PERFORM

WITH
PRECISION™

BOX CULVERT TRAVELER

CONCRETE
CONSTRUCTION
PRODUCTS

APPLICATION GUIDE
 A WORD ABOUT SAFETY
High productivity depends on safety; even a minor accident causes job delays and inefficiency, which run up costs. That’s why
Symons by Dayton Superior, in the design of its systems and products, makes the safety of those people who will be working
with and near the equipment one of its primary concerns. Every product is designed with safety in mind, and is tested to
be certain that it will perform as intended with appropriate safety allowances. Factory‑built systems such as these provide
predictable strength, minimizing the uncertainty that often surrounds “hand‑made,” “job‑shop” and “job‑built” equipment.
As a result, Symons by Dayton Superior products are your best assurance of a safe operation when used properly. To insure
proper use, we have published this application guide. We recommend that all construction personnel who will be involved,
directly or indirectly, with the use of this product be familiar with the contents of this guide.
As a concerned participant in the construction industry, Symons by Dayton Superior also recommends that regular safety
meetings be held prior to starting the forming operation, and regularly throughout the concrete placement, form stripping and
erection operations. Symons by Dayton Superior personnel will be happy to assist in these meetings with discussion of safe
use of the equipment, slide presentations and other formal safety information provided by such organizations as the Scaffolding,
Shoring and Forming Institute.
In addition to the above meetings, all persons involved with the construction should be familiar and in compliance with applicable
governmental regulations, codes and ordinances, as well as the industry safety standards developed and published by each of the
following:
American Concrete Institute
American National Standards Institute
The Occupational Safety and Health Administration
The Scaffolding, Shoring and Forming Institute
Because field conditions vary and are beyond the knowledge and control of Symons by Dayton Superior, safe and proper use of
this product is the responsibility of the user.
Max‑A‑Form® Box Culvert Application Guide 1

I. Introduction 3. Typical Conditions

The Symons Box Culvert Traveler is an all steel, rentable
traveler system intended to work in conjunction with the Figure 1 represents a typical culvert section with
Max-A-Form®, forming systems for Box Culvert Forming. referenced minimum and maximum dimen‑
sions according to type.
The Traveler is designed to function within a range of
heights and widths for traveling the inside form unit Figure 2 indicates the various corner conditions
intact to the next pour position. attainable using the various form systems

The Traveler is highly versatile and very simple in func‑ Figure 3 represents a typical starter wall detail.
tion and operation. Typical applications for the traveler The traveler is designed to work with a nominal
system are, but in no way limited to, the following: 6" starter wall at invert, using 2 x 6 lumber to
form a 5½" high starter wall is a common tech‑
Storm Drainage nique. However, the starter wall is not a neces‑
sity. Job-built or specially manufactured base
Tunnel Galleries forms can be used when there is no starter wall.
Contact your representative for application.
Irrigation Channels

Sewer Canals

Utility Tunnels

II. System Nomenclature

A. Design Criteria
1. The Traveler is divided into three size classifica‑
tions. The minimum and maximums for these
classifications or types are as follows:

Type I 5'-0 high x 5'-0 wide to 6'-6" high x

6'-6" wide

Type II 6'-6" high x 6'-6" wide to 9'-0" high x

9'-0" wide

Type III 9'-0" high x 9'-0" wide to 12'-0" high

x 12'-0 wide

Note: A 12" upright extension (PC 40274) is avail‑

able which increases the maximum height of each
Type by 1'-0".
Fig. 1
2. Maximum Deck Thickness Typical Box Section
MF 12 Module

4'-0" Header Spacing

1' and 4' from each end

Type I 24" maximum

Fig. 2 Fig. 3
Type II 21" maximum Corner Options Typical Starter Wall

Type III 18" maximum @ 9'-0 to 10'-0 wide

17" max. @ 10'-1" to 11'-0 wide
16" max. @ 11'-1" to 12'-0 wide
2 Max‑A‑Form® Box Culvert Application Guide

