Hanger

Stringer

Sheathing Hanger

Joist

Wood filler as necesary Steel overhang bracket with hanger support TYPE 6

Sheathing

Joist Overhang falsework similar to type 5 or 6 Borg hanger

TYPE 7

November 1, 2005

BRIDGE CONSTRUCTION MANUAL

Figure E 5-393.202

2x4
9"

11" for 36 " girder 13" for 42" girder 15-1/2" for 54" girder 2 x 6 for 36 " girder 2 x 8 for 42" girder

For light beams use a drive fit brace as shown

Adjustment 1

Adjustment 2

See anchor detail

EOH

Adjustable. Use max. that beam permits. 60" or 72"

AOH 1" COH 22" DOH 22"


Load - Lbs.

7500 Vertical 30" Distance 6000 4500 3000 1500 Vertical 18" Distance

6-1/2" adjustable

BOH GENERAL DIMENSIONS ANCHOR DETAIL Beam Precasting

Precast form

1"

1-1/2 1 1/2 Deflection Inches LOAD DEFLECTION CURVE 0 ITEM BOH 3/4 x 3 Stud Tapped Reusable ITEM DOH 1/4 x 2 Cap Screw Reusable

ITEM COH Plastic Cone

4'-0" 18" Deflection taken as shown above

ITEM EOH 3/4 x 3 Bolt ITEM AOH Special Anchor 9600 Capacity @ 2000 psi concrete CAPITAL OVERHANG BRACKET Pat. Applied for CAPITAL ENGINEERING CO.

Figure F 5-393.202

BRIDGE CONSTRUCTION MANUAL

November 1, 2005

DEFLECTION GRAPHS FOR ADJUSTABLE BRIDGE OVERHANG BRACKET (As produced by Superior Concrete Accessories Inc.)

A SlotA

SECTION A-A 9000 7500 7100 6000 4500 3000 1500 0 0 .25 3 Point loading WF connection .75 .50 1.00 Deflection (inches) 1.25 Failure: Buckling of Diagonal Member

Ductile Coil wing nut 54"

A 14" max. 23" 23" Coil rod

Load (lbs)

LOAD is the total weight of concrete and forms applied on the bracket by the stringers

Slot A

Ductile coil wing nut 9000 7500 Load (lbs) 6000 4750 4500 3000 1500 0 0 .25 3 Point loading concrete beam connection .50 .75 1.00 Deflection (inches) 1.25 Failure: Buckling of Diagonal Member 54"

A 14" max. Coil rod

Filler block 4 Bracket support points against beam

Figure G 5-393.202

USE OF INFLUENCE LINES FOR OVERHANG BRACKET Joist spacing These influence curves indicate the effect a unit joist load, at any point along the horizontal member, has on other members of the bracket. Loads are cumulative depending upon the number of joists that are used. Note that the influence factor (vertical axis) has two unit designations, one for the vertical member and one for the coil rod. 5.0 6"

12"

12"

Joist loads 400 lbs. 500 lbs. 200 lbs. "C" "B" "A"

INFLUENCE FACTOR 45 Coil rod and diagonal member: lbs/lb of applied load 4.0

BRIDGE CONSTRUCTION MANUAL

EXAMPLE Determine load on 45 coil rod due to joist loads shown above. 3.0 Joist "A" = (200 lb) (2.2) = Joist "B" = (500 lb) (1.85) = Joist "C" = (400 lb) (1.75) = Total load on rod (Safe working load of rod
Rod Coil r 45 be em M al on ag Di

440 925 700

A 2.0 B C

2065 lb 9000 lb)

Loads on the diagonal member are determined in a similar manner.


2

1.0

Area of diagonal member: 0.44 in. . Allowable load (lb) on diagonal member 4733 lbs. Compare this allowable with actual load that is obtained from influence chart.

NOTE: Pres-steel hanger must also have a safe working load of 9000 lbs.

November 1, 2005

54

48

42

36

30

24

18 JOIST LOCATIONS (Inches)

12

0 Out board end of bracket

NOTE: For use with Superior brackets only.

Figure H 5-393.202

BRIDGE CONSTRUCTION MANUAL

November 1, 2005

SAFE LATERAL (SHEAR) LOADS ON NAILS AND SPIKES Driven into the side grain of seasoned wood. Load applied in any lateral direction. *SAFE LATERAL LOAD ON EACH, IN LBS At penetration in diameters noted for each group, DIAMETER into piece holding the point. D GROUP I GROUP II GROUP III GROUP IV IN INCHES 10 x D 11 x D 13 x D 14 x D COMMON NAILS (Flat Head, Diamond Point) Note (1) Length from underside of head to tip of point. 0.113 104 84 68 54 0.131 129 104 86 68 0.148 154 126 102 82 0.148 154 126 102 82 0.162 176 142 118 93 SPIKES (Countersunk Head Diamond Point) Note (1) Length overall 0.192 228 186 151 121 0.192 228 186 151 121 0.207 254 206 168 134 DUPLEX HEAD NAILS (Heavy Double Head, Diamond Point) Note (1) Length from underside of head to tip of point. 0.113 104 84 68 54 0.131 129 104 86 68 0.148 154 126 102 82 0.162 176 142 118 93 0.192 228 186 151 121 0.207 254 206 168 134 SMOOTH BOX NAILS (Large Flat Head, Diamond Point) Note (1) Length from underside of head to tip of point. 0.099 84 68 56 44 0.099 84 68 56 44 0.113 104 84 68 54 0.138 136 101 83 67 TIMBER SPECIES GROUPS

SIZE PENNY WEIGHT

LENGTH (Note 1) INCHES

6d 8d 10d 12d 16d

2 2 1/2 3 3 1/4 3 1/2

GROUP I Ash, Elm, Maple, Oak GROUP II Douglas Fir, Larch, Southern Pine GROUP III Hemlock, Red Pine GROUP IV Cedar, White & Balsam Fir, White Sugar Ponderosa and Lodgepole Pines, Cottonwood, Spruce, Yellow Poplar

10d 12d 16d

3 3 1/4 3 1/2

6d 8d 10d 16d 20d 30d

1 3/4 2 1/4 2 3/4 3 3 1/2 4

6d 7d 8d 10d

2 2 1/4 2 1/2 3

COOLERS (Flat Head, Diamond Point). SINKERS (Flat Countersunk Head, Diamond Point) as per BOX NAILS except length overall is 1/8 less than shown.

When the penetration in nail or spike diameters is less than that shown in the above heading for each timber species group, but at least equal to 1/3 of that shown in the heading, the safe load may be determined by straight line interpolation between zero and the load tabulated above. For example, driven only 7 diameters into Group II timber species, the safe load would be only 7 / 11 of the tabulated load. Driven less than 1/3 that shown in the above heading, the nail or spike should not be considered as capable of carrying any lateral load. For example, for Group II timber species, the minimum penetration should be 11 / 3 or 3 2/3 diameters, at when penetration the safe load would be 1/3 of the tabulated load. End distance, side distance and spacing to be such that unusual splitting of the wood is avoided: pieces to be in close contact. Stagger nails, with fairly uniform spacing, along contact surface. Basic Formulas: Safe Load = 1.33 x K x D 3/2 Group I : K = 2040, Group II : K = 1650 Group III : K = 1350, Group IV : K = 1080 Formulas may be used when nails other than diameters listed are used. * Based on values given in Natl. Design Spec., Stress Grade Lbr. and Its Fastenings, recommended by the Natl. Lbr. Mfg. Assoc. latest Edition. The values given in this publication, which are for normal load duration of 10 years have been increased by 1/3 due to short duration of static load on falsework and high factor of safety against failure in the values.

November 1, 2005

BRIDGE CONSTRUCTION MANUAL

Figure I 5-393.202

NAILS The following diagram may be used as an aid in size identification of nails used in formwork.

60d

50d

40d

30d

20d

16d

12d

10d

9d

8d

7d

6d

5d

4d

3d

2d

COMMON NAILS - Flat Head Diamond Point

STOCK ITEMS Size 2d 3d 4d 5d 6d 7d 8d 9d 10d 12d 16d 20d 30d 40d 50d 60d Length In. 1 1 1/4 1 1/2 1 3/4 2 2 1/4 2 1/2 2 3/4 3 3 1/4 3 1/2 4 4 1/2 5 5 1/2 6 Gauge No. 15 14 12 1/2 12 1/2 11 1/2 11 1/2 10 1/4 10 1/4 9 9 8 6 5 4 3 2 Diamond Head 11/64 13/64 1/4 1/4 17/64 17/64 9/32 9/32 5/16 5/16 11/32 13/32 7/16 15/32 1/2 17/32 Approx. No. to Lb 847 543 294 254 167 150 101 92 66 61 47 29 22 17 13 10

Length from underside of head to tip of point. Safe loads for nails shall conform to the values listed in Fig. H 5-393.202.

5-393.203

BRIDGE CONSTRUCTION MANUAL

November 1, 2005

5-393.203 DEFLECTIONS AND ALIGNMENT Deflection will occur in any form or falsework member in which beam action is involved regardless of the design used or the material of which the forms or falsework are constructed. The surface and lines of the concrete being formed will reflect these deflections. Such deflections may detract from the appearance of lines or surfaces which are exposed to view. For this reason, a limit is placed on the amount of anticipated deflection of the form and falsework members which will be used for concrete exposed to view. The anticipated deflection of the members involved should be computed and checked against the allowable deflection described later in this section prior to approving a form or falsework system. The dead loads and concrete pressures used to compute deflections are the same as those used to check stresses in the member except that live load will normally not be included in the deflection loading. 3. When it is anticipated that the allowable deflection will be exceeded, the size or spacing of the members must be modified. In lieu of such modification of the members, in certain cases it is possible to compensate for these deflections during construction of the forms or falsework by use of profile strips or wedging to induce reverse deflection equal in amount to the computed deflection. Certain restrictions are placed on this practice of compensating for deflections which are discussed below. The following criteria will govern acceptance or rejection of the Contractors falsework details with regard to deflection of structures that are exposed to view: 1. On concrete surfaces exposed to view the computed deflection of any member shall not exceed 1/270 of its span or 1/4 inch, whichever is least, unless adequate provision is made to compensate for the deflection as was discussed above. (The 1/270 criteria will be applicable for spans up to 67 inches.) Between fascia beams, the falsework supporting the deck slab will not be limited by the foregoing. In this area, a limiting cumulative deflection (deflection of sheathing plus deflection of stringers plus deflection of joists, etc.) of inch should be applied. This limit is to avoid excessive addition of dead weight to the superstructure. At locations of transverse construction joints in the roadway slab, the falsework supporting the bulkhead must be sufficiently strong to reduce the computed bulkhead deflection to not more than 1/16 inch. Deflection of slab overhang falsework must normally be compensated for by wedging or raising the edge of overhang falsework by an amount equal to that of the anticipated deflection. The anticipated cumulative

deflection of the overhang falsework must not exceed 1/2 inch even though compensated for. When the main overhang falsework support members (the overhang bracket, needle beam or equivalent) are spaced at less than 48 inches, the anticipated deflection of these main members must not exceed S/100, where S = member spacing in inches. The following criteria will govern acceptance or rejection of the Contractors form details with regard to deflection of structures that are exposed to view: 1. Deflection in any form member which acts as a beam should not exceed 1/270 of its span or 1/8 inch, whichever is least. Concrete diaphragms for prestressed concrete girder spans will normally not, for this purpose, be considered to be exposed to view and their forms will not be subject to deflection controls. Except when used as pedestrian underpasses, the walls of box culverts will not be classified as concrete exposed to view. Head walls and wings of box culverts, or the projecting ends of interior walls of multiple opening box culverts, will be classified as concrete exposed to view.

2.

Forms for concrete surfaces that will be exposed to view must be so aligned and of sufficient stiffness that irregularities in any 10 foot length on the finished concrete surface will not exceed inch. When the Plans indicate that a bridge (or portions thereof) is to be constructed to a horizontal curve, the forms for edges of slab, curbs, copings, medians and railings must be constructed to their proper degree of curvature within a tolerance of 1/8 inch in 10 feet. Midordinates of 1/8 inch or more in 10 feet will occur with a degree of curvature of about 5Eor more. For a degree of curvature of less than 5E, concrete forms may be constructed on short chords along the intended curve line. It is intended that forms which can easily be placed to a scribed line on the falsework or on previously placed concrete, will be placed on the specified curved alignment. This would include forms for the edges of slabs, curbs and medians. Forms for curved railings, however, cannot always be aligned this easily. It is the intent of the Specification tolerance to permit rail construction on chords between railposts when the curvature is small enough (5E or less) so that a chord construction would not be visually objectionable. No offsets should exist at abutting joints of sheathing or at abutting form panels. The variation from plumb or from the specified batter in the lines and surfaces of columns, piers and walls should not exceed inch per 10 feet of height and, in any event, shall not exceed inch.

2.

3.

4.

November 1, 2005

BRIDGE CONSTRUCTION MANUAL

5-393.204 (1)

5-393.204

FORMULAS AND STANDARD LOADS

term (R-2h) in place of R. This applies to both continuous and simple spans.

Practically all falsework members act either as columns or as beams. The internal stresses and the deflections in these members due to the weight of the various construction loads (weight of forms and falsework, weight of concrete, weight of equipment and workcrew, etc.) can be determined by standard methods of Engineering mechanics and compared to the allowable stresses listed in Section 5-393.202 and the allowable deflections listed in Section 5-393.203 to aid in determining the acceptability of a proposed falsework system. Typical examples of the calculations necessary for checking the falsework systems are given in Sections 5-393.206 to 5-393.209. The following formulas will apply to falsework and form analysis: 1. 2. Flexure formula (bending stress) f = Direct stress formula a. Direct tension stress
f = P A P A M S

V' based on loads in this area only h h

Concrete pressure on forms have formulas that are recommended by ACI Committee 347. The formulas apply to standard concrete weighing 150 pcf having a maximum slump of 4 inches and internally vibrated during placement. For forms with rate of concrete placement not exceeding 7 feet per hour, and for all column pours, the maximum lateral pressure at a given point shall be equal to: a. or b. or c.
p = 150 + 9000R1 T

p = 150h p = 3000 psf

b.

End bearing

f =

Use whichever is least. The allowable side bearing stress given in Section 5393.202 applies to bearing surfaces 6 inches or more in length. For bearing surfaces less than 6 inches in length and located 3 inches or more from the end of the timber, the allowable working stress may be increased by a factor of where R is the length in bearing. (For circular bearing areas, R= diameter.) Figure A 5-393.204 lists safe side bearing loads for several common form and falsework details as derived from the above formula. 3. Shearing stress formulas Use whichever is least. a. b.
V Shear stress in steel members v = th l + 3/8 l

Note: R1 = rate of concrete placement per hour T = temperature in degrees Fahrenheit The forms with a rate of concrete placement exceeding 7 feet per hour, the maximum lateral pressure at a given point shall be equal to: a. or b. or c.
P = 150 + 43400 2800R1 + T T

p = 150h p = 2000 psf

Shear stress in plywood, known as rolling shear


v =

( I / Q) b

NOTE: I/Q is known as the rolling shear constant and is tabulated in Section 5-393.202 for the various thicknesses. c. Horizontal shear stress in timber beams H = 1.5
V bh

In the event that the above conditions do not apply (for example, if a greater than 4 inch slump is to be used), or if other factors are involved such as the proposed use of a retarder, the actual concrete pressure will increase and appropriate adjustment must be made in the calculated pressures. Vibration and depth of placement in layers should conform to Specifications if these formulas are to be applicable.

