HIGH PERFORMANCE
DOWEL SYSTEMS
For concrete slabs and pavements
High Performance Dowel Systems • •
Index
Why use high performance dowels?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Features and benefits of high performance dowels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Diamond® Dowels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Square Dowels with Dowelmaster® sleeves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Plate Dowel Cradles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Square Dowel Cradles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Construction joint dowels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Contraction joint dowels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Installation tolerances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Expansion joint load transfer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Research. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Companion Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Frequently asked questions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Danley Head Office
21 Steel Place, Morningside Qld 4170
PO Box 297, Cannon Hill Qld 4170
Phone: +61 7 3899 3466
Fax: +61 7 3899 1733
Email: [email protected]
Website: www.danley.com.au
Prepared by Danley Construction Products Pty Ltd
ABN 72 010 910 308.
Various products or systems shown in this brochure
are covered by Australian and / or international
patents, or have patents pending, or are registered
designs. Various marks in this brochure are registered
trademarks.
Dimensions and specifications are subject to change
without prior notification by the manufacturer. All
dimensions are nominal.
Freecall: 1800 280 573
New South Wales Sales & Distribution Office
2/34 Prime Drive, Seven Hills NSW 2147
Phone: +61 2 9838 4666
Fax: +61 2 9620 8065
Unless required by law Danley™ cannot accept any
responsibility for any loss, damage or consequence
resulting from the use of this publication. Photographs
shown are representative only of typical applications,
and are current as at March 2007.
The information in this brochure is copyright.
© Copyright 2007.
• • High Performance Dowel Systems
Why use high performance dowels?
Dowels are required at joints in concrete slabs to
transfer vertical loads across the joint and minimise
differential deflection between slabs under load.
Slabs shrink away from the corners during curing; this
shrinkage is diagonal from the intersection of joints,
not just perpendicular to the joint. Different concrete
batches will shrink at different rates, adjacent slabs
poured at different times shrink at different rates and
rapid shrinkage occurs during initial curing.
Joint
High performance dowels for
Construction joints
Diamond® Dowels
Square Dowels with
Dowelmaster® sleeves
High performance dowels for
Contraction joints
In addition to allowing horizontal slab movement
perpendicular to the joint, high performance dowel
systems allow horizontal slab movement parallel to
the joint as well as being very efficient load transfer
devices, compared to other dowel systems, and
provide excellent vertical differential deflection
characteristics.
Plate Dowel Cradles
Features and benefits of high performance
dowels:
•
•
•
•
•
•
•
•
•
Easy to use.
Easy to set up.
Sleeve configurations allow for horizontal slab
movement both perpendicular and parallel to joint.
Dowels are a neat sliding fit within the appropriate
sleeves.
All Danley dowels and dowel plates are saw-cut
from steel bar to AS/NZS 3679.1 Grade 300.
Very efficient load / deformation capacity.
Dowels or dowel plates available in black and galvanised.
Stainless steel dowels and dowel plates are also
available.
Can be used at wider centres, reducing cost.
High Performance Dowel Systems • •
Square Dowel Cradles (with
Dowelmaster® sleeves)
DIAMOND® DOWELS
Features and benefits:
•
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•
•
•
•
•
Diamond® Dowels at construction joints
•
Diamond Plate Dowel
110 x 110 mm
•
Plate 156 mm
Wide plate optimises
material where
stresses are highest
Sleeve allows for
slab shrinkage movement
Sleeve and diamond shaped plate
allows slab to shrink without being
restrained by the Diamond Dowel
Diamond Plate Dowel
•
•
•
•
•
•
Slab shrinkage
directions
•
Available with one-piece sleeves for both 6 mm and
10 mm Diamond® Dowels.
Sleeves are colour coded:
w 6 mm are orange
w 10 mm are blue
Ideal for perimeter-of-pour dowel applications, i.e. at
construction joints.
No need to drill forms to support dowels during
concrete pour.
Nailing flange provides secure attachment to form
boards.
Flange on sleeve ensures dowel is perpendicular to
form board and is stable.
Each sleeve is fitted with an internal spacer to prevent
collapse caused by pressure of concrete, but easily
displaced into the apex of the sleeve when inserting
the Diamond plate.
Sleeves moulded from durable, non-compressible
material.
Sleeves fitted with double-headed nails - second head
on nail acts as an anchor to help retain the sleeve in
the concrete when stripping the form boards.
Reduced likelihood of sleeve knock-off when placing
steel reinforcement mesh.
Simplifies form removal.
Dowel plates available in black and galvanised.
Stainless steel dowel plates are also available.
Ergonomically designed, user-friendly packaging,
complete kit and installation instructions.
Wide dowel plate at point of maximum load reduces
stress on concrete.
Can be integrated into other formwork systems.
Joint opens up due to
slab shrinkage
Packaging
Danley™ Diamond® Dowels are packaged in kit format, in
cartons that are illustrated with Installation Instructions.
Each carton contains 25 sets of 6 mm Diamond® Dowel
plates and one-piece sleeves [orange], or 15 sets of 10
mm Diamond® Dowel plates and one-piece sleeves
[blue]. Each sleeve is fitted with 2 double-headed steel
nails.
Diamond® Dowel Packaging
• • High Performance Dowel Systems
Diamond® Dowel plastic sleeves after stripping the timber formwork on a typical driveway set up.