III. Field Assembly C. Attach Forms

As always, a thorough shake-out of equipment is rec‑ Max-A-Form panels may be employed as deck
ommended prior to commencing assembly. Equipment panels. However, due to the limited widths of the
should be placed as close to assembly area as practical Max‑A‑Form panels, layouts must be produced to
to minimize “go-fer” time. illustrate the corner condition used and to incorpo‑
rate the proper gap (4" to 8") for installation of the
Max-A-Form is a walerless panel system with built-in tie slip plate. Refer to specific application drawings and
boxes which, with the attachment of the components Symons Technical Services for this condition.
discussed in this section, is well suited to culvert forming
applications. Place deck panels in accordance with form layout
drawings. This will result in a 4" to 8" gap typically
Generally, with Max-A-Form® in this application, panel at center of deck, although this gap may occur at
gangs will be assembled prior to attaching components. any point on the flat area of the deck. The gap is
This operation is almost totally crane- assembled with covered using the Deck Slip Plate which is furnished
the exception of certain components. in 3'-0, 4'-0, 6'-0 and 8'-0 lengths. The Slip Plate is
secured to the header using two Aluminum Beam
Refer to specific application drawings for location. This
Clamps (PC 36502) and ½" x 2½" Bolts (PC 49971)
section will show only the attachment of these compo‑
with ½" Nuts (PC 31411) to sandwich the flange
nents to the Max-A-Form panel.
on the Slip Plate to the flange on the header. See
A. Attach components Figures 5 and 6.
With panels laying skin plate down on sleepers, es‑
Securing the Slip Plate to the header, when using
tablish location of components on panel. Attach the
Max‑A‑Form as deck panels, is accomplished with
following components in accordance with Figures.
the Versiform® Clip Rod (PC 33265), Channel Aligner
PC 40260 - MF Header Bracket R/H Bracket (PC 33747) and 5∕8" Fit-Up Nut (PC 36085).

PC 40261 - MF Header Bracket L/H

PC 40275 - MF Header Connector

PC 40292 - MF Wheel/Jack Bracket - R/H

PC 40293 - MF Wheel/Jack Bracket L/H

PC 40270 - Wheel Bracket

PC 40271 - Jack Bracket

PC 40272 - Adjustable Jack

PC 40273 - Swivel Wheel

B. Raise Side Panels

With components installed and bolts fully tightened, Fig. 5
Max-A-Form side panels may be raised and braced in
vertical position to allow attachment of headers and
horizontal adjustable braces. Following completion
of these steps the unit is self-standing and aligner
angles and deck panels may be installed. Install
diagonal braces at prescribed locations and the
traveling unit is ready for installation of deck panels.

Fig. 6
Max‑A‑Form® Box Culvert Application Guide 3

D. Max-A-Form with Steel‑Ply® IV. Traveler Operation

When using the Max-A-Form panels with Steel-Ply This section deals with basic setting and stripping proce‑
panels at the deck a condition may exist which dures and recommendations for the Box Culvert Traveler.
requires additional support for the Steel-Ply panels Regardless of the form system being used, the setting
at the corners. This depends on the specific corner and stripping operation is identical. It should be noted
panel being used and must be addressed when ap‑ that prevailing job conditions and contractor preference
plication drawings are being prepared. An example must always be considered and may require or demand
of this is shown in Figure 7. Load conditions at this a change in sequence or method. In any case, sound,
detail will dictate whether or not additional support safe construction practices must always be employed.
is required, refer to specific application drawings for
recommendations. A. Setting
A prerequisite to setting is the casting of an invert
or slab. This is accomplished utilizing conventional
methods, in most cases with a wood system. The
starter wall may be formed using 2 x 6 lumber,
which will create a 5½" high starter wall. It is rec‑
ommended the invert be contructed several pours
out before using the Box Traveler in order to take
advantage of the efficiency and speed of the system.

1. Move traveler and forms into position at con‑

struction joints. It may be necessary to take
up on horizontal braces to obtain clearance at
starter wall. With traveler still on wheels, extend
horizontal braces until form face is just short of
contacting starter wall. Do not force against
starter wall at this time. Check alignment of deck
panels across gap at slip plate. If form/traveler is
racked, alignment can be attained by attaching
the Diagonal Strut Backet to the OCA on one side
to the OCA at the opposing side and actuating
the strut to pull forms into alignment. It may
be necessary to extend jacks at 2 or 3 uprights
to keep one side of traveler stationary.
Fig. 7
2. With forms aligned at ends, reinstall Diagonal
Strut at proper location and extend lower
horizontal struts to place form face against
starter wall.

3. Using leading end jacks, trailing end jacks,

and an intermediate jack, raise form to proper
height. Hydraulic jacks, if available, may be
used in lieu of screw jacks and placed beneath
wheel or jack brackets for this operation. With
form positioned to proper height, remaining
jacks may be hand cycled to contact invert slab.
Hydraulic jacks, if used, may now be removed.

4. Side forms can now be squared and plumbed

using the Diagonal Strut in conjunction with
upper horizontal brace. With this unit squared
and plumbed, the outside forms of adjoining
barrels may be spaced properly off this unit.
4 Max‑A‑Form® Box Culvert Application Guide

5. Position slip plates at deck panels and secure as V. Application Details

discussed in Section III. A. Corner Conditions
1. Figures 8 and 9 show various corner conditions
6. Check that all jacks are in contact with invert utilizing standard rentable components of the
slab, form is in contact with starter wall, and Max‑A‑Form and Steel‑Ply systems with the Box
all pin and bolt connections are secure. Unit is Culvert Traveler and associated components.
ready for tie and bulkhead installation.
Non-standard corner details which require
NOTE 1: If starter wall is not used, setting at lower special or custom panels can be furnished by
sections of form becomes more critical. This condi- Symons. Contact your Symons representative
tion will be included in the application drawings for for these situations.
this specific condition.