To simplify the calculation for determining VN, use the appropriate beam formula for determining shear but insert the

Figure A 5-393.204

BRIDGE CONSTRUCTION MANUAL

November 1, 2005

CONTACT AREAS AND ALLOWABLE STRESS INCREASE FACTORS FOR STUDS AND WALERS STUD WIDTH 1 1/2 2 2 1/2 3 3 1/2 4 (1) (2) (1) (2) (1) (2) (1) (2) (1) (2) (1) (2) WIDTH OF ONE WALER 2 1/2 2 1 1/2 4.50 1.25 6.50 1.19 7.50 1.15 9.00 1.13 10.50 1.11 12.00 1.09 6.00 1.19 8.00 1.19 10.00 1.15 12.00 1.13 14.00 1.11 16.00 1.09 7.50 1.15 10.00 1.15 12.50 1.15 15.00 1.13 17.50 1.11 20.00 1.09 3 9.00 1.13 12.00 1.13 15.00 1.13 18.00 1.13 21.00 1.11 24.00 1.09 3 1/2 10.50 1.11 14.00 1.11 17.50 1.11 21.00 1.11 24.50 1.11 28.00 1.09 4

(1) = CONTACT AREA SQ. IN. (2) = ALLOWABLE STRESS INCREASE FACTOR

16.00 1.09 20.00 1.09 24.00 1.09 28.00 1.09 32.00 1.09

3/4" Min.

Stud width

Bearing Area Shown Hatched

NOTE: Allowable stress increase factor = L+3/8 where L is the L length of bearing along grain. Use only if stud is less than 6" and not nearer than 3" from the end of a member Assume waler @ 2" nominal width

CONTACT AREAS AND ALLOWABLE STRESS INCREASE FACTORS FOR WALERS AND TIE PLATES CONTACT AREA Y ALLOWABLE STRESS X L SQ. IN. INCREASE FACTOR 3 1/4" 5" 3 3/4" 3" 5" 5 1/4" 5 3/4" 6" 6 1/4" 6 3/4" 5" 5" 5 1/4" 5 3/4" 6" 6 1/4" 6 3/4" 3 3/4" 3 1/4" 3 1/2" *3 3/4" *3 3/4" *3 3/4" *3 3/4" *3 3/4" *3 3/4" *3 3/4" 3 3/4" * 4" * 4" * 4" * 4" * 4" * 4" * or more 3/4" 3/4" 3/4" 3/4" 3/4" 3/4" 3/4" 3/4" 3/4" 3/4" 1" 1" 1" 1" 1" 1" 1" 9.75 12.50 10.31 9.00 15.00 15.75 17.25 18.00 18.75 20.25 13.75 15.00 15.75 17.25 18.00 18.75 20.25 1.12 1.08 1.10 1.13 1.08 1.07 1.00 1.00 1.00 1.00 1.08 1.08 1.07 1.00 1.00 1.00 1.00

Tie plate

1 1/2

1 1/2 X X + 3"

Dia. of Pile at Cut-off in Inches

BEARING AREA IN SQ. IN. BETWEEN CAPS AND PILES OF VARIOUS SIZES (Piles assumed circular) ACTUAL WIDTH OF CAP IN INCHES 6 7 1/2 8 9 1/2 10 11 1/2 12 13 1/2 14 99.7 105.6 121.9 81.4 127.0 140.4 144.2 152.7 153.9 14 95.8 101.3 116.7 78.2 121.4 133.6 136.9 143.1 13 1/2 91.8 75.1 115.7 126.6 129.4 132.7 111.4 97.0 13 87.8 72.0 109.9 119.4 121.5 122.7 106.0 92.7 12 1/2 83.7 68.9 113.1 104.1 111.9 100.6 88.3 12 Area = (W) (h) 79.7 65.7 98.1 103.9 95.1 83.9 11 1/2 2 75.6 62.6 95.0 91.9 89.4 79.5 11 0 + ( 90 ) (M) (R) 71.4 59.4 86.6 85.5 83.6 75.0 10 1/2 67.2 56.2 78.5 77.5 70.4 10 62.9 52.9 70.9 65.7 9 1/2 58.6 49.7 63.6 60.8 9 NOTE: Bearing area at rt. end of 54.0 46.4 56.7 55.8 8 1/2 each line = area of pile at cut-off of 49.3 43.0 50.3 8 diameter shown at left. Use when cap width equals or exceeds pile diameter.

Bearing area shown hatched Cap width W/2 sin 0 = W/2 R Pile diameter

Waler width

12.00 1.09

November 1, 2005

BRIDGE CONSTRUCTION MANUAL

5-393.204 (2)

When the ends of a beam are notched, as shown below, the horizontal shear stress should be determined by use of the accompanying formula. As shown by the formula, notching beams adds proportionately to the horizontal shear stress and should be avoided.

he

h H = 1.5 V x h b(he) he
1 1 V = W (L - 2he) 2

he h Beam Support Column deflection formula (elastic shortening) PL = AE Beam Formulas - Reactions, Moments, Shears and Deflections.

max. R a. Simple span - uniformly loaded w wL 2 L b. 2 continuous spans - uniformly loaded w 3 1 2

max. M

max. V

max.

wL 8

wL 2

5wL 384 EI

R 1 = R 2 =

3wL 8 5wL 4

wL M3 = 14.2 M2 = wL 8
2

V1 = V2 =

3wL 8 5wL 8

3 = wL 185 EI
4

c. 3 or more spans - uniformly loaded w 3 1 2

R 1 = 0.4 wL M 3 = 0.08 wL

V 1 = 0.4 wL V 2 = 0.6 wL

3 = 0.0069 wL EI
4

R 2 = 1.1 wL M 2 = 0.10 wL2

d. Cantilever beam - uniformly loaded w 2 1 L R 1 = wL wL M1 = 2


2

2 = V 1 = wL wL 8 EI
4

A more complete listing of beam formulas for use with point loads or other load variations may be found in the AISC Steel Construction Manual.

5-393.205

BRIDGE CONSTRUCTION MANUAL

November 1, 2005

The following loads and unit weights will be used in falsework analysis: lumber - 40 pcf steel - 490 pcf plain concrete and reinforced concrete - 150 pcf construction live load* - 50 psf on the upper concrete surface *This live load is considered a minimum and must be increased where known concentrated loads may produce higher live loads on the member. In addition, when a falsework platform extends outside of the concrete surface to provide working room, as for most pier cap construction, the 50 psf live load should be applied to such walk space as well as to the upper concrete surface. 5-393.205 FALSEWORK DETAILS AND ANALYSIS The inspector must be satisfied that the Contractors falsework plan or scheme is in conformance with the Specifications. A common way to do this is to compute the maximum deflection and maximum stresses (bending, bearing, shear, etc) based on plans of the proposed falsework and the assumed loading conditions. These computed stresses and deflections are then compared with the allowable values. If the computed stress and deflection is less than or equal to the allowable value, the member qualifies for use. The examples of falsework investigation given in this section are presented as being representative of commonly used methods. It is not intended that the Contractors methods be restricted to the details shown here. However, when it appears that unsafe or improper methods are being used, these details may be suggested as a guide. The American Concrete Institute recommends that three basic simplifications be used in checking forms and falsework. These are as follows: 1. Beams such as joists, studs and walers should generally be assumed to be uniformly loaded with the exception of that when only one or two point loads occur in a span then the assumption of uniform load should not be used. Beams supported over three or more spans are regarded as continuous and the appropriate continuous beam formulas should be used. For beams continuous over two spans, design values for simple spans may be safely used except for reaction loads.

2.

3.

In the event that the results of the preliminary investigation of the falsework appear marginal, more exact methods should be used. For very large members (falsework pier caps, etc.) more exact methods are recommended. Formulas used in the following computations are found in Section 393.202 and allowable deflections are listed in Section 5-393.203. 5-393.204. Allowable stresses are listed in Section 5-

Particular attention should be given to writing the unit (inches, feet, pounds, etc.) with each number used in the calculations to assure correct answers. 5-393.206 PIER CAP FALSEWORK EXAMPLE A check of the pier cap falsework details shown in Figure A 5-393.206 would require the following investigation: (NOTE: items above plyform for bottom of pier cap in this figure will be checked in Section 5-393.206.) 1. Plyform for Bottom of Pier Cap a. bending stress b. rolling shear stress c. deflection

November 1, 2005

BRIDGE CONSTRUCTION MANUAL

Figure A 5-393.206

EXAMPLE: PIER CAP FORMS AND FALSEWORK 37'-6" 6'-6" 24'-6"

6'-6"

2'-8" dia.

PIER ELEVATION 2'-10" 3/4" Plyform, Class I 2" x 4" @ 16" O.C. 1/2" dia. coil bolt with 4"x5" washer spaced @ 4'-0"
3'-8" 2'-2"

10"

2" x 4" Brace @ 4' O.C. both sides

2 - 2" x 6" (walers) 4' x 8' x 3/4" Plyform, Class I

HP 12x53 x 40' long

8"

2" - 6" x 10' Long @ 10" O.C. Friction Collar

3'-10" SECTION A-A All lumber to be used material (species unknown)

5-393.206 (1)

BRIDGE CONSTRUCTION MANUAL

November 1, 2005

2.

Joists a. bending stress b. horizontal shear stress c. bearing stress d deflection Main Support Beams (HP12x53) a. bending stress b. shear stress c. deflection Friction Collar a. Check against manufacturers safe carrying capacity. b. Tighten collar bolts to correct torque.

3.

4.

The necessary calculations corresponding to the above example items are as follows: 1. Plyform for bottom of pier cap Determine applied uniform load, w: concrete 3.67 ft x 150 lb/ft3 plywood .06 ft x 40 lb/ft live load Total load
3

= 550 lb/ft2 = = 3 lb/ft


2

3/4" Plyform 10"

2"x6" Joist

50 lb/ft2
2

w = 603 lb/ft

From the chart for Class I Plyform in Figure B 5-393.202 for face grain parallel to supports, for a concrete pressure of 603 psf, the maximum allowable stud spacing would be about 11 inches. Therefore, the proposed 10 inch spacing is safe. (Note that the 8 foot panels must be parallel to the joists in this detail and, therefore, the grain of face plies will be parallel to the joist.) In lieu of using the chart (as when the class of plywood is unknown), the following calculations would be necessary: (Assume 3 span continuous design conditions.) a. Bending stress f =
M S

M = 0.10 wL2 = 0.1 x 603 lb/ft x (10 in.)2 x 1 ft/12 in. = 503 in. lb

S = 0.305 in.3 [from Section 5-393.202] F=


503 in. lb 0.305 in.3

=1649 lb/in.2

This stress is higher than the allowable stress of 1500 psi (which would apply when the class of plywood is unknown). Therefore, care must be taken in determining type of plyform used. NOTE: the allowable stress of 1700 psi can only be used when it has been determined that a concrete form grade of plyform Class I is being used. b. Rolling shear stress v =

( I / Q) b

V = 0.6 wL = 0.6 x 603 lb/ft x .83 ft = 300 lb

November 1, 2005

BRIDGE CONSTRUCTION MANUAL

5-393.206 (2)

From Section 5-393.202,

I = 0.393 in. Q

b = 12 in.

v=

300 lb = 64 lb/in.2 12 in. x 0.393 in.

This is acceptable since it is less than the allowable stress of 70 psi. c. Deflection - =
0069 w L4 w = (603 lb/ft) - (50 lb/ft live load) = 553 lb/ft, L = 10 in. EI

NOTE: live load is not to be included in deflection computations. From Section 5-393.202 E = 1,600,000 lb/in.2 From Section 5-393.202 I = 0.088 in.4
= 0.0069 x 553 lb / ft x (10 in.) 4 1 ft. x = 0.023 in. 12 in. 1,600,000 lb / in.2 0.088 in.4

This span is less than 67 inches long; therefore, the allowable deflection = 1/270 x 10 in. = 0.037 in. Since actual deflection (0.023 in.) is less than allowable, (0.037 in.) the sheathing is acceptable. 2. Joists Determine applied uniform load due to weight of forms per linear foot along cap:

Width of applied load 10" w

Plyform 2"x6" joist

plywood = 16 ft x 1 ft x .062 ft x 40 lb/ft3 studs = 3.67 ft x 2 x


12 in. x 1.5 lb/ft 16 in.

= =

39.7 lb 8.3 lb

39.7 lb 8.3 lb

plates = 4 x 1 ft x 1.5 lb/ft walers = 8 x 1 ft x 2.5 lb/ft Total


10 in. forms = 74 lb / lf of cap x 12 in. 10 in. concrete = 2.83 ft x 3.67 ft x 150 lb / ft 3 x 12 in.

= =

6.0 lb 20.0 lb 74.0 lb/lf of cap

6.0 lb 20.0 lb .

74.0 lb/lf of cap

62

lb/joist

55.5 lb/joist

= 1298 lb/joist

1168.4 lb/joist

Total

1360 lb/joist (10 in. Spacing)

1224

lb/joist

(9 in. Spacing)

5-393.206 (3)

BRIDGE CONSTRUCTION MANUAL

November 1, 2005

This weight is spread over a length of 3.0 feet for all practical purposes; therefore, the corresponding uniform load on the joists is: form + concrete =
1360 lb / joist 3 ft 1224 lb / joist 3 ft

= 453.3 lb/lf of joist live load =


50 lb ft 2 x 10 in. 12 in.

408 lb/lf of joist


50 lb ft 2 x 9 in. 12 in.

= 41.7 lb/lf of joist weight of joist Total uniform w = 2.3 lb/lf =

37.5 lb/lf of joist 2.3 lb/lf 448 lb/lf

= 497 lb/lf (10 in. Spacing)

(9 in. Spacing)

a.

Bending stress f =

M S

NOTE: for beams with a very wide bearing area (such as the 12 inches wide beam flange in this example), it is reasonable to assume the span begins about 2 inches back from the edge of the support. For example span length would then be = (3'-10") - 8" = 3' - 2". To simplify calculations, assume the load w is for full length of the 3'-2" span. This will result in only an insignificant stress increase. Maximum bending stress in this example occurs with no load on the cantilevers. M =
497 lb / ft x (3.17 ft ) wL2 = 8 8
2

2" 3'-0" Uniform load

2" x 6" Joist L = 3'-2" 3'-10"

= 624 ft lb

S = 7.56 in.3 (For the member sizes used here, all lumber will be S4S.)
624 ft lb 12 in. f = = 990 lb / in.2 x 7.56 in.3 1 ft

Allowable bending stress (assuming the proposed form lumber is used material with no visible grade stamp, the allowable stress for Red Pine will be used) = 1375 psi. The member is acceptable with regard to bending stress. b. Horizontal Shear Stress H = 1.5
V1 bh

V1 =

497 lb / ft (3.17 ft - 2 x 5.5 in./12 in./ft ) w (L - 2h) = = 560 lb 2 2 1.5 x 560 lb = 102 lb/in.2 15 in. x 5.5 in. .

b = 1 in.

h = 5 in.