Dowel Thickness
[mm]
Product Code
Finish
Weight ea
[kg]
6
DDSLBPNEW06X110
Black
0.64
6
DDSLGPNEW06X110
Galvanised
0.65
10
DDSLBPNEW10X110
Black
0.99
10
DDSLGPNEW10X110
Galvanised
1.05
Installation instructions
STEP 1: Mark the form for slab centre and Diamond®
Dowel spacing (typically 450 mm to 600 mm). Using
the 2 nails, attach the base to the form. Ensure nailing
plate is parallel to top of slab.
STEP 2: Place concrete. Edge of slab must be vibrated
to consolidate concrete around the Diamond® Dowel
sleeve (avoid contact with the sleeve with vibrator
shaft).
STEP 3: Strip the form. This is best accomplished by
starting at one end and working along the form.
Form boards with Diamond® Dowel sleeves attached.
HOW TO SPECIFY
Specify: Danley™ Diamond® Dowel (dowel size) x
(dowel spacing), (finish or material),
e.g. Danley™ 6mm Diamond® Dowels at 450 mm
centres, galvanised.
STEP 4: Insert the Diamond® Dowel Plate into the
sleeve (at the centre point of sleeve) within 36 hours
of concrete pour. The second pour can now be made.
High Performance Dowel Systems • •
SQUARE DOWELS WITH
DOWELMASTER® SLEEVES
Features and benefits:
•
•
•
•
•
•
•
•
•
•
•
Ideal for construction joints.
Dowelmaster® sleeves available in 16 x 200 mm
and 20 x 250 mm sizes
Square dowels available for both 16 mm and
20 mm Dowelmaster® sizes.
Dowels available in black and galvanised.
Stainless steel dowels are also available.
Dowelmaster® sleeves supplied complete with
support stake and wedge.
Dowelmaster® sleeves provide expansion joint
capability.
No need to drill forms to support dowels during
concrete pour.
Nailing plate provides secure attachment to form
boards.
Flange on nailing plate ensures dowel is
perpendicular to form board and is stable.
Square Dowels also available with Metal Square
Dowel Covers for 16, 20, 25, 32 and 40 mm square
dowels (must be specified at time of ordering).
A worker installs Dowelmaster® sleeves to timber formwork
ready for pour.
Danley’s Dowelmaster® sleeves allow square dowels
to move both parallel and perpendicular to the
construction joint as the concrete slab shrinks during
curing. Simply secure the sleeves to the construction
joint forms with the optional nailing plates, pour the
concrete, strip the forms and insert square dowels
into the sleeves ready for the second pour.
eeve
r sl
aste
elm
Dow
Nailing plate
We
d
ge
Adjustable stake
Dowelmaster® sleeve attached to timber formwork using a
nailing plate.
HOW TO SPECIFY
NOTE: Please contact Danley for details on the Square
Dowels with optional Metal Dowel Covers.
Specify: Danley™ Square Dowel (dowel size) x
(dowel length) x (dowel spacing) (dowel material)
with Dowelmaster® sleeve (and nailing plate),
e.g. Danley™ Square Dowel 20 mm x 400 mm
at 450 mm centres, galvanised with 20 mm
Dowelmaster sleeve and nailing plate.
• • High Performance Dowel Systems
Dowelmaster®, Square Dowels and
Accessories
Part
Product Code
Size Length
[mm] [mm]
Installation instructions
Material or
Finish
Weight
ea [kg]
Dowelmaster® Sleeve [with wedge and steel stake]
SQDWMAST16MM
16
200 [1] Polypropylene
0.10
SQDWMAST20MM
20
250 [1] Polypropylene
0.11
Dowelmaster® Nailing Plate
SQDWMASTNL16
16
n/a
Polypropylene
0.01
SQDWMASTNL20
20
n/a
Polypropylene
0.02
SQDWL16X400
16
400
Black Steel
0.81
SQDWL16X500
16
500
Black Steel
1.01
SQDWL16X600
16
600
Black Steel
1.21
SQDWL20X400
20
400
Black Steel
1.26
SQDWL20X500
20
500
Black Steel
1.57
SQDWL20X600
20
600
Black Steel
1.89
[2]
SQDWL25X400
25
400
Black Steel
1.97
[2]
SQDWL25X500
25
500
Black Steel
2.46
[2]
SQDWL25X600
25
600
Black Steel
2.95
SQDGAL16X400
16
400
HDG Steel
0.83
SQDGAL16X500
16
500
HDG Steel
1.04
SQDGAL16X600
16
600
HDG Steel
1.25
SQDGAL20X400
20
400
HDG Steel
1.30
SQDGAL20X500
20
500
HDG Steel
1.62
SQDGAL20X600
20
600
HDG Steel
1.95
[2]
SQDGAL25X400
25
400
HDG Steel
2.03
[2]
SQDGAL25X500
25
500
HDG Steel
2.53
[2]
SQDGAL25X600
25
600
HDG Steel
3.04
Square Dowels [Black]
Square Dowels [Galvanised]
Notes: [1] Length of Dowelmaster® sleeves is nominal; actual
sleeve is 10 mm longer to allow for expansion joint capability.
[2]. Dowels 25 mm square require a Metal Square dowel Cover
- consult Danley for details.
[3] Stainless steel square dowels also available - specify when
ordering
[4] Other size square dowels and other lengths are available
- consult Danley for details.
Fig 1
Fig 2
Fig 3
Note:1. The project drawings will have specified the
dowel spacing required.
2. Each Dowelmaster® Nailing Plat has a flat portion across the flange to assist in positioning.
STEP 1: At one end of the formboard, mark a point
equal to one half of slab thickness – 32 mm (e.g. for
150 slab, mark the point 150/2 = 75 - 32 = 43 mm)
down from the top of the formboard. Repeat at other
end of formboard. Join both marks with a tight string
line. Mark position of the first dowel from the end
of formboard, then mark the position of subsequent
dowels along the string line. Place the first Nailing
Plate at the first position and nail in place – 2 nails
diagonally opposite each other should be adequate.