NOTE 2: If overhead reshore system is used, refer

to Section V for details.
B. Stripping
1. Remove ties and bulkheads.

2. Outside forms may be stripped and moved

ahead at any time.

3. Loosen nuts at header connection at slots. Do

not remove bolts or nuts.

4. Raise all jacks at Wheel andJack Backets to the

point they will still clear slab when traveler is
lowered to wheels. There is an access hole at
each Wheel and Jack Bracket to allow use of a
1¼" socket and extension with ratchet or impact
wrench to cycle jacks.

5. Check that all wheels are in the traveling position.

6. Remove pin at upper end of Diagonal Struts and Fig. 8

allow strut to lean against form.

7. Beginning at lower leading end horizontal brace,

“take up” on brace to begin collapsing traveler at
sides… generally 1" clear at each side is sufficient.
Next take up on the two (2) upper braces to ap‑
proximate the same clearance at top of form.
Return to next lower brace and do same. Form
will begin to lower itself along the walls. Repeat
this procedure at all braces until form is com‑
pletely clear of concrete. Additional clearance,
if needed, may be obtained by further take-up
on struts. Form and traveler may now be rolled
ahead for cleaning and presetting operations.

It is important to note that due to the large

diameter of the traveler wheels most form and
traveler units are able to be hand rolled using 4
to 6 workers. Crane or power tugging devices
may be attached if desired, but should be at‑
tached to a structurally sound area and rigged
to prevent eccentric forces. Fig. 9
Max‑A‑Form® Box Culvert Application Guide 5

2. Some culvert specifications incorporate fillet

conditions at the invert corners. In such cases,
it may become necessary to move the Wheel or
Jack Bracket outward in order to place jack and
wheel on flat portion of invert slab. This is the
purpose of the Fillet Wheel/Jack Adapter - PC
40269 shown in Figure 12.

Not coincidentally, it may also become neces‑

sary to relocate Wheel or Jack Bracket down‑
ward so that forms and traveler will clear the
top of the fillet during stripping and traveling.
The Fillet Wheel/Jack Adapter is furnished with
hole spacing to accomodate several variations
in height.

Corner fillets of 6" or less do not require this

application. Refer to specific application draw‑
ings for exact hole locations and configuration.

Fig. 10

Fig. 12

Fig. 11
6 Max‑A‑Form® Box Culvert Application Guide

3. Figure 13 shows the Fillet Wheel/Jack B. Single Barrel Conduit

Adapter used to adjust the dimensional relatio‑ A single barrel conduit schematic illustration is
ship between the bottom of the forms and the shown in Figure 14. Squaring and plumbing of the
wheel base. Due to the limited panel widths, inside form using the Diagonal Strut will provide
it is not always possible to maintain the ideal alignment for outside forms.
4" from slab to form bottom. This application
allows some adjustability which could eliminate
the need for additional fillers or job built fill
panels. Refer to specific application drawings
for exact hole location and configuration.

Fig. 14
C. Multiple Barrel Conduit
A multiple barrel conduit schematic illustration is
shown in Figure 15. Squaring and plumbing of the
inside form at the outboard barrels only will provide
alignment for outside forms and adjoining barrels.

In multiple barrel configurations it may be possible

Fig. 13 to eliminate diagonal struts at inward barrels. How‑
ever, this is dependent on prevailing job conditions
and contractor preference.

Fig. 15
Max‑A‑Form® Box Culvert Application Guide 7

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

Fig. 16
8 Max‑A‑Form® Box Culvert Application Guide

VI. Wall Ties

A. Industry Standards
Wall ties must be in compliance with industry
standards and safe practices established by the
American Concrete Institute, The American National
Standards Institute, The Occupational Safety and
Health Administration and The Scaffolding, Shoring
and Forming Institute. The following note applies to Fig. 17
all Wall-tie applications. A 2.0 to 1.0 Safety Factor
is required for all form work.

B. Load Capacities
Symons project drawings indicate safe load capaci‑
ties of taper ties and she-bolt assemblies, when both
outer unit and inner ties are supplied by Symons.

C. Concrete Pressure
It is the contractor’s responsibility to control con‑
crete mix and placement procedure to assure that
the maximum formwork design pressure is not
exceeded. Clamps flat
washers to
walers

J-Strong-
back Rod
Clamps

D. Tie installation precautions:

1. Be sure that the correct thread size hex nut
or cast contour nut is mated to all taper tie or
she-bolt out-unit threads.

2. Be sure that the inner ties engage full thread

depth in all she-bolts. Full thread engagement
is noted as dimension (E) on the illustration of
Fig. 18
she-bolt capacities and thread dimensions.