H=

This is more than the allowable horizontal shear stress of 88 psi for Red Pine and is, therefore, not acceptable. Thus, reduce the 2" x 6" joist spacing from 10 inches to 9 inches. (9/10) x 102 = 92 psi about 88 psi and, therefore, acceptable. Bending stress will reduce also, so it is also acceptable. c. Bearing stress in joist on the HP12x53 beam Determine total load of joist
Form Lumber 9 = 74 x = 55.5 lb / joist 12

November 1, 2005

BRIDGE CONSTRUCTION MANUAL

5-393.206 (4)

Concrete

9 in. = 2.83 ft x 3.67 ft x 150 lb / ft 3 x = 1168.4 lb / joist 12 in. 9 in. = 50 lb / ft 2 x 8 ft x 12 in.

Live Load

= 300.0 lb / joist

Weight of Joist = 2.3 lb/ft x 10 ft Total The bearing weight at each support =
P A

23.0 lb

= 1547 lb/joist

1547 lb = 774 lb 2

8'-0"

Bearing stress f =

P=

774 lb

Live load

Dead load + live load

A = 1 1/2 in. x 12 in. = 18.0 in.2 f =


774 = 43 lb/in2 18

2"x6" joist x 10'-0" long

861 lb

861 lb

This is less than the allowable side bearing stress of 350 psi (for Red Pine). d. Deflection of joist Assume similar loading condition to that which causes maximum bending stress. w = 448 lb/lf (for 9 inch spacing) ) =
5wL4 384 EI

w = (448 lb/lf) - (37.5 lb/ft live load) = 410 lb/ft L = 38 in. E = 1,300,000 psi (Red Pine) I = 22.53 in.4

5 x 410 lb / ft x (38 in.) 4 1 ft. = 0.032 in. 2 4 x 12 in. 384 x 1,300,000 lb / in. x 22.53 in.
1 x 38 in. = 0.141 in. 270

The allowable deflection =

Since actual deflection is less than allowable, the member is acceptable. 3. Main Support Beams (HP12x53)

Loads will be as determined for bearing stress in 2 c) above except that the live load can reasonably be reduced to 50 psf on only the horizontal concrete surface area for this member. Determine dead load on each joist which bears on the two HP 12x53 beams. Form Lumber Concrete Weight of Joist
Total Applied Dead Load

= = =
=

55.5 lb/joist 1168.4 lb/joist 23


1247

lb
lb/joist

5-393.206 (5)

BRIDGE CONSTRUCTION MANUAL

November 1, 2005

Convert to uniform load on each 12HPx53 beam.


Dead Load Live Load = 1247 lb / joist 12 in. x = 831 lb / ft 9 in. 2 = 71 lb / ft

2.83 ft = 50 lb / ft 2 x 2

Weight of Beam
M S

= 53 lb / ft w = 955 lb / ft

a.

Bending stress f =

Bending stress must be checked at locations and . There are no available formulas to determine these moments directly. Therefore, moments will be determined by combining two known loading conditions in the AISC Steel Construction Manual as follows:

2 w = 955 lb/ft

HP12x53

6'-6"

24'-6" Friction collar supports

6'-6"

w = 955 lb/ft

w = 955 lb/ft

w = 955 lb/ft

6'-6"

24'-6"

6'-6"
20174 ft lb 71655 ft lb

This results in the following bending moment diagrams: 1 1

M1 =

955 lb / ft x (6.5 ft ) wL2 = 2 2

= 20,174 ft lb

M2 =

955 lb / ft x (24.5 ft ) wL2 = 8 8

= 71,655 ft lb

51481 ft lb

November 1, 2005

BRIDGE CONSTRUCTION MANUAL

5-393.206 (6)

For an HP12x53, S = 66.8 in.3 (from AISC Manual). Use moments from summarized diagram at right above. At location , f1 =
20,174 ft lb (12 in./1 ft ) 66.8 in.3 51,481 ft lb (12 in./1 ft ) 66.8 in.3

= 3624 lb/in.2

At location , f2 =

= 9248 lb/in.2

Assuming that the steel pile material would likely be ASTM A 36 grade, the allowable temporary bending stress is 25,000 psi. Therefore, this member qualified in bending. 955 lb/ft b. Shear Stress in HP12x53 Load Diagram at location V1 = 6.5 ft x 955 lb/ft = 6208 lb Shear Diagram at location v2 = 955 lb/ft x = 11700 lb From AISC Manual, for HP12x53, web thickness =0.435 in. height = 11.78 in. At the point of maximum shear, v =
11700 lb = 2283 lb/in.2 0.435 in. x 11.78 in.

v =

V th

6'-6" 1

24'-6"

6'-6" 2

1 2

This is less than the allowable temporary shear stress of 15000 psi. c. Deflection of HP12x53 The loading diagram will be as shown above for shear except that live load will not be included for deflection computations. Therefore, w = (955 lb/ft) - (71 lb/ft live load) = 884 lb/ft. Deflections must be determined at points and . Since there are no readily available formulas for determining these deflections directly, this loading situation may be duplicated by combining two of the available loading diagrams in the AISC Steel Construction Manual as follows:

w = 884 lb/ft

5-393.206 (7)

BRIDGE CONSTRUCTION MANUAL

November 1, 2005

Deflection at point (midspan) is determined by the following formulas from the AISC manual for the loading diagrams shown above.
wa 2 x wx 2 = (L4 2L2 x 2 + Lx 3 2a 2 L2 + 2a 2 x 2 ) - 12EIL (L2 x 2 ) 24EIL

w = 884 lb/ft L = 24.5 ft x = x 24.5 ft = 12.25 ft a = 6.5 ft E = 29,000,000 psi I = 393 in.4 (from AISC manual)
884 lb / ft x 12.25 ft x (24.54 - (2 x 24.52 x 12.252 ) + (24.5 x 12.253 ) (2 x 6.52 x 24.52 ) + (2 x 6.52 x 12.253 )) 2 = 24 x 29,000,000 psi x 393 in.4 x 24.5 ft
3 3 884 lb / ft x (6.5) ft) 2 x 12.25 ft 12 in. 12 in. x (24.52 - 12.252 ) ft 2 ) x x - 1 ft 12 x 29,000,000 psi x 393 in.4 x 24.5 ft 1 ft

)2 = 0.523 in. - 0.106 in. = 0.416 in. The maximum allowable deflection in this member will be 1/4 inch. See Section 5-393.203 for further details. Since the allowable deflection at this point is exceeded, the member must either be increased in size or wedges must be placed to compensate for this deflection. (For example, at midspan 0.416 of wedging is necessary) The deflection at point may be determined with sufficient accuracy by use of the following loading condition from the AISC Manual:

w = 884 lb/ft

24'-6"

6'-6"

884 lb / ft x 6.5 ft x (4 x 6.52 x 24.5 - 24.53 + 6 x 6.52 x 6.5 - 4 x 6.5 x 6.52 + 6.53 ) ft 3 12 in. 3 = - 0.354 x 1 = 1 ft 24 x 29,000,000 psi x 393 in.4

Since this exceeds the allowable deflection of 1/4", compensation (by wedging or other) must be made in the falsework construction, in order to obtain true lines.

November 1, 2005

BRIDGE CONSTRUCTION MANUAL

5-393-207 (1)

HP 12x53 in deflected position (without deflection compensation)


0.354" 0.416"
NOTE: The minus sign indicates an upward deflection of the ends of the HP 12x53 as indicated in the diagram.

6'-6"

24'-6" C Columns L and friction collars

6'-6"

4.

Friction Collar The reaction on each side of the friction collar may be determined from the shear diagram in part b. F = 6208 lb + 11700 lb = 17908 lb Total load on each friction collar = 17908 lb x 2 beams = 35816 lb NOTE: The collar bolts shall be torqued adequately to develop friction collar load. This load should be checked against the allowable load listed in the manufacturers literature for the proposed friction collars.

5-393.207 ROADWAY SLAB FALSEWORK EXAMPLE Assume the Contractor has proposed the slab falsework details shown in Figure A 5-393.207. Assume also that rails for the strike off machine will be placed on the fascia beams. The following investigations will then be necessary to determine the acceptability of the proposed method: Interior Bays 1. Plywood Sheathing a. b. c. 2. Bending stress Rolling shear stress Deflection 2. 1. Slab Overhang Falsework Plywood sheathing a. b. c. Bending stress Rolling shear stress Deflection

Stringers a. b. c. d. Bending stress Horizontal shear stress Bearing stress Deflection

Stringers a. b. c. d. Bending stress Horizontal shear stress Bearing stress Deflection

3.

Joists (double 2" x 12" member) a. b. c. d. Bending stress Horizontal shear stress Bearing stress on washer Deflection

3.

Steel overhang bracket a. b. Safe load Deflection

4.

Hanger a. b. Direct tension on bolt Capacity of hanger

4.

Hanger a. b. Direct tension on bolt Capacity of hanger

Figure A 5-393.207

BRIDGE CONSTRUCTION MANUAL

November 1, 2005

EXAMPLE: ROADWAY SLAB FALSEWORK A 2" x 4" @ 1'-0" O.C. Hangers @ 5'-0" O.C. 8" Min. conc. slab 3/4" Plyform, Class I

Double 2" x 10" @ 5'-0" O.C. 1/2" Dia. coil bolt (typ.) Superior overhang bracket @ 5'-0" O.C. 3'-10" 8'-2" (typical) CROSS SECTION OF DECK FALSEWORK 8" Min. conc. slab 3/4" Plyform, Class I 2" x 4" @ 12" O.C. A

2" x 10" 1/2" Dia. coil bolt with 3" x 4" washer 5'-0" SECTION A-A All lumber to be Douglas Fir, No. 1. 2" x 4" @ 12" O.C. 5'-0"

Figure A 5-393.207 INTERIOR BAYS 1. Plywood Sheathing Determine applied load w. Concrete 0.67 ft x 1 ft x 150 lb/ft3 Plywood 0.06 ft x 1 ft x 40 lb/ft3 Live Load

3/4" Plyform
= = = w= 100.0 lb/ft 2.5 lb/ft 50.0 lb/ft 152.5 lb/ft

12"

2" x 4" Stringers @ 12" O.C.

a., b., and c. - Bending, Rolling Shear and Deflection are all automatically checked when using Figure B 5-393.202. Assume face grains will be placed the weak way, (face grain parallel to supports). According to this Figure, 12 inch spacing on inch plyform Class I will safely support about 550 psf; therefore, the sheathing is acceptable.

November 1, 2005

BRIDGE CONSTRUCTION MANUAL

5-393.207 (2)

2.

Stringers Determine applied load w per foot of stringer. Concrete, plywood and live load Weight of member (2 x 4) = 152.5 lb/ft = 1.5 lb/ft w = 154.0 lb/ft

12"

w = 152.5 lb/ft

2" x 4" Stringers

a.

Bending Stress A 2 or 3 span continuous situation will very likely apply for the spans given (5'-0"). Assume 2 span continuous for the design check.

w = 155 lb/ft

2" x 4" Stringer 5'-0" 5'-0" Waler spacing

M =

154 lb / ft x (5 ft ) wL2 = 8 8

= 481.2 ft lb

S = 3.06 in.3
F = M 481.2 ft lb 12 in. = x = 1887 psi 1 ft S 3.06 in.3

Since the allowable bending stress in Douglas Fir is 1875 psi, this member is acceptable in bending with slight overstress. b. Horizontal Shear Stress
V1 H = 1.5 bh

Assuming the stringers are continuous over two spans, the maximum shear occurs at the center support and is equal to V = 5/8 wR. To convert this to the applicable horizontal shear, use L = (L-2h) as follows:
1 ft V 1 = 5 / 8 w (L - 2h) = 5 / 8 x 154 lb / ft 5 ft - 2 x 3.5 in. x = 425 lb 12 in. b = 1 in.
h = 3 1/ 2 in. 426 lb H = 1.5 x = 121 psi 1.5 in. x 3.5 in.

The allowable horizontal shear for Douglas Fir is 120 psi; therefore, the member is acceptable with regard to horizontal shear with a slight overstress.

5-393.207 (3)

BRIDGE CONSTRUCTION MANUAL

November 1, 2005

c.

Bearing Stress - f = P/A For a two span continuous stringer, the maximum P will be at the center reaction point.

P = R2 =

5wL 4

5 x 154 lb / ft x 5 ft = 962.5 lb 4

2" x 4" Stringer

A = 2 (1 in.) (1 in.) = 4.5 in.2 f=


962.5 lb 4.5 in.2 = 214 psi

1 5/8"

Bearing surface (shaded) 1 1/2"

2 - 2" x 12" 1 1/2"

The temporary allowable side bearing stress for Douglas Fir is 480 psi; therefore, member is acceptable. d. Deflection of Stringers )=
wL4 185 EI

Since deflection is to be based on dead load only, the value for w will be: w = 154 lb/ft - 50 lb/ft = 104 lb/ft L = 5 ft E = 1,760,000 lb/in.2 I = 5.36 in.4

12 in. 104 lb / ft x 5 ft x 1 ft
4

185 x 1,800,000 lb / in.2 x 5.36 in. 4

= 0.063 in.

The surface being formed is not exposed to view and is, therefore, not subject to the normal deflection limitation. However, this value will be used later to determine the cumulative deflection of the falsework. 3. Joists (double 2 x 10 member) Dead load is applied to this member through eight 2 x 4 stringers. As a general rule, when the concentrated loads are applied through 3 or more crossing members, the assumption of uniform loading may be used.

November 1, 2005

BRIDGE CONSTRUCTION MANUAL

5-393.207 (4)

7'-4" (Concrete carried by joist)

Double 2" x 10" (joist)

8'-2" O.C.

Determine uniform load on the joist: Concrete Plywood Stringers Double 2 x 10 Live Load
1 ft 3 8 in. x x 1 ft x 150 lb / ft x 5 ft 12 in. = 500.0 lb

0.06 ft x 1 ft x 40 lb/ft3 x 5 ft
1 8 x 1.5 lb / 1f x 5 ft x 7.33

8"

= 12.5 lb
= 8.2 lb

2 x 3.9 lb/lf 50 lb/ft2 x 5 ft x 1 ft Total w

7.8 lb

= 250.0 lb = 778.5 lb/lf

w = 778.5 lb/ft 2 - 2" x 10"

7'-4" Assumed design condition

a.