Locate and nail in place subsequent Nailing Plates
(Fig 1).
Step 2: Place the first Dowelmaster® sleeve over the
protruding tabs on the Nailing Plate (Fig 2), then push
the sleeve firmly against the back face of the Nailing
Plate (Fig 3). This will ensure wet concrete does not
seep into the sleeve.
Step 3: Insert the adjustable stake through the hole in
the end of the first Dowelmaster® sleeve and hammer
it into the ground making sure it is secure (Fig 4).
Break the wedge off the sleeve. Accurately level
the sleeve and hold in place by inserting the wedge
between the stake and the back end of the sleeve
(Fig 5). Repeat at last Dowelmaster® sleeve along the
formboard.
Step 4: Hammer a stake in at both ends of the
formwork and run a string line across the entire length
of the joint (Fig 6). Once you have the string line to
the correct height you can adjust all of the remaining
Dowelmaster® sleeves to the correct height and again
lock them into place with stakes and wedges. (Fig 7).
Fig 4
Fig 5
Dowelmaster® sleeves must be placed on the first-pour side
of the formboard. After the concrete has cured, remove the
formwork and the Nailing Plates and insert the appropriate
Danley Square Dowels into the Dowelmaster® sleeves before
the second concrete pour is made.
Fig 6
Fig 7
High Performance Dowel Systems • •
PLATE DOWEL CRADLE
Features and benefits:
•
•
•
•
•
•
•
•
•
•
•
Available for both 6 mm and 10 mm plate dowel
sizes.
Available heights to suit slabs 100 to 300 mm thick.
Sleeves are colour coded:
w 6 mm are orange
w 10 mm are blue
Dowel plates are 300 mm long, dowel sleeves are
165 mm long.
Dowel plates available in black and galvanised.
Stainless steel dowel plates are also available.
Ideal for sawn contraction joints.
Supplied in 3 m lengths.
Simple installation.
Minimises set up time.
Excellent deflection capabilities.
300 long dowel
Plastic sleeve
On set up, cut cross wire
Plate Dowel Cradle prior to pour.
Plate Dowel Cradle is available in 6 or 10 mm plate sizes.
Danley Plate Dowel Cradles are well suited for
contraction joints in concrete slabs and pavements.
As well as the Plate Dowel Cradle efficiently limiting
deflection, the 3 m long fabricated cradles ensure the
dowels are set at the exact height for the specified
slab thickness, and at precise spacing to minimize
installation time.
HOW TO SPECIFY
Specify: Danley™ Plate Dowel Cradle (dowel
size) x (dowel spacing) x (slab thickness) and
(dowel material),
e.g. Danley™ Plate Dowel Cradles 6 mm at
450 mm centres, for 150 mm slab, galvanised
dowels.
Cutting the cross wire at site.
• • High Performance Dowel Systems
Typical set up of Plate Dowel Cradles and slab reinforcing prior to concrete pour (reinforcing mesh yet to be placed on bar chairs
at correct height)
Saw cut or Danley™ Crack-A-Joint®
Hold mesh back 75 - 150 mm
Slab reinforcing
Optional Ground Crack Inducer
Plate Dowel Cradle
Commonly available Plate Dowel Cradles
Product Code
Dowel Size
[mm]
Dowel
Spacing
[mm]
Slab
Thickness
[mm]
Approx. Weight
[kg]
DCP6450125
6 X 50
450
125
8.4
DCP6450150
6 X 50
450
150
8.5
DCP6450175
6 X 50
450
175
8.6
DCP6450200
6 X 50
450
200
8.7
DCP10450175
10 X 50
450
175
11.8
DCP10450200
10 X 50
450
200
11.9
DCP10450250
10 X 50
450
250
12.1
DCP10500200
10 X 50
500
200
10.7
DCP10600150
10 X 50
600
150
9.4
DCP10600200
10 X 50
600
200
9.5
Note: 1. Plate Dowel Cradles with other dowel spacings and for
other slab thicknesses are available as custom orders.
2. Engineer to confirm exact requirements for projects.
3. Add postscript “G” to Product Code for galvanised dowels,
e.g. DCP10450200G
NOTE: When placing concrete, care should be taken
not to move the cradles, nor stand on them.
Installation instructions
STEP 1: Mark the position of contraction joint with
string line or a paint line on the sub-grade (or on
top of poly sheet if used). If the Danley™ Ground
Crack Inducer is to be used, place this directly over
the marked line, then place the first Danley Plate
Dowel Cradle centrally over the marked line. Place
the second Plate Dowel Cradle over the marked line,
spacing the first dowel of the second cradle from the
last dowel on the first cradle an equal distance to
the dowel spacing on the cradles. Place subsequent
cradles similarly.
Step 2: Once the cradle is correctly positioned, cut
the cross restraints to allow independent movement
of the two cradle halves contained within the adjacent
concrete slabs.
Step 3: Install the slab reinforcement mesh (if
specified) as directed by the slab designer.
Step 4: Pour the concrete as usual ensuring that
concrete placement and minimum reinforcement
coverage is achieved as per slab design. Install CrackA-Joint® or saw cut as directed.
High Performance Dowel Systems • •
SQUARE DOWEL CRADLES
Features and benefits:
•
•
•
•
•
•
•
•
•
•
•
Available for both 16 mm and 20 mm square dowel
sizes.
