allen BDF4836 User manual

BRIDGE DECK FINISHER SET-UP GUIDE
BDF4836 - BDF6036 - BDF6048
Manual Part #: 069596 | Revision: A

BRIDGE DECK FINISHER SET-UP GUIDE - 069596Page 2
36’ to 48’ Machine (Appx Weight 6,500 to 10,500 Lbs.)
84’ to 108’ Machine (Appx Weight 10,000 to 13,500 Lbs.)
PICTURE 1
WARNING
• Please use extreme caution when lifting the BDF. Make
sure crane or lifting equipment has enough capacity
to lift the weight of the machine. Please make sure all
lifting apparatus, straps & cables are free from structural
damage and are rated for the proper lifting capacity.
• Please make sure all ground personnel are clear of
danger while the machine is being lifted.
• LOCK all (4) legs prior to lifting the machine as they could
roll causing an unbalanced load and personal injury.
• ALLOWING the weight of the machine to rest on the
carriage paving rollers WILL cause damage to the
carriage or the paving rollers, ALWAYS place blocks
under end-frame
• ALWAYS attach LONG safety ropes or tag lines to the
ends of the machine prior to lifting.
• Position the paving carriage opposite the power unit end
to provide a balance lift for the machine.
• Lifting straps are provided. Please be aware of the lifting
capacity for all straps.
• Lifting angles should not be less than 45° from horizontal.
SEE PICTURE 1 BELOW
• If using a center cable, CAUTION should be taken when
adjusting the length.
When Lifting Your Machine

BRIDGE DECK FINISHER SET-UP GUIDE - 069596 Page 3
• CHECK all height restrictions prior to loading the
machine as all Drop-Deck trailers and at-bed trailers
have different dimensions. Paving Carriage may need to
be removed for legal transport. Tighten the leg clamps
on the four legs (SEE PICTURE 2).
• DO NOT secure the BDF to the trailer over the truss
frame in the center of the machine. Use the tie-down
loops on the end frames (SEE PICTURE 3) of the machine
using chains.
• Tighten the chains by pulling towards the center of the
machine.
• When loading with Bogie Wheel Frames attached to the
legs – IT IS IMPORTANT to keep the frame & bogies
elevated above the trailer bed. Multiple 2 x 4’s or a 4 x
4 block needs to be place in between the bogie wheels
and under the bogie frame (SEE PICTURE 4). Screw or
nail the wood to secure it to the truck bed.
• When loading without Bogie Wheel Frames - Place
multiple 2 x 4’s or a 4 x 4 the width of the trailer under
the leg yokes on both ends of the machine (SEE PICTURE
5). Secure the wood by screwing or nailing it to the truck
bed.
• When loading the machine with the Paving Carriage
attached - block the carriage so that the machine or
carriage weight does not rest on the paving rollers.
Place the blocks under the end frames of the carriage
and nail them to the deck. (SEE PICTURE 6). With the
carriage frame now setting on the blocks, adjust the hold
down rollers, located on the carriage hanger frame at
the top of the carriage, to the lowest position. Using the
leg cranks or power leg option, lower the machine just
enough so that the carriage rollers are not tight against
the carriage rail. This allows movement of the machine
truss while transporting and will not cause damage
to the carriage rail. If the paving carriage is loaded
separately, block the carriage in the same manner under
the end frame and secure the carriage to the truck.
PLEASE NOTE: Whether transporting with or without
carriage, the carriage rollers cannot rest on the
trailer bed and need to be blocked under the end
frames.
Picture 2
Picture 3
Picture 6
Picture 5
Picture 4
When Loading & Transporting Your Machine