Bending Stress - f =

M S

M=

778.5 lb / ft x (7.333 ft.) wL2 = 8 8

= 5233 ft lb

for two (2) 2 x 10's, S4S, S = 2 x 21.39 in.3 = 42.78 in.3


12 in. 5233 ft lb x 1 ft 4278 in.3

f =

= 1468 psi

5-393.207 (5)

BRIDGE CONSTRUCTION MANUAL

November 1, 2005

The allowable bending stress for Douglas Fir is 1875 psi; therefore, the member is acceptable in bending. b. Horizontal Shear Stress H = 1.5
V1 bh

V1 =

w (L - 2h) 1 ft = 778.5 lb / ft x 7.333 ft - 2 x 9.5 in. x / 2 = 2238 lb 12 in. 2

Half of this amount is carried on each 2 x 10 or V1 = 1119 lb per 2 x 10. b = 1 in. h = 9 in. H=
1.5 x 1119 lb = 118 psi 1.5 in. x 9.5 in.

This is less than the allowable stress of 120 psi and is acceptable. c. Bearing Stress on Washer f = P/A P=
778.5 lb / ft x 7.33 ft = 2853 lb 2

4" 3" 1 1/2" 1 1/2" 3/4"


3

With a 3" x 4" washer placed as shown, and assuming a 3/4 inch space is used between the 2" x 10" members, A = 3 in. x 3 in. = 9.0 in.2 f=
2853 lb 9 in.2

= 317 psi

The allowable side bearing stress for Douglas Fir is 480 psi. A stress increase factor of 1.13 is permitted in accordance with Figure A 5-393.204 resulting in a total allowable stress of 480 x 1.13 - 542 psi which is considerably more than the actual stress. d. Deflection )=
5wL4 384 EI

w = 778.5 lb/ft - 250 lb/ft = 528.5 lb/ft = 7' - 4" E = 1,760,000 psi

For 2-2 x 10's

I = 2 x 98.93 in4 = 197.86 in.4


12 in. 5 x 528.5 lb / ft x (7.333 ft) 4 x 1 ft 384 x 1,800,000 lb / in.2 x 197.86 in.4

= 0.097

November 1, 2005

BRIDGE CONSTRUCTION MANUAL

5-393.207 (6)

The cumulative deflection of the falsework in the interior bays is limited to about 1/2 inch (see Section 5-393.203). It can be seen that the cumulative deflection of stringers (0.063 in.) plus joists (0.097 in.) will be only 0.160 inches (approximately 3/16 inch) and is, therefore, acceptable. 4. Hanger Rods The load on each hanger rod will be equal to the bearing load on the plate washers, or 2853 pounds. The inch diameter coil bolts for the hangers are manufactured in various strengths such as 6000 pound capacity, 9000 pound capacity, etc.. When required, the Contractor should furnish evidence of the safe capacity of the proposed coil bolts. In addition to checking the coil bolt, the hanger must be checked for rated capacity. Most hangers are rated for the load carrying capacity of the entire hanger. The load on either side should not exceed one-half of this value. SLAB OVERHANG FALSEWORK 1. Plywood Sheathing Maximum stress in the sheathing will occur adjacent to the beam, at the point where concrete depth is a maximum.

8"

3'-10"

8"

8 3/4"

10 1/4"

9 1/2"

2"

1'-0"

1'-0" 1'-0" 54" (Top mem ber of superior bracket)

1'-0"

3"

8"

4"

* Stool height is an estimated value


for computation purposes only.
Assume the concrete stool plus flange thickness at the maximum depth will be 3 inches. Where this value is known to be greater, use the known maximum value. Determine uniform dead load on the sheathing based on this maximum thickness:
Concrete 1 ft 3 11 in x x 1 ft x 150 lb / ft = 137.5 lb / ft 12 in.

Plywood Live Load

0.06 ft x 1 ft x 40 lb/ft3

2.5 lb/ft lb/ft

= 50 Total w

= 190.0 lb/ft

5-393.207 (7)

BRIDGE CONSTRUCTION MANUAL

November 1, 2005

From Figure B 5-393.202, the safe carrying load for Class I plywood placed weak way with supports at 12 inches is 550 psf. Therefore, the sheathing is acceptable. 2. Stringers The second stringer from the right will be the controlling stringer for design. (The stringer on the right carries only about one-half as much load.) The average slab thickness at this controlling stringer can be determined by calculation or by scaling the drawing. In this case, an average thickness of 10 inches was scaled. The uniform load on this stringer will be:
Concrete

1 ft 3 10.25 in. x x 1 ft x 150 lb / ft 12 in.

1'-0"
= 128.1 lb / ft

Plywood Stringer Live Load

.06 ft x 1 ft x 40 lb/ft3

= =

2.5 lb/ft 1.5 lb/ft

= 50 lb/ft Total w = 182.1 lb/ft

2" x 4" Stringer

The uniform load on interior stringers was 154 lb/ft. Since stringers on the overhang have the same span length as the stringers on the interior bays, their stresses may quickly be checked by ratios as follows: a. Bending Stress F=
182.1 lb / ft x 1887 psi = 2231 psi 154 lb / ft

This is 19% over the allowable bending stress of 1875 psi for Douglas Fir. Therefore, this member should have its spacings reduced 20% or down to 10 inch spacing.
Concrete

1 ft 1 ft 3 10.40 in. x x 10 in. x x 150 lb / ft 12 in. 12 in.

= 108.3 lb / ft

Plywood Stringer Live Load

0.06 ft x 0.833 ft x 40 lb/ft3

= =

2.1 lb/ft 1.5 lb/ft 41.7 lb/ft

50 lb/ft2 x (0.833 ft)

= Total w

10" 10 1/4" (Ave.)

= 153.6 lb/ft

2" x 4" Stringer


Repeat a. and b. steps as follows: The uniform load on interior stringers was 154 lb/lf. Since stringers on the overhang have the same span length as the stringers on the interior bays, their stresses may quickly be check by ratios as follows:

10 1/4" (Ave.)

November 1, 2005

BRIDGE CONSTRUCTION MANUAL

5-393.207 (8)

a.

Bearing Stress

f=

153.6 lb / ft x 1887 psi = 1882 psi 154 lb / ft

This is about the allowable bending stress of 1875 psi for Douglas Fir; therefore, this member is acceptable in bending. b. Horizontal Shear Stress H=
153.6 lb / ft x 121 psi = 120.7 psi 154 lb / ft

This is about the same as the allowable stress of 120 psi and is, therefore, acceptable. c. Bearing Stress f= P A

Using the Superior bracket as recommended by the manufacturer with a slotted 2" x 6" top bearing surface, the bearing area is:

2" x 4" Stringer

A = 4 in. x 1 1/2 in. = 6.0 in. P=

2" x 6" with center slot END VIEW 1-5/8" 1-1/2" Wide slot

153.6 lb / ft x 962.5 lb = 960 lb 154 lb / ft

f=

960 lb 6.0 in.2

= 160 psi

Contact surfaces (shaded) 5 1/2" PLAN VIEW


The allowable stress increase factor need not be figured since this stress is much less than the allowable stress of 490 psi. d. Deflection of Stringers =
wL4 185EI

The uniform load is the only factor which differs from the calculation for deflection of the interior stringers. For this member, w = 153.6 lb/ft - 41.7 lb/ft (live load) = 111.9 lb/ft. Deflection of the overhang stringers can be determined by using a ratio of the uniform loads. )=
111.9 lb / ft x 0.063 in. = 0.068 in. 104 lb / ft

Since this surface is considered to be exposed to view and the span length is less than 67 inches, the maximum allowable deflection will be:
12 in. 5 ft x 1 ft 270

L / 270 =

= 0.222 in.

The actual deflection is less than this; therefore, the member is acceptable.

5-393.207 (9)

BRIDGE CONSTRUCTION MANUAL

November 1, 2005

3.

Steel Overhang Brackets Superior brackets may be checked using the influence lines in Figure F 5-393.202. To use this chart, the load on individual stringers must be determined and the distance from the outboard end of the bracket to each stringer must be determined. A calculation summary of the loads and distances are on the next page.

50" 40" 30" 20" 10" 2"

Spacing of brackets = 5'-0"

* Use 8.30' because most of concrete section


is to the right of "B".

**

Stool height is an estimated 3" for computation purposes only.

B 8" 8.15"*

C 8.90"

D 9.65"

E 10.40"

F 11"**

SLAB DEPTHS AT STRINGER LOCATIONS

November 1, 2005

BRIDGE CONSTRUCTION MANUAL

5-393.207 (10)

1 ft 3 1 ft Plywood load = x (40) x (10 in.) x x 12 in. 4 in. 12 in.

= 2.1 lbs / linear ft

Stringer load
10 in. Live load = (50 lbs / ft 2 ) x 12 in.

= 1.2 lbs/linear ft
= 1.2 lbs / linear ft

Concrete loads:
1 ft 1 ft. 1 in. 3 PA = 8.075 in. x x (2 in.) x x x 150 lbs / ft 12 in. 12 in. 10 in.
1 ft 1 ft 1 ft 1 ft 9 in. 3 PB = 8.30 in. x x (5 in.) x + 8.075 in. x x (2 in.) x x x (150 lbs / ft ) 12 in. 12 in. 12 in. 12 in. 10 in.

= 1.7 lbs / linear ft

= 58.4 lbs / linear ft

1 ft 1 ft 3 PC = 8.90 in. x x (10 in. ) x x 150 lbs / ft 12 in. 12 in. 1 ft 1 ft 3 PD = 9.65 in. x x (10 in. ) x x 150 lbs / ft 12 in. 12 in. 1 ft 1 ft 3 PE = 10.4 in. x x (9 in. ) x x 150 lbs / ft 12 in. 12 in. 1 ft 8 in. 1 ft 3 PF = 10.7 in. x x x x 150 lbs / ft 12 in. 2 12 in.

= 92.7 lbs / linear ft

= 100.5 lbs / linear ft

= 97.5 lbs / linear ft

= 44.6 lbs / linear ft

TOTAL =395.4 lbs/linear ft

LIVE LOADS

BRACKET LOADS = 5/4 wL w = dead load plus live load

PA = 25 lbs/linear ft PB = 41.7 lbs/linear ft PC = 41.7 lbs/linear ft PD = 41.7 lbs/linear ft PE = 37.5 lbs/linear ft PF = 16.7 lbs/linear ft Examples: Bracket load

PA = 188 lbs PB = 646 lbs PC = 861 lbs PD = 909 lbs PE = 865 lbs PF = 403 lbs PA = 5/4 x (1.7 + 2.1 + 1.2 + 25) x (5.0') = 188 lbs PB = 5/4 x (58.4 + 2.1 + 1.2 + 41.7) x (5.0') = 646 lbs

5-393.207 (11)

BRIDGE CONSTRUCTION MANUAL

November 1, 2005

Stringer No. A B C D E F

Load On 45ECoil Rod 188 lb x 2.7 = 508 lb 646 lb x 1.3 = 840 lb 861 lb x 1.95 = 1679 lb 909 lb x 1.7 = 1545 lb 865 lb x 1.58 = 1367 lb 403 lb x 1.45 = 584 lb Total Load = 6523 lb Manufacturers Allowable Load = 9000 lb

Load on Diagonal Member 188 lb x 2.7 = 508 lb 646 lb x 1.9 = 1227 lb 861 lb x 1.3 -= 1119 lb 909 lb x 0.80 = 727 lb 865 lb x 0.40 = 346 lb 403 lb x 0.10 = 40 lb Total Load = 3967 lb Manufacturers Allowable Load = 4733 lb*

* This load is only for overhang brackets on steel beams.

Since the applied loads are less than the allowable load, the coil rod and diagonal are acceptable with regard to strength. However, other bracket components such as the hanger assembly must also be checked for strength requirements as per manufacturers allowable loads. b. Deflection of Overhang Bracket The manufacturers literature indicates that the deflection is determined by summarizing the total vertical weight on the bracket. Only the weight of concrete need be applied since deflection due to dead weight of the falsework may be allowed for prior to concrete placement.
8 in. + 11 in. 1 ft Total weight of concrete = x 3.33 ft x 5 ft x 150 lb / ft x = 1977 lb 12 in. 2

Using Figure F 5-393.202 as a guide, the deflection resulting from a load of 1977 lb would be about 3/16 inch. The cumulative deflection of the overhang falsework may now be summarized. Deflection of sheathing Deflection of stringers Deflection of brackets Seating of wood members (2 x 1/16")* Total Deflection at center of stringer span = negligible 0.068 in. 0.190 in. 0.120 in. 0.378 in.

*Abutting faces of wood members are assumed to crush about 1/16 inch when heavy load is applied. This value will be less for tightly constructed falsework. In addition, wood fillers against the web as used on prestressed concrete girders must be uniformly fitted and seated to prevent uneven overhang deflections. The falsework along the edge of coping should, therefore, be set about 3/8 in. above final grade to compensate for the anticipated deflection.

November 1, 2005

BRIDGE CONSTRUCTION MANUAL

5-393.208 (1)

4.

Hanger a. The bolt on this hanger is actually the 45E coil rod which was checked in Item 3. above. Note that the manufacturer specifies a 9000 lb capacity coil bolt. Hangers are normally rated for vertical load carrying capacity. The vertical component on this hanger can be determined as follows: P = 0.707 x 6523 lb = 4612 lb

b.

45
65 23

This value should not exceed 1/2 of the safe working load for the total hanger. Preferably, the manufacturer should furnish information as to the safe load along the 45E angle for the overhang hangers. Note: The safe working loads ascribed to these hangers only applies when the device has full bearing contact on the top flange of the beam and when the hanger bolts are flush with the edge of the beam flange. 5-393.208 SLAB SPAN FALSEWORK Assume the Contractor has proposed the falsework scheme shown in Figure A 5-393.208. In addition, assume they have stated that a strike-off machine weighing 8000 pounds will be used and strike-off rails will be located as shown in the figure (outside berm). The following stress investigation would be necessary. 1. Sheathing a. b. c. 2. Bending stress Rolling shear stress Deflection 4. Pile Cap a. b. c. d. Joist (2 x 6) a. b. c. d. 3. Bending stress Horizontal shear stress Bearing stress Deflection 6. Strike-off machine support system a. b. Beams (6 x 14) a. b. c. d. Bending stress Horizontal shear stress Bearing stress Deflection c. d. Bending stress Horizontal shear stress Bearing stress Deflection 5. Pile - total reaction Bending stress Horizontal shear stress Bearing stress Deflection

Figure A 5-393.208

BRIDGE CONSTRUCTION MANUAL

November 1, 2005

EXAMPLE: FALSEWORK FOR SLAB SPAN A Concrete slab 1'-9" 3/4" Plyform sheathing

C Supporting rail for L strike-off machine

2" x 6" @ 1'-0" O.C. Bolts

6" x 14" Beams @ 5'-0" O.C. 12" x 12" Pile cap

Drift pins 2" x 12" Bracing

A 10'-0"

Timber piles butt dia. 12" 10'-0" CROSS SECTION OF SLAB FALSEWORK Concrete slab 10'-0"

2" x 6" @ 1'-0" O.C. 12" x 12" cap 6" x 14" @ 5'-0" O.C. 2" x 12" Bracing

Timber piles

10'-0"

10'-0" SECTION A-A All lumber to be Douglas Fir, Construction Grade

10'-0"

November 1, 2005

BRIDGE CONSTRUCTION MANUAL

5-393.208 (2)

Calculations are as follows: 1. 3/4 inch Sheathing Determine applied uniform load Concrete 1.75 ft x 1 ft x 150
lb ft 3 lb ft 3

= 262.5 lb/ft

Plywood Live Load

0 .06 ft x 1 ft x 40

2.5 lb/ft

= 50.0 lb/ft Total w = 315.0 lb/ft

Figure B 5-393.202 indicates that even the lowest grade plyform (Class II) placed in the weak direction will safely support about 500 psf; therefore, the sheathing is acceptable. 2. Joist (2 x 6) Since these members are spaced at 1'-0", the applied uniform load = 315 lb/ft + 2.3 lb/ft (weight of joist) = 317.3 lb/ft. Assume two span continuous design with L = 5 feet. a. Bending Stress f=
M S

M=

317.3 lb / ft x (5 ft ) wL2 = 8 8

= 991.5 ft/lb

S = 7.56 in.3
12 in. 991.5 ft / lb 1 ft 7.56

f =

= 1574 psi

Since this is less than the 1875 psi allowable stress, it is acceptable. b. Horizontal Shear Stress H = 1.5
V1 bh

1 ft At the center support, V1 = 5 / 8 w (L - 2h) = 5 / 8 x 317.3 lb / ft x 5 ft - 2 x 5.5 in. x = 809.8 lbs 12 in. b = 1 1/2 in. h = 5 1/2 in
H = 1.5 809.8 lb = 147.2 psi 1.5 in. x 5.5 in.