Available heights to suit slabs 100 to 300 mm thick.
Dowel plates available in black and galvanised.
Stainless steel dowel plates are also available.
Supplied with Dowelmaster® sleeves as standard.
Ideal for sawn contraction joints.
High load capacities.
Supplied in 3 m lengths
Simple installation.
Minimises set up time.
Also available with Metal Dowel Covers for 16,
20, 25, 32 and 40 mm square dowels (must be
specified at time of ordering).
Square Dowel Cradles (with optional Ground Crack Inducer
under) set up prior to pouring concrete.
On set up, cut cross wires.
Danley Square Dowel Cradles are suitable for
contraction joints in concrete slabs and pavements.
The 3 m long fabricated cradles ensure the dowels are
set at the exact height for the specified slab thickness,
and at precise spacing to minimise installation time.
The standard range of 16 and 20 mm Square Dowel
Cradles with Dowelmaster® sleeves is supplemented
by the availability of optional Square Dowel Cradles
with Metal Dowel Covers for 16, 20, 25, 32 and 40 mm
square dowels.
NOTE: Please contact Danley for details on the
optional Square Dowel Cradles with Metal Square
Dowel Covers.
HOW TO SPECIFY
Specify: Danley™ Square Dowel Cradle (dowel
size) x (dowel length) x (dowel spacing) x (slab
thickness) and (dowel material),
e.g. Danley™ Square Dowel Cradle 20 mm x
400 mm at 450 mm centres for 200 mm slab,
galvansied dowels.
NOTE: When placing concrete, care should be taken
not to move the cradles, nor stand on them.
• 10 • High Performance Dowel Systems
Preparing for slab pour. Square Dowel Cradles set at contraction joint locations
Saw cut or Danley™ Crack-A-Joint®
Hold mesh back 75 - 150 mm
Slab
reinforcing
Optional Ground Crack Inducer
Square Dowel Cradle
Commonly available Square Dowel Cradles
[with Dowelmaster® sleeves]
Part
Product Code
Dowel
Size
[mm]
Dowel
Length
[mm]
Dowel
Centres
[mm]
Cradle
Weight
[kg]
Square Dowel Cradles with black dowels [1]
DCS16X400X300 [2]
16
400
300
9.2
DCS16X400X450 [2]
16
400
450
9.9
DCS16X400X600 [2]
16
400
600
10.6
DCS20X400X300 [2]
20
400
300
12.4
DCS20X400X450 [2]
20
400
450
13.5
DCS20X400X600 [2]
20
400
600
14.6
Square Dowel Cradles with galvanised dowels [1]
DCS16X400X300G [2]
16
400
300
9.5
DCS16X400X450G [2]
16
400
450
10.3
DCS16X400X600G [2]
16
400
600
11.1
DCS20X400X300G [2]
20
400
300
12.8
DCS20X400X450G [2]
20
400
450
14.0
DCS20X400X600G [2]
20
400
600
15.1
Notes: [1] Square Dowel Cradles are fitted with DowelMaster®
sleeves as standard.
[2] Thickness of slab MUST be specified
[3] Square Dowel Cradles with stainless steel dowels are also
available - specify when ordering.
[4] Other combinations of square dowel cradles are available
as special order.
[5] Square dowel cradles with Metal Dowel Covers can be
supplied as special orders.
Installation instructions
STEP 1: Mark the position of contraction joint with
string line or a paint line on the sub-grade (or on
top of poly sheet if used). If the Danley™ Ground
Crack Inducer is to be used, place this directly over
the marked line, then place the first Danley Square
Dowel Cradle centrally over the marked line. Place
the second Square Dowel Cradle over the marked
line, spacing the first dowel of the second cradle from
the last dowel on the first cradle a distance equal to
the dowel spacing on the cradles. Place subsequent
cradles similarly.
Step 2: Once the cradle is correctly positioned, cut
the cross restraints to allow independent movement
of the two cradle halves contained within the adjacent
concrete slabs.
Step 3: Install the slab reinforcement mesh (if
specified) as directed by the slab designer.
Step 4: Pour the concrete as usual ensuring that
concrete placement and minimum reinforcement
coverage is achieved as per slab design. Install CrackA-Joint or saw cut as directed.
High Performance Dowel Systems • 11 •
Construction Joint Dowels
Load and deflection
characteristics in 10 mm wide joints
Construction
joint dowels
Construction Joint Dowels
Load and deflection characteristics in 10 mm wide joints
Load and deflection characteristics in 10 mm wide joints
120
120
In 40 MPa
In 40
MPa
Slabs
110
100
100
90
120
110
110
100
deflection = 1.2 mm
100
90
90
80
80
10 mm DD 80
10 mm DD 70
S20
80
S20
70
70
60
60
22
40
40
70
60
60
66 mm
mm DD
DD
42
42 kN
kN load
load
6 mm
mm DD
DD
6
50
50
S20
S20
30
30
30
30
20
20
10
10
20
20
1
10
0
0 100
100
1
150
150
200
225 mm slab
3
225 mm slab
250
300
200
250
300
Slab Thickness
[mm]
350
350
400
400
Slab Thickness [mm]
110
120
100
110
90
100
80
90
70
In 32 MPa
Slabs
0.5
3
1.0
= 0.75 mm
1.5
0.0 0.5
1.0 1.5
2.0 2.5
Deflection
[mm]
110
120
100
110
90
100
80
80
60
10
mm
DD
6 mm DD 50
70
S20
6 mm DD
40
60
S20
S20
30
50
20
40
60
6 mm DD 30
50
20
6 mm DD
40
S20
10
30
0
100
120
10 mm DD 90
70
50
70
10
2.5 0
Recommended max
deflection = 1.2 mm
10 mm DD
80
60
0
20 100
2.0
10
0
Recommended max
deflection = 1.2 mm
10 mm DD
In 32 MPa
Slabs
0.0
Deflection
Deflection
=
0.75 mm
Deflection [mm]
120
Design Load,
V [kN]
DesignILoad,
IV [kN]
40
40
10
30
0
150
200
250
300
350
400
0.0
0.5
1.0
1.5
2.0
2.5 20
Deflection [mm]
Slab Thickness [mm]
10
0
150
200
250
300
350
400
0.0 0.5 1.0 1.5 2.0 2.5
Slab Thickness [mm]
• 12 • High Performance Dowel Systems
Deflection [mm]
DesignILoad,
IV [kN]
Design Load,
V [kN]
Design
Load,IVIV
[kN]
Design Load,
[kN]
10 mm DD
Slabs
90
50
50
Recommended max.