BRIDGE DECK FINISHER SET-UP GUIDE - 069596Page 4
Placing Screed Rail & Paving Forms
• The set-up is what determines the longitudinal prole
of your roadway paving or bridge deck surface.
• There are two screed rail setups for bridges. The
engineer or DOT specications will determine if the
BDF will ride on the pipe located on the edge forms or
on the pipe located on the bridge girders.
FIRST TYPE OF BRIDGE DECK SET-UP:
- Look at the type and spacing of the overhang
brackets if the machine is riding on forms and
refer to the manufacturer’s specications for size
of overhang brackets and spacing. Consult with
the factory about your machine weight and
wheel loads.
- Once the BDF loads have been determined, THIS
will dictate placement of the Screed Rail.
- The Rail position must be accurate and conform
to the grade required. Allen Engineering
recommends 2-inch schedule 80 pipe with a
sleeve at one end to connect two sections of pipe
together.
- 24 inches on center is the recommended spacing
for the screed chairs. (Special situations may
have a maximum 30 inches).
- The rails and chairs should be double checked
after placing the machine on the deck.
- After the BDF has been set on the deck, it will
need to run up and down to take out any timber
crunch or settling of the form work.
- Double check the form-work again.
SECOND TYPE OF BRIDGE DECK SET-UP:
- When the machine is riding on bridge girders you
will need to fabricate
a screed chair stand
that will be epoxied or
welded to the beam
or a girder plate (SEE
PICTURE 7)
- We recommend you tie
the vertical tube to the rebar mats for stability.
- The top of the vertical tube will be below the
nished surface grade.
- The screed rail needs to be adjusted to
conform to the longitudinal prole which can be
accomplished in various ways.
- A folding ruler or tape measure with the use of a
level can be used to determine the quarter points
on the deck to the top of the screed rail.
- Pulling a string-line between the 2 points or
measuring from the grade-line on the form to
the top of the screed pipe to set the grade of the
pipe.
- Remember this is just an initial setup at this
time and the rails and chairs should be double
checked after placing the machine on the deck.
- Double check the form-work again.
PAVING FORM SET UP:
• A strong solid sub-base is required for all concrete
paving forms to sit on to prevent the paving forms from
sinking into the sub-grade causing an improper grade
prole.
• Allen recommends our Steel Forms or forms designed
and engineered to carry the weight and load of the
paver. The BDF will be outtted with at ange poly-
bogie wheels with a 3-inch width to ride on the top of
the paving form.
PICTURE 7
The screed, pipe rail, and
concrete paving forms provide the
longitudinal prole of the paving
surface and the proper set-up is as
equally important as the machine
operation.
Screed Chair
Screed Chair
Stand

BRIDGE DECK FINISHER SET-UP GUIDE - 069596 Page 5
BDF Assembly & Set-up
Your BDF assembly process can be performed by a 2-3
person crew with the help of an Allen Field Technician.
Typically: one operator and two ground people. A crane or
capable lifting device will be required, along with an impact
tool, crescent wrenches, socket set and various hand tools
for the nuts & bolts assembly. Depending on the complexity
of the project, this can/may take 1-3 days.
INSERT ASSEMBLY
• A level working area is required and necessary for
the proper assembly of your BDF in a safe working
environment.
• Know where your crown is located and what insert
sizes will be needed for the proper assembly.
• It may be required to assemble additional inserts
separately.
• Always move the carriage to the power unit side
when adding additional inserts.
• To reduce machine frame stress, when extending
to lengths greater than 55’-60’, install the smaller
size inserts (3’, 4’ 5’ 6’ 7’, 8’ 9’ etc…) on the two
end sections of the machine.
• Loosen the chain tightener to disconnect the
carriage travel chain and also remove the chain
master link, then pull the chain over the top of
the idler sprocket, roll up the chain to keep from
tangling and place it near the paving carriage.
• Roll up the hydraulic hoses that stretch across the
top of the machine for the travel bogies & power
legs on the idler end of the machine and place near
the power unit end
• Additional frame inserts are added to the machine
after splitting the machine at the hinge point of the
power unit section.
• The power unit end needs to be supported at the
hinge point some type of support which could be
constructed with scaffolding, barrels, I-beams etc.
• PLEASE MAKE SURE the power unit end is
secure and stable and the support is strong
enough!
• Attached lifting straps to the idler end of the
machine and remove the crown bolts at the top of
the truss frame and the hinge pins on the bottom
of the truss frame and can be placed out of the
way for additional assembly.
• Add the required insert sections for proper length
& deck layout on the power unit insert and connect
the idler end section of the machine.
• Lubricate the crown bolt when attaching the
inserts together.
CAUTION - Prior to removing the paving carriage chain
PLEASE secure the carriage by attaching vise grips on
each side of the carriage rail rollers. This will prevent
the carriage from moving when the chain is removed
when adding additional inserts.
TYPICAL BRACING
TYPICAL BRACING
TYPICAL BRACING