Allowable horizontal shear is 120 psi; therefore, this is not acceptable, so reduce joist spacing to 10 inch.
1 ft V 1 = 5 / 8 (264.8) x 5 ft - 2 x 5.5 in. x = 675.8 lbs 12 in. 1.5 (675.8) H = = 122.9 psi 120 psi allowable. 1.5 in. x 5.5 in.
w = 264.8

Also, bending is OK with the reduced spacing.

5-393.208 (3)

BRIDGE CONSTRUCTION MANUAL

November 1, 2005

c.

Bearing Stress f =

P A

For two span continuous, maximum P is at the center support. P = R2 =


5wL 5 x 264.8 lb / ft x 5 ft = 1655 lbs = 4 4

Bearing surface

6" x 14" Beam

A = 1 1/2 in. x 5.5 in. = 8.25 in.2 NOTE: The 6 x 14 beams will normally be rough cut and, therefore, will have the full 6 x 14 dimensions and the area will be 1 1/2 in x 6.0 in. = 9.0 in.2. f=
1655 lb 8.25 in.2

2" x 6" Joist PLAN VIEW

= 201 psi

This is much less than the 480 psi allowable and is, therefore, acceptable. d. Deflection of 2 x 6 joist ) =
wL4 185EI

w = 264.8 lb/ft - 41.7 lb/ft (live load) = 223.1 lb/ft L = 5 feet


= 12 in. 223.1 lb / ft x (5 ft) 4 x 1 ft
3

E = 1,800,000 lb/in.2 I = 20.80 in.4


The limiting deflection is

185 x 1,800,000 lb / in.2 x 20.80 in.4

= 0.035 in.

L 12 in. = 5 ft x = 0.22 in. (as specified in Section 5- 393.202). 1 ft 270

Since .035 inches is less than the allowable, the member is acceptable) 3. Beams (6 x 14) Assume the Contractor has stated that these beams will be furnished in 22 foot lengths. Two span continuous design will then apply. Determine applied, uniform load: = 1324.0 lb/ft Live load, concrete, sheathing and joists = 264.8 lb/ft2 x 5 ft 2 1 ft x 40 lb / ft 3 = 23.3 lb / ft Weight of 6 x 14 member (rough cut) = 6 in. x 14 in. x 144 in. 2 w = 1347.3 lb/ft NOTE: It can be assumed that the ends of joists will be staggered so that the critical load determined in 2c. above will not occur on any one beam. Bending stress M= f=
M S
2

a.

1347.3 lb / ft x (10 ft ) wL2 = 8 8

= 16841.3 ft lb

S = 196.0 in.3 (for rough cut 6 x 14)

November 1, 2005

BRIDGE CONSTRUCTION MANUAL

5-393.208 (4)

f =

12 in. 16841.3 x 1 ft 196.0 in. 3

= 1031 psi

The allowable bending stress is 1875 psi; therefore, this is acceptable. b. Horizontal shear stress H=
1.5 V1 bh

1 ft 5 x 1347.3 lb / ft x 10 ft - 2 x (14 in.) x 12 in. 5w (L - 2h) 1 For 2 span continuous, V = = 8 8

= 6456 lb

b = 6 in.

h = 14 in.

H =

1.5 x 6456 lb = 115 psi 6 in. x 14 in.

This is less than the allowable stress of 120 psi and is, therefore, acceptable. c. Side bearing stress f =
P A

For 2 span continuous, the maximum P will be over the center support. P = R2 =
5wL 5 x 1347.3 lb / ft x 10 ft = 16841 lb = 4 4 16841 lb 84 in.2

A = 6 in. x 14 in. = 84 in.2 f =

= 200 psi

Allowable side bearing stress is 480 psi; therefore, this is acceptable. d. Deflection ) =
wL4 185 EI

w = 1347.3 lb/ft - 41.67 lb/ft2 x 5 ft (live load) = 1139.0 lb ft L = 120 in. E = 1,800,000 lb/in.2 I = 1372 in.4 (rough cut)
= 12 in. 1139.0 lb / ft x (10 ft) 4 x 1 ft
3

185 x 1,800,000 lb / in. 2 x 1372 in. 4

= 0.043 in.

This is less than the allowable deflection of 1/4 inch for the member but must also be checked later as part of the cumulative deflection. 4. Pile cap (12 x 12) The reaction of the 6 x 14 beams on the pile cap will be as follows: NOTE: A simple span reaction will be used since the higher reaction R2 determined in Step 3 c) above will occur at random locations rather than all on one pier cap. This simplification is also in agreement with ACI recommendations. Live load, concrete, sheathing, joist and beam = 1347.3 lb/lf of beam Load on pile cap = 1374.3 lb/ft x 10 ft = 1347.3 lb per beam

5-393.208 (5)

BRIDGE CONSTRUCTION MANUAL

November 1, 2005

Assume the Contractor has stated that pile caps will be furnished in 20 foot lengths. Two span continuous design will apply. The following loading diagram will be typical of each two span segment:

13473 lb

13473 lb 1 10'-0"

13473 lb 2

13473 lb

13473 lb

w = 40 lb/ft (due to weight of pile cap) 12" x 12" Pile cap

10'-0"

Pile spacing

a.

Bending Stress in Pile Cap Maximum bending stresses should be checked at points and . To determine the bending moments in the cap, use the applicable load diagrams from the AISC Manual. For this example, there is no identical loading diagram in the manual, but it is possible to obtain the moments by summarizing diagrams for each of the individual loads as follows:
13473 lb 2 1 1 2 1 13473 lb

w = 40 lb/ft

Note: The load from the 6 x 14 beams directly over the piles are not shown since they do not cause bending in the pile cap. M =
40 lb / ft x (10 ft ) 13 3 wL2 13 3 PL - 1 / 2 PL + = x 13473 lb x 10 ft x 13473 lb x 10 ft + 14.2 64 32 14.2 64 64
2

= 21333 ft lb

M = 2x

40 lb / ft x (10 ft ) 3 wL2 3 PL + = 2x x 13473 lb x 10 ft + 8 32 8 32

= 25762 ft lb

f =

M for 12" x 12" rough cut, S = 288 in.3 S

25762 ft lb x f =

12 in. 1 ft. = 1073 psi 288 in.3

This is less than the allowable stress of 1875 psi and is therefore acceptable.

November 1, 2005

BRIDGE CONSTRUCTION MANUAL

5-393.208 (6)

b.

Horizontal shear stress in pile cap

H =

1.5 V1 bh

This stress will be maximum over the center support. Summarize the shear formulas for the three diagrams used to determine bending moments.
1 ft 5 x 40 lb / ft 10 ft - 2 x 12 in. x 12 in. 19 1 3 5w (L - 2h) 20.5 1 V = P + P + = x 13473 lb + = 8831 lb 32 2 32 8 8 32

H=

1.5 x 8831 lb 144 in.2

= 92 psi

This is less than the allowable stress of 120 psi and is, therefore, acceptable. c. Bearing stress of pile cap on pile. f =
P A

The maximum P will be over the center support. Use the applicable formulas for reactions for the load diagrams used to determine bending moments. P = R2 = 2 x
11 5wL P + (Reaction from beam directly over the pile) + 16 4 11 5 x 40 lb / ft x 10 ft x 13473 lb + 13473 lb + = 32498 lb 4 16

=2x

Assuming 12 inch diameter piles under the 12 x 12 cap, the contact area would be: A = Br2 = 3.14 x 62 = 113.1 in.2 [This value may also be determined by Figure A 5-393.204] f=
32498 113.1 in.2

= 287 psi

This is less than the allowable side bearing stress of 480 psi on the 12 x 12; therefore, it is acceptable. d. Deflection of pile cap The exact deflection of the pile cap cannot be readily determined since a formula to cover this load situation is not available in the AISC Manual. However, formulas are available to determine an approximate value of the deflection, assuming a simple span loading condition as shown below: (NOTE: This deflection will be slightly greater than the actual deflection of the two span continuous pier cap.)

13473 lb minus live load 40 lb/ft

10'-0"

5-393.208 (7)

BRIDGE CONSTRUCTION MANUAL

November 1, 2005

At , ) =

PL 3 5wL4 + 384EI 48EI

P = Total reaction minus live load = 13473 lb - (50 lb/ft2 x 5 ft x 10 ft) = 10973 lb L = 10 ft E = 1,800,000 lb/in.2 I = 1728 in.4 (full sawn) w = 40 lb/ft
12 in. 10973 lb x (10 ft)3 x 1 ft
3

) =

48 x 1,800,000 lb / in.2 x 1728 in.4

12 in. 5 x 40 lb / ft x (10 ft) 4 x 1 ft

384 x 1,800,000 lb / in2 x 1728 in.4

= 0.130 in.

The maximum cumulative deflection of the joists, beams and pile caps will be as follows: . Joists Beams Pile Cap Total 0.035 in. 0.043 in. 0.130 in. (conservative value) 0.208 in.

It can be concluded that deflections will approach a value of 1/4 inch at points of maximum deflection. Each of the individual members (joists, beam and pile cap) are within the limiting deflection value of 1/4 inch and the cumulative deflection is also close enough to this value to be acceptable. 5. Pile Load The maximum pile load will be as shown in 4c above. P = 32498 lb = 16.25 tons. This pile load is not an average pile load but rather is based on the assumption of two span continuous action of the pile caps. The average load per pile is as follows (assume each pile supports a 10 foot square area above it since piles are spaced at 10 feet in both directions): Sheathing, concrete and live load Joists Beams Pile cap 315.0 lb/ft2 x 10 ft x 10 ft 12 x 10 ft x 2.3 lb/ft 2 x 10 ft x 23.3 lb/ft 1 x 10 ft x 40 lb/ft Total = 31500 lb = = = = 276 lb 467 lb 400 lb 32643 lb = 16.32 tons

The chart of page 5-393.202 indicates that piles having 12 inch butts may be used for loads of up to 18 tons and that piles having 14 inch butts may be used for loads of up to 21 tons. In consideration of the relative values of the maximum pile load and the average pile load shown above, it would be reasonable to permit the use of piles having 12 inch butts for the falsework in this example. Had the maximum pile load been significantly larger, some falsework revision would have been necessary.

November 1, 2005

BRIDGE CONSTRUCTION MANUAL

5-393.208 (8)

6.

Strike-off Machine Support Assume the Contractor (for this example) has provided information regarding the strike-off machine which indicates a total weight of 8000 pounds. Assume also that the machine wheel base is 5' 0" and that posts for the strike-off rail are spaced at 5'0". The maximum loads on the 6 x 14 beams supporting the strike-off machine can then be determined.

Load on beam 1 = 1618 lb/ft

Load on beam 2 = 1415 lb/ft

Load on beam 3 = 202 lb/ft

Conc. slab 2 x 6 Joist 6 x 14 Beams @ 5'-0" O.C. Pile cap 1

Wt. of strikeoff machine 8000 lb

Falsework piles CROSS SECTION OF FALSEWORK NEAR EDGE OF SLAB


Beam will support the full design loads determined in part 2. of this section. With the edge of slab ending midway between beams and and, assuming the joists are simple spans, it can be shown that beam will carry about 7/8 of the load carried by beam , and beam will carry about 1/8 of the load carried by beam (plus the weight of the strike-off machine). This will result in the following loading diagram for beam :
Strike-off machine

Rail for strikeoff machine Rail support posts

6" x 14" Beam 12" x 12" Cap Falsework pile

2'-6"

5'-0"

2'-6"

ELEVATION OF BEAM 3

2000 lb

2000 lb w = 202 lb/ft

10'-0"

10'-0"

ASSUMED CRITICAL LOAD CONDITION FOR BEAM 3

5-393.208 (9)

BRIDGE CONSTRUCTION MANUAL

November 1, 2005

The position of the strike-off machine shown in the load diagram will result in the maximum bending stress and maximum deflection of the 6 x 14 beam. Note that the rail support posts are placed in locations which will have approximately equal deflections. This is preferable to placing one post over the non-deflecting pier cap and having the remaining posts fall at mid-span where deflection is greatest. The strike-off machine will not appreciably affect the falsework joists since the rail supports fall directly over the 6 x 14 beams. In addition, the strike-off machine will not cause bending, deflection or horizontal shear in the pile cap, since the supporting beams fall directly over the outside row of piles. Therefore, only the 6 x 14 beam (beam ) will be investigated. To simplify calculations, this will be assumed to be a simple span rather than two span continuous. (Use the left half of the load diagram shown above.) a. Bending stress in 6 x 14 beam f=
M S

M=

wL2 + Pa (formulas from AISC Manual) 8


2

202 lb / ft x (10 ft ) + 2000 lb x 2.5 ft = 7525 ft/lb 8

for rough cut 6 x 14, S = 196.0 in.3


12 in. 7525 ft / lb x 1 ft 196.0 in.3

f =

= 461 psi

This is less than the allowable bending stress of 1875 psi and is, therefore, acceptable. b. Horizontal shear stress in 6 x 14 beam H=
1.5 V1 bh

1 ft 202 lb / ft x 10 ft - 2 x 14 in. x 12 in. 1 V = 2000 lb + 2

= 2774 lbs

H =

1.5 x 2774 lb = 49.5 psi 6 in. x 14 in.