deflection
= 1.2 max.
mm
Recommended
10 mm DD
Design Load,
Design
Load,IV
[kN]
IV[kN]
120
110
Construction joint dowels
120
120
100
Design Load, IV [kN]
90
Recommended max
deflection = 1.2 mm
In 25 MPa
Slabs
110
100
90
10 mm DD
80
80
10 mm DD
70
60
60
S20
50
40
50
6 mm DD
6 mm DD
30
70
40
S20
30
20
20
10
10
0
100
0
150
200
250
300
350
400
Slab Thickness [mm]
LEGEND:
LEGEND:
Design Load, IV [kN]
110
0.0
0.5
1.0
1.5
2.0
2.5
Deflection [mm]
denotes dowels at 600 mm centres
denotes
dowels
at 600
denotes
dowels
atmm
450 centres
mm centres
denotes
dowels
at
450
mm
centres
denotes dowels at 300 mm centres
at 300
mm centres
10 mm DD denotes
= 10 mmdowels
Diamond®
Dowel
[with sleeve]
®
10 mm DD 6=mm
10 mm
Diamond
Dowel
[with
sleeve]
DD = 6 mm Diamond® Dowel [with sleeve]
6 mm DD = 6 mm Diamond® Dowel [with sleeve]
S20 = 20 mm Square Dowel with either DowelMaster®
sleeve or metal dowel cover
S20
= 20 mm Square Dowel with either Dowelmaster® sleeve or metal dowel cover
HOW TO USE MONOGRAMS:
HOW TO USE MONOGRAMS:
1 Select slab thickness, and project line upwards.
1 Select slab
thickness, and project line upwards.
2 Select applied load to be transferred across joint, and project horizontal line across both
graphs.
2 Select applied
load to be transferred across joint, and project horizon line across both graphs.
3 Where line 2 crosses preferred dowel deflection curve, project line downwards to determine
3 Where line 2 crosses preferred dowel deflection curve, project line downwards to determine predicted
predicted deflection.
deflection.
NOTES:
1. Design Loads [IV] include I = 0.6 for fixings in accordance with AS 3600 Table 2.3.(j) for loads controlled
NOTES:
by
or I[f=V]0.9
in accordance
ASin4100
Table 3.4
controlled
1. concrete;
Design loads
include
f = 0.6 for with
fixings
accordance
withfor
ASloads
3600 Table
2.3. (j)by
forsteel
loadsstrength.
controlled by
or fSquare
= 0.9 inDowels
accordance
ASDiamond
4100 Table
3.4 for is
loads
controlled
by steel
strength.
2. Dataconcrete;
for 20 mm
and with
6 mm
Dowels
based
on testing.
Data
for 10 mm
2. Data for
20 mmisSquare
Dowels and 6 mm Diamond® Dowels is based on testing. Data for 10 mm Diamond®
Diamond
Dowels
approximated.
Dowels
is approximated.
3. Design
Loads
apply to concrete strength at dowel for that particular slab thickness.
3.
Design
loads
apply to
concrete strength
atSLAB
dowel DESIGN.
for that particular slab thickness.
4. DO NOT USE THESE
MONOGRAMS
FOR
4. DO NOT
USE THESE MONOGRAMS
FOR
SLABproperties
DESIGN. and are not influenced by slab thickness,
5. Deflection
characteristics
are based on
dowel
5. Deflection
characteristics
are based on dowel properties and are not influenced by slab thickness, concrete
concrete
strength
or dowel spacing.
strength
or dowel
spacing.on load capacities for other joint widths, other dowel spacings and other
6. Contact
Danley
for guidance
6.
Contact
Danley
for
concrete strengths. guidance on load capacities for other joint widths, other dowel spacings and other concrete
strengths.