3. Be sure that all ties using hex nuts with Cast

Bearing Washers or flat washers are installed
perpendicular to both form faces. Hex nuts
installed on ties not perpendicular to the form
face are subject to eccentric loading that can
cause tie failure.
Max‑A‑Form® Box Culvert Application Guide 9

E. Non-Perpendicular Ties
Batter Plate Castings, with mating Cast Contour
Nuts, should be installed to support ties that are not
perpendicular to the form face (Figure 20).

F. Initial impact release of embedded taper ties:

1. Taper-tie Hammering Caps (Figure 19) are avail‑
able in two sizes: 1" contour thread, or 1¼"
contour thread.

2. The correct diameter and thread-type Hammer‑

ing Cap must be utilized during initial impact
release of embedded taper ties.

3. The Hammering Cap is positioned at the smaller Fig. 20

diameter end of the taper tie. The protruding
end of the Hammering Cap is then struck with
96K Taper Tie
an 8 lb. or heavier sledge-hammer. All mush‑ or 85K She-Bolt
rooming type impact damage is accumulated at
the end of the Hammering Cap, rather than the
butt end of the taper tie so as not to damage
tie threads.

Contour
Threaded Nut

Fig. 21

Fig. 19
10 Max‑A‑Form® Box Culvert Application Guide
 Safety Information

Improper Use of Concrete Forms and Shores Can

Cause Severe Injury or Death
Read, understand and follow the information and instructions in this publication before using any
of the Dayton Superior concrete accessories displayed herein. When in doubt about the proper
use or installation of any Dayton Superior concrete accessory, immediately contact the nearest
Dayton Superior Service Center or Technical Service Department for clarification.

Dayton Superior products are intended for use by trained, qualified and experienced workmen only. Misuse or lack of supervision and/or inspec-
tion can contribute to serious accidents or deaths. Any application other than those shown in this publication should be carefully tested before use.
The user of Dayton Superior products must evaluate the product application, determine the safe working load and control all field conditions to
prevent applications of loads in excess of a product’s safe working load. Safety factors shown in this publication are approximate minimum values.
The data used to develop safe working loads for products displayed in this publication are a combination of actual testing and/or other industry
sources. Recommended safe working loads given for the products in this publication must never be exceeded.

Worn Working Parts

For safety, concrete forms must be properly used and maintained. Concrete products shown in this publication may be subject to
wear, overloading, corrosion, deformation, intentional alteration and other factors that may affect the device’s performance. All reus-
able products must be inspected regularly by the user to determine if they may be used at the rated safe working load or should be
removed from service. The frequency of inspections depends upon factors such as (but not limited to) the amount of use, period of
service and environment. It is the responsibility of the user to schedule inspections for wear and remove the hardware from service
when wear is noted.

Shop or Field Modification

Welding can compromise a product’s safe working load value and cause hazardous situations. Knowledge of materials, heat treating and welding pro-
cedures is necessary for proper welding. Consult a local welding supply dealer for assistance in determining required welding procedures.
Since Dayton Superior cannot control workmanship or conditions in which modifications are done, Dayton Superior cannot be responsible for any
product altered in the field.

Interchangeability
Many concrete products that Dayton Superior manufactures are designed as part of a system. Dayton Superior strongly discour-
ages efforts to interchange products supplied by other manufacturers with components supplied by Dayton Superior. When used
properly, and in accordance with published instructions, Dayton Superior products have proven to be among the best designed and
safest in the industry. Used improperly or with incompatible components supplied by other manufacturers, Dayton Superior products
or systems may be rendered unsafe.

Installation
WARNING
1. Dayton Superior Corporation products shall be installed and used only as indicated on the Dayton Superior Corporation installation guidelines
and training materials.
2. Dayton Superior Corporation products must never be used for a purpose other than the purpose for which they were designed or in a manner
that exceeds specific load ratings.
3. All instructions are to be completely followed to ensure proper and safe installation and performance
4. Any improper misuse, misapplication, installation, or other failure to follow Dayton Superior Corporation’s instruction may cause product mal-
function, property damage, serious bodily injury and death.
THE CUSTOMER IS RESPONSIBLE FOR THE FOLLOWING:
1. Conformance to all governing codes
2. Use of appropriate industry standard hardware
3. The integrity of structures to which the products are attached, including their capability to safely accept the loads imposed, as evaluated by a
qualified engineer.
SAFETY INSTRUCTIONS:
All governing codes and regulations and those required by the job site must be observed. Always use appropriate safety equipment

Design Changes
Dayton Superior reserves the right to change product designs, rated loads and product dimensions at any time without prior notice.
Note: See Safety Notes and Safety Factor Information.
 1125 Byers Road
Miamisburg, OH 45342
937-866-0711
888-977-9600

PERFORM
WITH
PRECISION™

SYM213
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