This is less than the allowable stress of 120 psi and is, therefore, acceptable. c. Bearing stress on 6 x 14 beam f=
P A

This critical bearing load would occur with the strike-off machine centered over a pile cap. The following load diagram would apply: 2000 lb 2000 lb 202 lb/ft

2'-6" 10'-0" R1 R2

2'-6" 10'-0" C pile bents L

LOADING CONDITION FOR HORIZONTAL SHEAR IN BEAM 3

November 1, 2005

BRIDGE CONSTRUCTION MANUAL

5-393.208 (10)

Assume two simple spans:


Pa wL P = R2 = 2 x + 2 x L 2

a = 10 ft less 2' 6" = 7' 6" (First portion of formula from AISC Manual)
2000 lb x 7.5 ft = 2x + 201 lb / ft x 10 ft 10 ft

= 5010 lb (Area of 6 x 14 beam on pile cap = 6 in. x 12 in. = 72 in.2) f=


5010 lb 72 in.2

= 69.6 psi

This is less than the allowable side bearing stress of 480 psi and is, therefore, acceptable. d. Deflection of 6 x 14 beam under strike-off machine Assume simple span with loading as for maximum bending stress. )=
5wL4 Pa (3L2 - 4a2) (formulas from AISC Manual) + 384 EI 24 EI

w = 202 lb/ft L = 10 ft E = 1,800,000 psi I = 1372 in.4 a = 2.5 ft P = 2000 lb

12 in. 5 x 202 lb / ft x (10 ft) 4 x 1 ft

384 x 1,800,000 lb / in.2 x 1372 in.4

12 in. 2000 lb x 2.5 ft x 1 ft

24 x 1,800,000 lb / in.2 x 1372 in.4

x [3 x (10 ft)2 - 4 (2.5 ft)2 ] ) = 0.58 in. This represents a deflection of approximately 1/16 inch and could be ignored. However a provision should be made for seating of wood members (about 1/16 inch per wood interface) when setting strike-off rail to grade.

5-393.209 (1)

BRIDGE CONSTRUCTION MANUAL

November 1, 2005

5-393.209 NEEDLE BEAM EXAMPLE Assume that a Contractor is submitting slab falsework plans for a bridge which has shallow steel beams. Due to the difficulty of preventing rotation of the fascia beam which would occur with a cantilevered overhang bracket, they have proposed a scheme which includes the needle beam falsework shown in Figure A 5-393.209. Assume the strike-off machine will be run on the fascia beams. The following stressed items must be investigated: 1. Sheathing a. Bending stress b. Rolling shear stress c. Deflection Joist (2 x 4) a. Bending stress b. Horizontal shear stress c. Bearing stress on runner d. Deflection Runner (4 x 4) a. Bending stress b. Horizontal shear stress c. Bearing stress on post d. Deflection Post (2 x 4) end bearing stress-column stress Needle beams a. Bending stress b. Horizontal shear stress c. Bearing stress on plate washer d. Deflection Supporting bolt a. Tension

2.

3.

4. 5.

6.

Calculations will be based on the assumed loading condition shown below:

6"

Conc. supported on inside runner = 1'-4"

Conc. supported on outside runner = 2'-0"

11"

1'-7" 3" 3'-2"

9.8"

1'-7" 5" C of 4 x 4 runners L

8"

November 1, 2005

BRIDGE CONSTRUCTION MANUAL

Figure A 5-393.209

EXAMPLE: NEEDLE BEAM OVERHANG FALSEWORK A 8'-0" 2" x 4" Joist @ 16" O.C. 3/4" Plyform Class II First. Interior beam W 24x104 3/4" Dia. bolt 4" x 5" Washer Filler plate Needle beam 2 - 2" x 10" @ 5'-0" O.C. 3" 6" 4x4 Runner 2" x 4" Post @ 5'-0" O.C. Fascia beam 4x4 Runner Wedges Supporting bolt 2" x 4" Post @ 5'-0" O.C. 1" x 4" Braces 2" x 6" Plate 3'-10"

3'-2" 5'-3" 9"

2" x 4" Joists @ 16" O.C.

Sheathing

Conc. slab

Bracing (as necessary)

4" x 4" Runner 2" x 4" Posts W24x104 Wedges

5'-0" SECTION A-A

5'-0"

All material to be Douglas Fir, Construction Grade

5-393.209 (2)

BRIDGE CONSTRUCTION MANUAL

November 1, 2005

1.

Sheathing Sheathing is supported on joists spaced at 16 inches. The maximum load on the sheathing will be near the beam flange with an estimated concrete depth of 11 inches. Determine the uniform applied load: Concrete Sheathing Live Load w Refer to Figure B 5-393.152: For 3/4 inch thick Class II Plyform placed the strong way (which is most likely here) the safe load for 16 inch spacing is about 240 psf. The sheathing is therefore acceptable.
1 ft 150 lb / ft 3 x 1 ft x 11 in. x = 137.5 lb / ft 12 in.

40 lb/ft3 x 1 ft x 0.06 ft

= =

2.5 lb/ft 50 lb/ft lb/ft

= 190

2.

Joists (2 x 4) Check the joists using the average slab thickness of 9.8 inches. Determine uniform applied load: Concrete Live Load Sheathing Joist w a. Bending stress f =
M S

1 ft 1 ft 3 9.8 in. x x 16 in. x x 150 lb / ft = 163.3 lb / ft 12 in. 12 in.

1.33 ft x 50 lb/ft2 40 lb/ft3 x 1.33 ft x .06 ft

= 66.7 lb/ft = = 3.3 lb/ft 1.5 lb/ft

= 234.8 lb/ft

Check joists as a simple span. M =


wL2 8

L = 3' 2"
2

M =

234.8 lb / ft x (3.167 ft ) 8

= 294.4 ft/lb

S = 3.06 in.3
12 in. 294.4 ft / lb x 1 ft 3.06 in.3

= 1155 psi

This is less than the allowable stress of 1875 psi and is, therefore, acceptable.

November 1, 2005

BRIDGE CONSTRUCTION MANUAL

5-393.209 (3)

b.

Horizontal shear stress


H = 1.5 V1 bh

1 ft 234.8 lb / ft x 3.167 ft - 2 x 3.5 in. x 12 in. w (L - 2h) V1 = = = 303.3 lbs 2 2

b = 1.50 in. h = 3.50 in.


H = 1.5 x (303.3 lbs) = 86.7 psi 1.5 in. x 3.5 in.

This is less than the allowable stress of 120 psi and is, therefore, acceptable. c. Bearing stress on runner f =
P A

Determine the reaction on the outer runner by assuming that the outer 2' 0" of slab concrete is supported on this runner as indicated on the previous sketch. Concrete =
9.9 in. + 8 in. 1 ft 3 x x 2 ft x 150 lb / ft = 222.5 lb / f 12 in. 2

Sheathing = 5 ft x .06 ft x 40 lb/ft3 (for falsework and for edge of slab form) 2x4 = 7 lf/ft x 1.5 lb/ft (for falsework joist and edge of slab form) Runner (4 x 4) Live Load = 50 lb/ft2 x 2 ft w

= 12.5 lb/ft

= 10.5 lb/ft

3.4 lb/ft

= 100 lb/ft = 348.9 lb/ft

Since joists are spaced at 16 inches or 1.333 ft, the reaction per joist is: P = 1.333 ft x 348.9 lb/ft = 465.2 lb A = 1.5 in. x 3.5 in.
f = 464.4 lbs 5.25 in.2 = 88.6 psi

5.25 in.2

This is much less than the allowable stress of 480 psi and is, therefore acceptable. d. Deflection of joist
=
5wL4 384 EI

Use the same loading criteria for deflection as was used for determining bending stress except that live load is deleted from the uniform load. w = 234.8 - 66.7 = 168.1 lb/ft L = 3' 2"

5-393.209 (4) E = 1,800,000 lb/in.2 I = 5.36 in.4

BRIDGE CONSTRUCTION MANUAL

November 1, 2005

12 in. 5 x 168.1 lb / ft 3.167 ft) 4 x 1 ft 384 x 1,800,000 lb / in.2 x 5.36 in.4

= 0.039 in.

Since this is a surface that is exposed to view, the allowable deflection is:
12 in. 3,167 ft x 1 ft = 0.141 in. 270

L = 270

3.

Runners (4 x 4) Approximately 3 joists will bear on each runner span; therefore, assume the joists produce a uniform load on the runners. This uniform load has been determined in part c) above. w = 348.9 lb/ft a. Bending stress in runners f =
M S

Assume the runners will be furnished in lengths of two spans or more. In following the recommended ACI design simplifications, simple span design will be used. L = 5 ft
M = 348.9 lb / ft x (5 ft ) wL2 = 8 8
2

= 1090.3 ft lb

S = 7.15 in.3
12 in. 1090.3 ft lb x 1 ft 7.15 in.3

f =

= 1830 psi

Since this is less than the allowable stress of 1875 psi, the member is acceptable in bending. b. Horizontal shear stress in runners
H = 1.5 V1 bh

V1 =

w ( L - 2h) 2

1 ft 348.9 lb / ft x 5 ft - 2 x 3.5 in. x 12 in. = = 770.5 lbs 2

b h

= 3.5 in. = 3.5 in.


1.5 x 770.5 lbs = 94.3 psi 3.5 in. x 3.5 in.

H =

This is less than the allowable stress of 120 psi and is, therefore, acceptable.

November 1, 2005

BRIDGE CONSTRUCTION MANUAL

5-393.209 (5)

c.

Bearing stress on 2 x 4 post

f =

P A

P = 348.9 lb/ft x 5 ft = 1744 lbs


f = 1744 lb = 332 psi 3.5 in. x 1.5 in.

This is less than the allowable side bearing stress of 480 psi and is, therefore, acceptable d. Deflection of runner
=
5wL4 384 EI

w = 348.9 lb/ft - 100 lb/ft (live load) = 248.9 lb/ft L = 5 ft E = 1,800,000 lb/in.2 I = 12.51 in.4
12 in. 4 5 x 248.4 lb / ft x (5 ft ) x 1 ft
3

384 x 1,800,000 lb / in.2 x 12.51 in.4

= 0.155 in.

Since this concrete surface will be exposed to view, the allowable deflection is:
12 in. 5 ft x 1 ft = 0.222 in. 270

L = 270

The actual deflection is less than the allowable deflection; therefore, the member is acceptable. 4. 2x4 Post The total load and the resulting bearing stress on this post was determined in part c. above (f = 332 psi). By measurement on the falsework plan, the post height is determined to be about 15 inches. The L/d ratio can then be determined:
L 15 in. = = 10.0 d 1.5 in.

The allowable column stress will be 1562 psi as determined by the graph in Section 5-393.202. Actual stress (332 psi) less than allowable stress; therefore, the column is acceptable. 5. Needle Beam Assume each needle beam supports 5 feet of falsework. (Although the runners are continuous members, they are quite flexible; therefore, simple span reactions can be safely used to determine the applied load on the needle beam.)

5-393.209 (6)

BRIDGE CONSTRUCTION MANUAL

November 1, 2005

The loading diagram for the needle beam is as follows:


First interior beam

Fascia beam

Supporting bolt Walkway Runner

Needle beam 8'-6" 2.92' 3.00' 5.25' 6.00' Weight of member

Determine loads on needle beam: Concrete, live load, sheathing, joists, runner Post 2 x 6 plate Total reaction at runner 2 x 8 walk plank Live load on walkway Total reaction at walkway Weight of cantilevered needle beam a. Bending stress in needle beam
f = M S

= 348.9 lbs/ft x 5 ft = 1.5 lb/ft x 1.3 ft = 2.3 lb/ft x 5 ft

= 1744.5 lb = = 2.0 lb 11.5 lb

= 1758.0 lb = 3.0 lb/ft x 5 ft = 5 ft. x 50 lb/ft = = = = 3.9 lb/ft x 2 x 6 ft = 15.0 lb 250.0 lb 265.0 lb 46.8 lb

Maximum bending moment will be at the supporting bolt. The bending moment is determined as follows: Reaction 1758 lb 265 lb 46.8 lb 2069.8 lb x x x x distance 2.92 ft 5.25 ft 3.00 ft Total = = = = = Moment 5133.4 ft lb 1391.3 ft lb 140.4 ft lb 6665.1 ft lb

for two 2 x 10's S = 21.39 in.3 x 2 = 42.78 in.3


12 in. 6665.1 ft lb x 1 ft = 1869.6 psi f = 42.78

This is less than the allowable stress of 1875 psi; therefore, the member is acceptable in bending.

November 1, 2005

BRIDGE CONSTRUCTION MANUAL

5-393.209 (7)

b.

Horizontal shear stress in needle beam

H =

1.5 V1 bh

The shear in this member can most easily be visualized by drawing a shear diagram. To do this, the reaction (P) at the first interior beam must be determined.
P = 6665.1 ft / lb M = 784.1 lb = 8.50 ft L

C First interior beam L 784.1 lb

C Supporting bolt L on fascia beam 784.1 lb 265 lb 1758 lb C Walkway L C Runner L

Zero shear 2069.8 lb

SHEAR DIAGRAM

The maximum shear (V1) will be about 2069.8 pounds. (Since there is no significantly large uniform load, the shear is not noticeably reduced by using the shear at a distance h from the support.) b = 2 x 1.50 in. = 3.00 in. h = 9.25 in.
H = 1.5 x 2069.8 lb = 111.9 psi 3.00 in. x 9.25 in.

This is less than the allowable stress of 120 psi and is, therefore, acceptable.

5-393.209 (8)

BRIDGE CONSTRUCTION MANUAL

November 1, 2005

c.

Bearing stress on plate washer

f =

P A

The bearing reaction, as determined from the shear diagram above, will be: P = 7841 lb + 2069.8 lb = 2853.9 lb The area of contact for a 4 x 5 washer, as determined from Figure A 5-393.204 is: A = 15.0 in.
f = 2853.9 lb. = 190.3 psi 15.0 in.

This is less than the allowable stress of 480 psi and is, therefore, acceptable. d. Deflection of needle beam The needle beam can be set to plan elevation after the deflection due to weight of the members has occurred. Therefore, the calculations for deflection must only determine the additional amount of deflection due to the weight of concrete applied through the runner. The uniform weight of concrete on the outside runner has already been determined to be 222.5 pounds per foot. The concrete load on each needle beam will be: P = 222.5 lb/ft x 5 ft = 1112.5 lb

1112.5 lb Needle beam Supporting bolt


8.50'
R1 x 8.50 ft = 1112.5 lb x 2.9167 ft R1 R2 = 381.7 lb = 1112.5 l + 381.7 lb = 1494.2 lb

2.92'

R1 R2 Beam in deflected position

1112.5 lb

The formula for determining this deflection, which can be found in the AISC Manual, is as follows:
= Pa 2 (L + a) 3EI

P = 1112.5 lb L = 8.5 ft a = 2.9167 ft for two 2 x 10s, I = 2 x 98.93 in.2 = 197.86 in.4

November 1, 2005

BRIDGE CONSTRUCTION MANUAL

5-393.210

12 in. 12 in. 2 112.5 lb x (8.5 ft + 2.9167 ft) x x (2.9167 ft ) x 1 ft 1 ft 3 x 1,800,000 lb / in.2 x 197.86 in.4

= 0.175 in.