High Performance Dowel Systems • 13 •
Contraction Joint Dowels
Load and deflection
characteristics in 10 mm wide joints
Contraction
joint dowels
Contraction
Joint characteristics
Dowels
Load
and deflection
in 10 mm wide joints
In 40 MPa
Slabs
70
60
Design
Load,
[kN][kN]
IV IV
Design
Load,
S20
10 mm
Plate
D
10 mm
60
60
Plate D
60
50
2
50
40
50
2
40
S20
40
40
S20
30
30
30
30
6 mm Plate D
6 mm Plate D
20
20
00
100
100
225 mm
mm slab
slab
11 225
150
150
200
200
250
250
300
300
Slab Thickness [mm]
350
400
Deflection [mm]
Deflection [mm]
70
60
S20
10 mm
Plate D
Slabs
10 mm
Plate D
60
50
70
70
60
60
50
50
40
S20
40
30
20
30
6 mm
Plate D
6 mm Plate D
10
40
30
S20
6 mm Plate D
20
30
20
10
20
6 mm
Plate D
0
150
200
250
300
350
400
Slab Thickness [mm]
0
100
80
Plate D
50
40
10100
80
Recommended max
deflection = 1.2max
mm
Recommended
mm
deflection = 1.210
mm
Plate
10 mmD
S20
In 32 MPa
Slabs
In 32
MPa
00
0.0 0.5 1.0 1.5 2.0 2.5
400 0.0
0.5 1.0 1.5 2.0 2.5
350
80
70
10
10
Deflection
Deflection
1.15mm
mm
==1.15
33
Slab Thickness [mm]
80
20
20
66mm
mm
Plate
PlateDD
10
10
IV [kN]
DesignDesign
Load, Load,
IV [kN]
70
Plate
D
10 mm
Plate D
50
80
70
Recommended max
10mm
mm
deflection = 1.2
150
200
250
Design Load,IV [kN]
Design Load,IV [kN]
70
Recommended max
deflection = 1.2 mm
S20
In 40 MPa
Slabs
80
80
Design Load,
[kN]
Design Load, IV IV
[kN]
Load and deflection characteristics in 10 mm wide joints
80
300
Slab Thickness [mm]
0.0
0.5
1.0
1.5
2.0
0
10
2.5
Deflection [mm]
350
400
0.0
• 14 • High Performance Dowel Systems
0.5
1.0
1.5
2.0
Deflection [mm]
0
2.5
Contraction joint dowels
70
S20
In 25 MPa
Slabs
10 mm
Plate D
Design Load, IV [kN]
60
80
Recommended max
deflection = 1.2 mm
70
10 mm
Plate D
60
50
50
40
40
S20
30
30
6 mm Plate D
20
0
100
150
200
250
300
350
400
10
0
0.0
0.5
Slab Thickness [mm]
LEGEND:
LEGEND:
20
6 mm
Plate D
10
Design Load, IV [kN]
80
1.0
1.5
2.0
2.5
Deflection [mm]
denotes dowels at 600 mm centres
denotes
dowelsdowels
at 600 at
mm
centres
denotes
450
mm centres
denotes dowels at 450 mm centres
denotes dowels at 300 mm centres
denotes dowels at 300 mm centres
10 mm Plate D = 10 mm Plate Dowel cradles
10 mm Plate D= 10 mm Plate Dowel cradles
6 mm Plate D = 6 mm Plate Dowel cradles
6 mm Plate D = 6 mm Plate Dowel cradles
S20 = 20 mm Square Dowel cradles with either DowelMaster® sleeve or metal dowel cover
S20
= 20 mm Square Dowel cradles with either DowelMaster® sleeve or metal dowel cover
HOW TO USE MONOGRAMS:
HOW TO USE MONOGRAMS:
1 Select slab thickness, and project line upwards.
1 Select slab thickness, and project line upwards.
2 Select applied load to be transferred across joint, and project horizontal line across both
graphs.
2 Select applied
load to be transferred across joint, and project horizontal line across both graphs.
3 Where line 2 crosses preferred dowel deflection curve, project line downwards to determine
3 Where line 2 crosses preferred dowel deflection curve, project line downwards to determine predicted
predicted deflection.
deflection.
NOTES:
1.
Design Loads [IV] include I = 0.6 for fixings in accordance with AS 3600 Table 2.3.(j) for loads controlled
NOTES:
concrete;
I =include
0.9 in accordance
with in
AS
4100 Table
3.4ASfor
loads
controlled
steelcontrolled
strength.
1. by
Design
Loadsor
[fV]
f = 0.6 for fixings
accordance
with
3600
Table
2.3.(j) forby
loads
2. Data
for
20
mm
Square
Dowels,
6
mm
and
10
mm
Plate
Dowels
is
based
on
testing.
by concrete; or f = 0.9 in accordance with AS 4100 Table 3.4 for loads controlled by steel strength.
3.2.Design
Loads
apply
to concrete
for that
particular
thickness.
Data for
20 mm
Square
Dowels, 6strength
mm and at
10dowel
mm Plate
Dowels
is basedslab
on testing.
4.3.DO
NOTLoads
USE apply
THESE
MONOGRAMS
SLAB
Design
to concrete
strengthFOR
at dowel
forDESIGN.
that particular slab thickness.
5.4.Deflection
characteristics
are based
onSLAB
dowel
properties and are not influenced by slab thickness,
DO NOT USE
THESE MONOGRAMS
FOR
DESIGN.
concrete
strength
or
dowel
spacing.
5. Deflection characteristics are based on dowel properties and are not influenced by slab thickness,
6. Contact
fororguidance
on load capacities for other joint widths, other dowel spacings and other
concreteDanley
strength
dowel spacing.
concrete
strengths.
6. Contact Danley for guidance on load capacities for other joint widths, other dowel spacings and other
concrete strengths.
High Performance Dowel Systems • 15 •
Installation tolerances
It is vital that the dowels be placed:
• In the centre of the slab
• Evenly spaced along the joint
• At the correct depth of embedment
• Parallel to the top surface
• Square to the face of the joint
Misalignment of dowels will result in inferior
performance of dowelled joints, will frequently cause
premature failure of the surrounding concrete under
loads much smaller than design loads, or lock up
joints rendering the dowels ineffective and initiating
unplanned cracks.
Placement using the following tolerances will
ensure the optimum performance of dowels and the
surrounding concrete.
1. Location - 1/2 x slab thickness +/- 5% of slab
thickness e.g. for 200 mm thick slab, location is 100
mm +/- 10 mm from top of slab. This positions the
dowel in the most effective location in the concrete,
maximising shear load transfer.
Slab
thickness
= 200mm
Position
= 100mm
10mm
2. Spacing – specified pitch +/- 5% e.g. for 450 pitch,
tolerance is +/- 22 mm.
3. Embedment depth – 1/2 x specified length of
the dowel +/- 25 mm e.g for 300 mm long dowel,
embedded length in each slab = 150 mm +/- 25 mm.
The centre line of Plate Dowel and Square Dowel
Cradles must be positioned on the line of the sawcut
+/- 25 mm. Diamond® Dowel plates should be fully
inserted into the sleeve. Square Dowels should be
inserted into the Dowelmaster® sleeves for 1/2 the
specified length +0, - 25 mm – this allows for up to
10 mm of expansion capability for the longest dowel
appropriate for the Dowelmaster® sleeve.
4. Parallel to top face of the slab – nailing plates
should be securely fastened to the form boards, and
the form boards must be square to the face of the
concrete. For Diamond® Dowels, one end of the
nailing plate to be no more than 3 mm higher than
the other end. For Plate Dowel Cradles and Square
Dowel Cradles, the sub-grade must be smooth and
parallel to the intended top face of the slab. If the
dowel is severely misaligned and not parallel to the
top edge of the slab, the misaligned dowel could
restrict the slabs from moving parallel to each other.
5. Perpendicular to the face of the dowel joint - the
top of the sleeve at the extreme end should be no
more than 3 mm higher or lower than the face of
the sleeve behind the nailing flange. For cradles, the
top face of the dowel at one end should be no more
than 3 mm higher or lower than the other end of the
adjacent dowels. Misalignment here can severely
restrict joint opening during concrete curing and lead
to failure of the concrete surrounding the dowels, or
unplanned cracking of the slab remote from the joints.
Expansion joint load transfer
Square dowels, when used with Dowelmaster® sleeves, have 10 mm expansion capability built into the sleeves.
Expansion capabilities greater than 10 mm can be achieved by reducing the depth of embedment of the square
dowel in the Dowelmaster® sleeve. A compressible filler should be used between adjacent slabs.
Diamond® Dowels can also be used in expansion joints if the dowel plates are first inserted to full depth then
pulled back a distance equal to the anticipated expansion. A compressible filler should be used between
adjacent slabs.
Plate Dowel Cradles and Square Dowels Cradles are not normally appropriate for expansion joint conditions.
• 16 • High Performance Dowel Systems
Research
The engineering design data presented on pages 12
Edge of concrete
to 15 of this brochure has been developed from the
data generated by this research program, combined
with analysis methods contained in documents
of Standard
highest
referenced byZone
Australian
ASstress
3600-2001, and
additional tools such as finite-element analysis.
The loading and deflection data presented in the
monograms on pages 12 to 15 recognises eight
variables that need to be considered when designing
for load transfer. These are:
• Construction joint or sawn contraction joint
• Load to be transferred
• Concrete slab thickness
• Concrete compressive strength
• Joint width
• Dowel type
• Dowel spacing
• Dowel deflection
Additionally, the following observations have been
made:
• Diamond® Dowels and Plate Dowels have
superior load carrying capacity and are efficient at
minimising differential deformation.
m
m that the optimum spacing
• Failure patterns indicate
of dowels is approximately
3 times the slab
10
1
thickness for slabs in the 150 to 225 mm range. So
for 150 slabs, the most efficient spacing is 450 mm.
• Close spacing of dowels (e.g. at 300 mm centres)
reduces the capacity of the adjacent concrete to
absorb the loads generated by the dowels.
Approx
of that
depth
analysis 1/6th
has shown
maximum
• Finite element
stresses on aof
loaded
Diamond®
Dowel
are
embedment
located at approximately 1/6th of the depth of
embedment.
tress
Edge of concrete
Zone of highest stress
0
11
m
m
A Queensland University of Techn
research program on different dow
Approx 1/6th
of depth
funded by Danley
Construction
Pr
of embedment
confirmed the efficiency of Diamo
compared to other systems. Over
The r
have
Stress
blocks
1m square x 150 mm thick
are su
with round, square, plate and Diam
defor
syste
Each test
block
was
instrumented
Distance from joint
load and deflection before being
Baselo
Diam
failure.
than o
there
80
70
60
50
Comparison of Dowel Perform
Note. Deflection data is for joint
10 mm Diamond Dowels
[approximated]
6 mm Diamond Dowels
10 mm Plate Dowels
40
30
The research
determined that Dia
have very20efficient load carrying c
are superior
in minimising differen
10
deformation
when compared to ot
0
0
1
2
3
systems.
Deflection [mm]
6 mm Plate Dowels
Distance from joint
Rese
Finite
Diam
stress
the de
A Que
resea
funde
Research
confir
Finite-element analysis of onecomp
hal
block
Diamond Dowel indicates thatwith
ther
Each
stresses are located at approxima
load a
the depth of embedment.
failure
Load [kN]
A Queensland University of Technology research
program on different dowel systems, funded by
Danley Construction Products, confirmed the
efficiency of Diamond® Dowels, Plate Dowels and
Square Dowels compared to other dowelling systems.
Over 90 test blocks 1m square x 150 mm thick were
cast with different types of dowels spanning 10 mm
joints. Some blocks 225 mm thick were also cast.
Each test block was instrumented to record load and
deflection while being loaded to failure.