The falsework should be set 0.175 inches high at the outer runner to compensate for deflection of the needle beam. In addition, five or more wood to wood surfaces should exist in the support falsework, all of which will tend to seat (deflection downward), when the concrete load is applied. A commonly used practice is to set the falsework high by 1/16 inch per interface or 5/16 inch in this example. The net height adjustment to the outer runner would then be: 0.175 in. + 0.31 in. = 0.485 in. (above plan elevation) 5-393.210 COLUMN EXAMPLES 1. 2. 1. Wood column Steel column

Wood Column A Douglas Fir 6 x 8 S4S member will be used as a falsework column to support a load of 16,000 pounds. The unsupported length of the column is 14 feet. To determine if this member is acceptable with regard to calculated stresses, the following computations are necessary: The actual stress in the member = f =
P 16000 lb = = 401.3 psi A 5.5 in. x 7.25 in.

Allowable stress is dependent on the L/d ratio.


L/d = 14 ft 12 in. x = 30.55 5.5 in. 1 ft

From the graph in Section 5-393.202, the allowable stress for a Douglas Fir column with L/d ration of 30.55 is 578 psi. Since the actual stress (401.3 psi) is less than the allowable stress, the column is acceptable. 2. Steel Column A length of new HP10x42 piling will be used as a falsework column to support a load of 40,000 pounds. The unsupported length of the column is 16 feet. The following calculations are necessary to determine acceptability of this column. The actual stress in the member will be f =
P = Area of HP 10 x 42 = 12.4 in.2 A
40,000 lb 12.4 in.2 = 3226 psi

(NOTE: Areas of steel members are found in the AISC Manual.) The allowable stress is determined by the appropriate formula from Section 5-393.202. allowable f = 16980 - 0.53 x
kL r
2

12 in. L = 16 ft x = 192 in. 1 ft

5-393.211 (1)

BRIDGE CONSTRUCTION MANUAL

November 1, 2005

from the AISC Manual, r = 2.41 (use the smallest r value) allowable f = 16,980 - 0.53 x
192 in. 2.41 in.
2

= 13616 psi

The member will obviously qualify for use with regard to stress. 5-393.211 JOIST AND STRINGER TABLES The following bridge deck falsework Joist and Stringer Tables can be used as an aid to checking slab falsework. These tables show the maximum allowable spans and dead load deflections for joists and stringers for commonly used allowable bending and shear stresses. The applied dead load and live load per square foot and allowable lumber stresses must be known to obtain the allowable span lengths from the tables. See the following example illustrating the use of the tables.

9"

4 sps. @ 2'-0" (2" x 6" stringers) 8 1/4" min.

9"

Double 2" x 10" joists @ 4'-0" O.C. 5" 8'-8" 9'-6" 5"

FALSEWORK EXAMPLE
1. Stringers Determine applied load per square foot: Concrete
1 ft 3 8.25 in. x x 150 lb / ft 12 in. 1 ft 3 0.75 in. x x 40 lb / ft 12 in.
= 103.1 lb / sf

Plywood

2.5 lb / sf

2" x 6" Stringer Live Load Dead Load + Live Load

2.3 lb / ft x

1 2 ft (Spacing)

1.2 lb / sf

50.0 lb/sf

= 156.8 lb/sf

Read the allowable span from the stringer table using the 160 psf load. The maximum allowable span in the column for lumber having an allowable bending stress of 1875 psi and an allowable shear of 120 psi, 4.22 feet which is greater than the 4' 0" joist spacing and, therefore, the stringer design meets shear and bending requirements. The deflection may be estimated from the table value as 0.017 inches. The stringer bearing stress should be checked as indicated in previous examples in the Bridge Construction Manual. 2. Joists Determine applied load per square foot: Stringer - Dead Load + Live Load = 156.9 lb/square foot

November 1, 2005

BRIDGE CONSTRUCTION MANUAL

5-393.211 (2)

Double 2 x 10 - 2 x 4.3 lb / ft x

1 4 ft (spacing)

2.2 lb / square foot

Total

= 159.1 lb/square foot

Read the allowable span from joist table using 160 psf load. The maximum allowable span in the column for lumber, having an allowable bending stress of 1875 psi and an allowable shear of 120 psi, is 8.48 feet which is approximately the 8'8" joist span and therefore the stringer design meets shear and bending requirements. The deflections will be slightly greater than the 0.144 in. shown in the table. The bearing stress in the lumber and the stress in the hanger hardware should be checked as indicated elsewhere in the Bridge Construction Manual. If lumber is used which has allowable stresses differing from those used in the tables, and the tables indicate that the design is questionable, exact formulas which are shown in the Bridge Construction Manual should be used to check the falsework design. STRINGER TABLE (for two continuous spans)
M = wL2 8 H = 1.5 V1 bh V, = 5 w (L - 2h) 8 = wL4 185 EI

Nominal Stringer Size (actual size) inches

Ctr. to Ctr. Spacing of Stringers

DL+LL lb/ft2

Allowable Stress 1875 psi -bending 120 psi- shear E = 1,800,000 Allowable Span in ft DL ) in inches 0.063 0.056 0.049 0.044 0.099 0.088 0.077 0.068 0.031 0.028 0.025 0.022 0.049 0.043 0.039 0.035 0.012 0.011 0.010 0.009 0.019 0.017 0.016 0.014

Allowable Stress 1312 psi -bending 94 psi - shear E = 1,400,000 Allowable Span in ft 4.09 3.87 3.68 3.51 6.43 6.09 5.78 5.51 3.22 3.05 2.91 2.78 5.05 4.79 4.57 4.36 2.34 2.23 2.13 2.05 3.67 3.50 3.35 3.21 DL ) In inches 0.035 0.031 0.027 0.025 0.055 0.048 0.043 0.039 0.018 0.016 0.014 0.013 0.028 0.025 0.022 0.020 0.007 0.007 0.006 0.006 0.012 0.011 0.010 0.009

2x4 (1 x 3 )

12" 12" 12" 12" 12" 12" 12" 12" 16" 16" 16" 16" 16" 16" 16" 16" 24" 24" 24" 24" 24" 24" 24" 24"

150 160 170 180 150 160 170 180 150 160 170 180 150 160 170 180 150 160 170 180 150 160 170 180

5.05 4.78 4.54 4.32 7.94 7.52 7.13 6.78 3.94 3.73 3.55 3.38 6.20 5.87 5.58 5.32 2.82 2.68 2.56 2.45 4.44 4.22 4.02 3.85

2x6 (1 x 5 )

2x4 (1 x 3 )

2x6 (1 x 5 )

2x4 (1 x 3 )

2x6 (1 x 5 )

5-393.211 (3)

BRIDGE CONSTRUCTION MANUAL

November 1, 2005

JOIST TABLE (for a simple span)


5 w DL L4 = 384 EI M = w L2 8 H = 1.5 V1 bh V, = w (L - 2h) 2

Nominal Stringer Size (actual size) inches

Ctr. to Ctr. Spacing of Stringers

DL+LL lb/ft2

Allowable Stress 1875 psi -bending 120 psi- shear E = 1,800,000 Allowable Span in ft DL ) in inches 0.127 0.113 0.101 0.091 0.162 0.144 0.129 0.116 0.315 0.304 0.294 0.284 0.402 0.388 0.375 0.362 0.052 0.047 0.043 0.039 0.067 0.060 0.055 0.050 0.210 0.203 0.197 0.176 0.268 0.259 0.251 0.224 0.030 0.028 0.025 0.024 0.038 0.035

Allowable Stress 1312 psi -bending 94 psi - shear E = 1,400,000 Allowable Span in ft 5.75 5.47 5.22 4.99 7.34 6.98 6.66 6.37 8.75 8.48 8.22 7.99 11.17 10.81 10.49 10.20 4.24 4.05 3.88 3.73 5.41 5.16 4.95 4.76 7.15 6.89 6.55 6.26 9.12 8.79 8.36 7.98 3.48 3.34 3.21 3.10 4.44 4.26 DL ) In inches 0.074 0.066 0.060 0.055 0.094 0.085 0.077 0.070 0.200 0.192 0.185 0.179 0.253 0.244 0.236 0.229 0.033 0.030 0.028 0.026 0.042 0.038 0.035 0.033 0.132 0.125 0.112 0.101 0.169 0.160 0.143 0.128 0.020 0.018 0.017 0.01 0.025 0.024

2x8 (1 x 7 )

2'-0" 2'-0" 2'-0" 2'-0" 2'-0" 2'-0" 2'-0" 2'-0" 2'-0" 2'-0" 2'-0" 2'-0" 2'-0" 2'-0" 2'-0" 2'-0" 3'-0" 3'-0" 3'-0" 3'-0" 3'-0" 3'-0" 3'-0" 3'-0" 3'-0" 3'-0" 3'-0" 3'-0" 3'-0" 3'-0" 3'-0" 3'-0" 4'-0" 4'-0" 4'-0" 4'-0" 4'-0" 4'-0"

150 160 170 180 150 160 170 180 150 160 170 180 150 160 170 180 150 160 170 180 150 160 170 180 150 160 170 180 150 160 170 180 150 160 170 180 150 160

7.01 6.65 6.33 6.04 8.94 8.48 8.07 7.71 10.46 10.13 9.83 9.55 13.35 12.93 12.54 12.19 5.08 4.83 4.62 4.43 6.48 6.17 5.89 5.65 8.54 8.27 8.03 7.65 10.90 10.56 10.24 9.76 4.11 3.93 3.77 3.63 5.24 5.01

2 x 10 (1 x 9 )

Double 2x8 (1 x 7 ) Double 2 x 10 (1 x 9 ) 2x8 (1 x 7 )

2 x 10 (1 x 9 )

Double 2x8 (1 x 7 ) Double 2 x 10 (1 x 9 ) 2x8 (1 x 7 )

2x8 (1 x 9 )

November 1, 2005

BRIDGE CONSTRUCTION MANUAL

5-393.211 (4)

Nominal Stringer Size (actual size) inches

Ctr. to Ctr. Spacing of Stringers

DL+LL lb/ft2

Allowable Stress 1875 psi -bending 120 psi- shear E = 1,800,000 Allowable Span in ft DL ) in inches 0.032 0.030 0.127 0.113 0.101 0.091 0.162 0.144 0.129 0.116 0.020 0.019 0.018 0.017 0.026 0.024 0.023 0.021 0.077 0.069 0.062 0.057 0.098 0.088 0.079 0.072 0.015 0.014 0.014 0.013 0.020 0.018 0.017 0.017 0.052 0.047 0.043 0.039 0.067 0.060 0.055 0.050

Allowable Stress 1312 psi -bending 94 psi - shear E = 1,400,000 Allowable Span in ft 4.10 3.96 5.75 5.47 5.22 4.99 7.34 6.98 6.66 6.37 3.03 2.91 2.81 2.72 3.86 3.72 3.59 3.47 4.84 4.62 4.42 4.24 6.18 5.89 5.63 5.41 2.72 2.63 2.54 2.47 3.47 3.35 3.25 3.15 4.24 4.05 3.88 3.73 5.41 5.16 4.95 4.76 DL ) In inches 0.022 0.021 0.074 0.066 0.060 0.055 0.094 0.085 0.077 0.070 0.014 0.013 0.013 0.012 0.018 0.017 0.016 0.015 0.046 0.042 0.039 0.035 0.059 0.054 0.049 0.045 0.011 0.011 0.010 0.010 0.014 0.014 0.013 0.013 0.033 0.030 0.028 0.026 0.042 0.038 0.035 0.033

2 x 10 (1 x 9 ) Double 2x8 (1 x 7 ) Double 2 x 10 (1 x 9 ) 2x8 (1 x 7 )

4'-0" 4'-0" 4'-0" 4'-0" 4'-0" 4'-0" 4'-0" 4'-0" 4'-0" 4'-0" 5'-0" 5'-0" 5'-0" 5'-0" 5'-0" 5'-0" 5'-0" 5'-0" 5'-0" 5'-0" 5'-0" 5'-0" 5'-0" 5'-0" 5'-0" 5'-0" 6'-0" 6'-0" 6'-0" 6'-0" 6'-0" 6'-0" 6'-0" 6'-0" 6'-0" 6'-0" 6'-0" 6'-0" 6'-0" 6'-0" 6'-0" 6'-0"

170 180 150 160 170 180 150 160 170 180 150 160 170 180 150 160 170 180 150 160 170 180 150 160 170 180 150 160 170 180 150 160 170 180 150 160 170 180 150 160 170 180

4.81 4.63 7.01 6.65 6.33 6.04 8.94 8.48 8.07 7.71 3.53 3.38 3.26 3.14 4.50 4.32 4.15 4.01 5.85 5.56 5.30 5.08 7.46 7.09 6.77 6.48 3.14 3.02 2.91 2.82 4.01 3.85 3.72 3.60 5.08 4.83 4.62 4.43 6.48 6.17 5.89 5.65

2 x 10 (1 x 9 )

Double 2x8 (1 x 7 ) Double 2 x 10 (1 x 9 ) 2x8 (1 x 7 )

2 x 10 (1 x 9 )

Double 2x8 (1 x 7 ) Double 2 x 10 (1 x 9 )

5-393.212

BRIDGE CONSTRUCTION MANUAL

November 1, 2005

5-393.212 FORM DETAILS All of the comments in Section 5-393.205 regarding Falsework Details and Analysis apply equally to this Section on Form Details and Analysis. In addition to the formulas used in the falsework examples, the formula for lateral concrete pressure (see Section 5-393.204) will be used here for the examples concerning form plans. The pressure determined by these formulas is based on anticipated concrete temperatures and an anticipated rate of concrete placement. The actual value of these two items must be determined during the operation of concrete placement. Any deviation from the anticipated values used for checking stresses must be evaluated to assure that unsafe (over stressed) conditions will not result. 5-393.213 PIER CAP FORM EXAMPLE Assume the Contractor has proposed that pier cap form plans shown in Figure A 5-393.206. Assume all lumber will be Douglas Fir, No. 1. The members which require stress investigation are as follows: (NOTE: Items defined as falsework are checked in Section 5-393.205.) 1. Sheathing a. Bending stress b. Rolling Shear Stress c. Deflection Studs a. b. c. d. Walers a. b. c. d.

2.

Bending stress Horizontal shear stress Bearing stress on walers Deflection

3.

Bending stress Horizontal shear stress Bearing on tie plates Deflection

4.

Tie Rods a. Tension stress or manufacturers safe load

Calculations would be as follows: The lateral concrete pressure is the only load applied on the forms. About 17 cubic yards of concrete are required for the pier cap. Assume the Contractor anticipates placing this concrete in a thirty minute period. The rate of placement would then be: 3.67 feet 30 minutes or 7.33 feet 1 hour

The formula for rate of pour exceeding 7 feet/hour would then apply. The three conditions for determining this pressure are as follows: (Assume T = 70F) 1. T = 70 and R1 = 7.33 feet/hour

P = 150 + 43400 + 2800R1 T T = 150 + 43400 + 2800 x 7.33 70 70 = 1063.2 psf (maximum pressure at any depth)

2.

P = 150h = 150 x 3.667 feet = 550 psf (at bottom of cap forms)

November 1, 2005

BRIDGE CONSTRUCTION MANUAL

5-393.213 (1)

3.

Neither of the above can exceed 2000 psf. The following sketch illustrates the concrete pressure as determined above.

h=0 (Top of concrete)

p=0

h = 3.67 ft (Bottom of pier cap)

p = 550 psf

p = 1060

Only the cross-hatched portion of the pressure diagram applies in this example. 1. Sheathing When a triangular shaped pressure diagram is involved, check sheathing for the maximum pressure. In this case, check the sheathing for a pressure of 550 psf on a stud spacing of 16 inches. The sheathing material is 7/8 inch plyform, Class I. The chart for face grain across (see Figure B 5-393.202) indicates that 7/8 inch plyform with 16 inch stud spacing can safely carry just 550 psf. It must be verified later that the Contractor actually places the plyform the strong way. 2. Studs The studs in this example should be checked as a simple span. In the following sketches, the stud will be shown horizontal to more clearly illustrate its beam action.

550 psf 450 psf 287.5 psf @ mid span 125 psf 1'-1" 1'-1" 2 x 4 stud

8"

2'-2" C Walers L

10"

a.

Bending stress

The pressure at mid span (287.5 psf) may be used as a uniform load for computing bending moments. The results will be slightly more conservative than would result from use of the actual loading. The pressure of 287.5 psf must be converted to a load per linear foot on the studs with a 16 inch spacing. w = 287.5 lb/ft2 x 16 in. x 1 ft = 383.3 lb/ft 12 in.

5-393.213 (2)

BRIDGE CONSTRUCTION MANUAL M = wl2 = 383.3 lb/ft x (2.167 ft)2 = 225 ft lb 8 8 S = 3.06 in.3 225 ft/lb 12 in. 1 ft 3.06 in.3

November 1, 2005

f =

M S

= 882.3 psi

This is less than the allowable bending stress of 1875 psi for Douglas Fir and is, therefore, acceptable. b. Horizontal shear stress This should be checked by assuming that the load at the left support (450 psf) extends uniformly across the simple span. Results will be slightly more conservative than would result from the use of the actual loading. First convert the load to a uniform load for studs at 16 inch spacing. = 600 lb/ft w = 450 lb/ft2 x (16 in.) x 1 ft 12 in. 600 lb/ft x 2.167 ft - 2 x 3.5 in. x V1 = w (L-2h) = 2 2 1 ft 12 in. = 475 lb

H = 1.5 V1 = 1.5 x 475 lb = 135.7 psi bh 1.5 in. x 3.5 in. This is more than the allowable stress of 120 psi and is not acceptable. Therefore, reduce the stud spacing to 12", then H = 101.8 psi, which is less than the allowable value of 120 psi. c. Bearing stress of studs on walers
1009.3

14.5"

29.5"

The maximum reaction will be at the lower waler. Actual reactions at each waler can be determined as follows: The total weight of the pressure block on each stud is:
8" 26" 3.67' = 44" 1009.3 19.3" 10"

= (550 lb/ft x 3.67 ft x 1/2) x 12 in. x

= 1009.3 lb 1 ft 12 in.
6.7"

1009.3 lb x 19.3 in. = R1 x 26 in. R1 = 749.2 lb R2 = 1009.3 - 749.2 = 260.1 lb Bearing Stress f = P A

R1

26"

R2

P = 749.2 lb A = 4.50 in.2 [from Figure A 5-393.204] f = 749.2 lb = 166.5 psi 4.50 in.2

This is less than the allowable stress of 480 psi and is, therefore, acceptable.

November 1, 2005

BRIDGE CONSTRUCTION MANUAL

5-393.213 (3)

d.

Deflection of studs - The load condition used for determining maximum bending stress will be used for determining deflection. = 5wL4 384EI w = 287.5 lb/ft L = 2.167 ft E = 1,800,000 lb/in.2 I = 5.36 in.4 = 5 x 287.5 lb/ft x (2.167 ft)4 x 12 in. 3 ft = 0.015 in. 384 x 1,800,000 lb/in.2 x 5.36 in.4 2.167 ft x 12 in. 1 ft 270

Allowable deflection =

= 0.096 in.

The studs are, therefore, acceptable with regard to deflection. 3. Walers The bottom waler will be checked since the higher stud reaction was found to exist at this location. A condition of uniform loading may be assumed to exist since three studs bear on each waler span (between tie rods). w = 749.2 lb/ft a. Bending stress in waler f = M S

The waler span length is equal to the tie rod spacing (4 feet). This member will be continuous over two or more spans. In keeping with the recommended simplifications, the assumption of simple spans may be used here. M = wL2 749.2 lb/ft x (4 ft)2 8 8 For two 2 x 6s S = 2 x 7.56 in.3 = 15.12 in.3 1498.4 ft/lb x 12 in. 1 ft 15.12 in.3 = 1498.4 ft/lb

f =

= 1189.2 psi

This is less than the allowable bending stress of 1875 psi and, therefore, is acceptable. b. Horizontal shear stress in walers H = 1.5V1 bh 749.2 lb/ft x 4 ft - 2 x 5 1/2 in. x V1 = w(L - 2h) = 2 2 1 ft 12 in. = 1155 lb

5-393.213 (4)

BRIDGE CONSTRUCTION MANUAL

November 1, 2005

H =

1.5 x 1155 lb = 105.0 psi 2 x 1.5 in. x 5.5 in.

This is less than the allowable horizontal shear stress of 120 psi and, therefore, is acceptable. c. Bearing stress of waler on plate washer f = P A

P = 749.2 lb/ft x 4 ft = 2996.8 lb From Figure A 5-393.204, for a 4" x 5" plate washer: A = 15.0 in.2 f = 2996.8 lb = 199.8 psi 15 in.2 This is less than the allowable side bearing stress of 480 psi and is, therefore, acceptable. d. Deflection of waler Using the assumption of simple span: = 5wL4 384EI w = 749.2 lb/ft L = 4 ft E = 1,800,000 lb/in.2 For two 2 x 6's I = 20.80 in.4 x 2 = 41.60 in.4 5 x 749.2 lb/ft x (4 ft)4 x 12 in. 3 = 0.058 in. = 1 ft 384 x 1,800,000 lb/in.2 x 41.60 in.4 This surface is exposed to view. The allowable deflection of the span will be 1/8 inch since the L/270 value for this span is greater than 1/8 inch. 4 ft x (NOTE: L 270 = 12 in. 1 ft 270

= 0.178 in.)

Actual deflection is less than allowable deflection; therefore, the member is acceptable. 4. Tie Rods f = P A

As determined in part 3 c. above, P = 2996.8 pounds The form plan indicates that 1/2 inch diameter coil bolts (and coil ties) will be used as form ties. The manufacturers literature must indicate a load capacity of at least 2996.8 pounds for both the coil bolt and the coil tie.

November 1, 2005

BRIDGE CONSTRUCTION MANUAL

5-393.214 (1)

5-393.214 ABUTMENT WALL FORM EXAMPLE A check for the abutment forms shown in Figure A 5-393.214 would require the following investigations. The anticipated rates of concrete placement are indicated on the figure. 1. Sheathing a. Bending stress b. Rolling shear stress c. Deflection Studs a. b. c. d. Walers a. b. c. d.

2.

Bending stress Horizontal shear stress Bearing stress on walers Deflection

3.

Bending stress Horizontal shear stress Bearing on tie plate Deflection

4.

Tie Rods a. Tension stress or manufacturers safe loading

The stress investigation listed above will be necessary for both the main wall forms and the parapet forms. Calculations for the main wall forms are as follows: First determine the amount of pressure on the forms. The Contractor has indicated a proposed rate of pour of 3 feet per hour in this example. Assuming this concrete will be placed in mid-July, an anticipated temperature of 75 may be used. The three pressure criteria for rates of pour less than 7 feet per hour are as follows: a. p = 150 + 9000R1 T R1 = 3 ft per hour T = 75 = 150 + 9000 x 3 75 = 510 psf (maximum pressure at any depth) b. p = 150h - (150 x 18 feet) = 2700 psf (this will not govern) This formula will only apply to the upper portion of the pressure diagram on a high pour such as this: 150 h = 510 psf. h = 510 psf = 3.4 feet 150 psf c. Neither of the above can exceed 3000 psf. The resulting pressure diagram is shown on Figure A 5-393.214.

Figure A 5-393.214
150h 3'-4"

BRIDGE CONSTRUCTION MANUAL


Strongbacks as necessary 2 x 4 Studs @ 1'-0" O.C.

November 1, 2005

3/4" Plyform Class I 7 Spaces @ 2'-6" 18'-6" 8'-6" 2 x 6 Studs @ 1'-0" O.C.

510 psf

Double 2 x 6 waler

1/2" Dia. coil bolt, coil ties, and 3 x 4 flat washers spaced @ 3'-0"

Concrete Pressure Diagram Estimated conc. temp. = 75 Rate of pour = 3 ft/hr

MAIN WALL FORMS Example Abutment Forms 3/4" Plyform Class I 2 x 4 Studs @ 1'-0" O.C.

4.43"

6"

4 Spaces @ 1'-10"

150h

1/2" Coil ties with 3 x 4 washers spaced @ 2'-6"

664 psf Concrete Pressure Diagram Estimated conc. temp. = 70 Rate of pour = 4 ft/hr 6"

Double 2 x 6 walers

PARAPET FORMS All lumber to be Douglas Fir, Construction grade.

November 1, 2005

BRIDGE CONSTRUCTION MANUAL

5-393.214 (2)

1.

Sheathing The sheathing must support a pressures of 510 psf over a stud spacing of one foot. Assume the Class I Plyform will be placed the "strong" way (face grain across supports). From Figure B 5-393.202 for 3/4" Plyform, it can be seen that the safe load is about 760 psf. The sheathing is, therefore, acceptable.

2.

Studs The 2 x 6 studs are spaced at one foot with a uniform load of 510 psf. Span length is 2' 6". Assume these are continuous for more than three spans. a. Bending stress in studs f = M S w = 510 psf

For 3 span continuous, For one 2 x 6,

M = 0.1wL2 = 0.1 x 510 lb/ft (2.5 ft)2 = 318.8 ft lb S = 7.56 in.3 318.8 ft/lb x 12 in. 1 ft = 506 psi 7.56 in.3

f =

This is less than the allowable stress of 1875 psi and, therefore is acceptable. b. Horizontal shear stress in studs H = 1.5V1 bh 1 ft 12 in. = 484.5 lb

For 3 span continuous,

V1 = 0.6 w (L-2h) = 0.6 x 510 lb/ft x 2.5 ft - 2 x 5.5 in. x

H = 1.5 x (484.5 lb) = 88.1 psi 1.5 in. x (5.5 in.) This is less than the allowable stress of 120 psi and is, therefore is acceptable. c. Bearing stress of stud on waler f = P A

For 3 span continuous,

P = 1.1wL = 1.1 x 510 lb/ft x (2.5 ft) = 1402.5 lb A = 1.50 in. x 1.50 in. x 2 = 4.5 in.2 f = 1402.5 4.5 = 311.7 psi

This is less than the allowable stress of 480 psi and, therefore is acceptable. d. Deflection of studs For 3 span continuous, = 0.0069 wL4 EI

w = 510 lb/ft L = 2.5 ft E = 1,800,000 lb/in2 I = 20.80 in.4

5-393.214 (3)

BRIDGE CONSTRUCTION MANUAL 0.0069 x 510 lb/ft x (2.5 ft)4 x = 1,800,000 lb/in.2 x 20.80 in.4 2.5 ft x 12 in. 1 ft = 0.111 in. 270 12 in. 3 1 ft = 0.006 in.

November 1, 2005

The allowable deflection is

L = 270

Since actual deflection is less than allowable, the studs are acceptable. However, cumulative deflection of sheathing plus studs plus walers must not exceed 1/8 inch to meet the alignment and stiffness criteria of Section 5-393.203. 3. Walers (double 2 x 8 member) Tie rods are spaced 3' 0". Assume walers will be continuous for three spans or more and use the three span continuous formulas. Since studs are spaced at 12 inches, there are at least 3 studs in each waler span and a condition of uniform load may be assumed on the walers. Uniform load w = 510 lb/ft2 x 2.5 ft = 1275 lb/ft of waler a. Bending stress of waler f = M S

M = 0.10 wL2 = 0.1 x 1275 lb/ft x (3.0 ft)2 = 1147.5 ft/lb For two 2 x 8's S = 13.14 in.3 x 2 = 26.28 in.3 1147.5 ft/lb x 12 in. = 524 psi 1 ft 26.28 in.3

f =

This is less than the allowable stress of 1875 psi and is, therefore, acceptable. b. Horizontal shear stress in waler H = 1.5 V1 bh

V1 = 0.6 w (L-2h) = 0.6 x 1275 lb/ft x 3.0 ft - 2 x 7.25 in. 1 ft = 1370.6 lb 12 in. H = = 94.5 psi 1.5 (1370.6 lb) 2 (1.5 in.) (7.25 in.)

This is less than the allowable horizontal shear stress of 120 psi and is, therefore, acceptable. c. Bearing on tie plate f = P A

P = R2 = 1.1 wL = 1.1 x 1275 lb/ft x (3.0 ft) = 4207.5 lb From Figure A 5-393.204, for a 3 x 4 flat washer with a 3/4 in. Spacer between the waler members, A = 9.0 in.2. f = 4207.5 lb = 467.5 psi 9 in.2

Allowable stress = 480 psi x 1.13 (stress increase factor) = 542.4 psi Since actual stress is less than allowable stress, the member is acceptable.

November 1, 2005

BRIDGE CONSTRUCTION MANUAL

5-393.214 (4)

4.

Tie Rods - Tension Stress The tension load as shown in part 3 c. above is 4207.5 pounds. The form details indicate that 1/2 inch diameter coil bolt and coil tie will be used. The manufacturers literature must be checked to determine that these bolts and ties will safely carry the 4207.5 pound load. Calculations for checking the parapet forms (see Figure A 5-393.214) are as follows: First determine the amount of pressure on the forms. The form plan indicates a proposed rate of concrete placement of 4 feet per hour. Assuming concrete placement will be late in August, a concrete temperature of 70 may reasonably be used. The three criteria for determining form pressure with rates of pour less than 7 feet per hour are as follows: a. p = 150 + 9000R1 T = 150 + 9000 x 4 70 = 664 psf (maximum pressure at any depth) b. p = 150 h = 150 x 8.5 ft = 1275 psf (this will not govern) Form pressure will be determined by this formula above the point where pressure is 664 psf. 150 h = 664 psf h = 664 150 = 4.43 ft R1 = 4 ft per hour T = 70

c.

Neither of the above can exceed 3000 psf. The resulting concrete pressure diagram is shown on Figure A 5-393.214. The actual stress calculations for the parapet forms will be similar to those for the main wall forms and, therefore, will not be repeated in this example. However, it would be necessary to perform these calculations since the concrete pressure and member spacings differ from those of the main wall forms.

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