High Performance Dowel Systems • 17 •
Companion products
Crack-A-Joint®
As an option to saw cutting, place Crack-A-Joint® into
the wet concrete along the joint line (above the Plate
Dowel Cradles or Square Dowel Cradles), to induce
a crack for the full depth of the concrete. Available
in 3 m long lengths, formed from galvanised steel in
heights of 25 and 45 mm. Can be supplied with Rip-AStrip® capping in 4 colours.
Metal Dowel Covers
Metal Dowel Covers are normally used with square
dowels in situations where slab shrinkage parallel to
the joint is expected to be greater than the +/- 5 mm
allowed by Dowelmaster® sleeves. Can be substituted
for Dowelmaster® sleeves at construction joints,
and can be used on Square Dowel Cradles. Are also
appropriate for larger size square dowels.
Ground Crack Inducer
An inverted V-shaped PVC extrusion 3 m long
available in 25 and 50 mm heights, it is positioned
on the sub-grade before the Plate Dowel Cradles
or Square Dowel Cradles are placed. Produces a
weakening in the slab that initiates a crack in the slab
from the bottom up. Ground Crack Inducer should
only be used when Crack-A-Joint® is used, or when
saw cuts are to be made in the slab on the same day
as the slab is poured.
Keyjoint
Danley’s Dowelmaster® sleeves and square dowels
may be used with Danley’s preformed metal Keyjoint
profiles, to combine the performance of square
dowels with the efficiency of 3 m or 6 m long stay-inplace forming system for slabs 100 to 250 mm thick.
Keyjoint is formed from galvanized steel, secured with
unique stakes that provide adjustability during set-up,
and is available with PVC capping.
• 18 • High Performance Dowel Systems
Frequently asked questions about dowel joints in concrete slabs
1. What is the connection between concrete
shrinkage, joints in concrete slabs, and dowels?
• Chemical reactions begin as soon as concrete has
been poured, and the concrete begins to gain
strength. During the first few hours of curing, rapid
strength build-up and the natural tendency of
concrete to shrink creates stresses in the concrete.
• Shrinking during curing is the main cause of
cracking in concrete, and concrete will crack
wherever a defect is present.
• Good work practices such as protecting the pour
from wind or high temperatures by having walls
and roofs in place prior to pouring, well-trained,
well-equipped and adequately sized paving crews,
and controlled curing will help minimise cracking
problems.
• Deliberately placing defects (e.g. saw cutting the
slab) will result in controlled cracks.
• Relieving the stresses built up during curing as
early as possible by making the saw cuts as soon as
practical after the concrete pour.
• Joints [as well as uncontrolled cracks] will continue
to open up for months after a slab has been
poured.
• When vehicles or equipment travel from one slab
over a joint onto the adjacent slab, dowels assist in
distributing the stresses from the loaded slab into
the adjacent slab – this is sometimes called load
transfer or shear transfer across the joint.
• Appropriate dowels sharing the loads adjacent
to or travelling over joints enhances the life and
durability of the slab or pavement.
• And finally, appropriate dowels provide a smooth
transition for the wheels of equipment travelling
across the joint.
2. Why not space dowels as closely as possible
– the more steel the better, right?
• No, there are two factors to consider; the ability
of the concrete surrounding the dowel to
accommodate the loads, as well as the strength
and stiffness of the steel in the dowel.
• In almost all circumstances, the loads applied on a
slab will be distributed onto two or more dowels.
• If dowels are closely spaced, the shear cones
developed in the concrete that resist the loads will
intersect neighbouring shear cones, reducing the
overall capacity of the concrete in the region of the
loaded dowels.
• In relatively thin slabs, it has been shown by
physical testing that the optimum dowel spacing
to maximise concrete capacity is at least 3 times
the thickness of the slab (e.g. in a 150 slab, space
the dowels at least 450 mm apart). So the further
apart the dowels are, the more load that can be
absorbed by the concrete in the region of the load.
• However, it is also necessary to check that the
strength of the steel in the dowel has not been
exceeded.
• And finally, there is a point where the deflection
capacity of the steel in the dowel may be the
limiting factor – both the concrete and the steel
in the dowels may be strong enough, but the
flexibility of the dowel may exceed appropriate
differential deflections between adjacent slabs.
3. Why not carry steel through the joint?
• If reinforcing mesh is not cut at the joint line, it will
hinder the natural shrinkage of the concrete; but
more importantly, the mesh has very little capacity
to assist with load transfer across the joint.
• If reinforcing bars cross the joint, they will prevent
the contraction joint from activating, and also do
not have sufficient strength to provide adequate
load transfer.
High Performance Dowel Systems • 19 •
Setting up Plate Dowel Cradles and reinforcing mesh prior to a
pour.
Close-up view during concrete placement. Note the cut cross
wire and the reinforcing mesh supported on chairs (not on the
cradles).
First-pour slab on right with Diamond® Dowels
sleeves cast in and dowel plates in place for
second pour. At left, form board with dowel
sleeves attached, ready for concrete pour.
Finishing a freshly
placed slab, and
saw cutting the
contraction joins with
an early-entry saw.
Danley Head Office
21 Steel Place, Morningside Qld 4170
PO Box 297, Cannon Hill Qld 4170
Phone: +61 7 3899 3466
Fax: +61 7 3899 1733
Email: [email protected]
New South Wales
Sales & Distribution Office
2/34 Prime Drive, Seven Hills NSW 2147
Phone: +61 2 9838 4666
Fax: +61 2 9620 8065
Freecall: 1800 280 573
Website: www.danley.com.au
• 20 • High Performance Dowel Systems