Rice Lake Survivor SR User manual

SURVIVOR SR
Siderail Truck Scale
Assembly Instructions
45698 Rev D
®

Contents i
Technical training seminars are available through Rice Lake Weighing Systems.
Course descriptions and dates can be viewed at www.ricelake.com/training
or obtained by calling 715-234-9171 and asking for the training department.
Contents
1.0 Introduction..................................................................................................................................... 1
1.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2.1 Foundation Slab Cure Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2.2 Delivery, Crane Rental, and Assembly Estimates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2.3 Recommended Equipment and Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2.4 Determine Frame Assembly Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.0 Assemble Frame Siderails and Cross Beams ................................................................................ 5
2.1 Connecting Siderails into Multi-Module Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Siderail Beam Identification and Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2.1 Siderail Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2.2 Siderail Numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Cross Beam Identification and Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3.1 Cross Beam Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3.2 Cross Beam Numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.0 Level and Align Frame, and Bolt Tightly......................................................................................... 7
3.1 Align and Square Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Level Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.0 Set Load Cell Mounts...................................................................................................................... 8
4.1 Attach Mount Chair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2 Prepare Baseplate and Load Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3 Set Baseplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.4 Raise Link and Load Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.5 Tighten Load Cell Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.6 Raise Mount into Final Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.7 Attach Flexible Conduit Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.0 Install Anchor Bolts and Grout...................................................................................................... 10
5.1 Anchor Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.2 Grouting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.0 Install Support Bars, Corrugated Metal, and Deck Rebar ............................................................ 11
6.1 Support Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.2 Corrugated Metal Sheeting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.3 Deck Rebar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
7.0 Pour and Finish Concrete Deck .................................................................................................... 13
8.0 Install Conduit, Cabling, and J-Boxes .......................................................................................... 15
8.1 Flexible Conduit Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8.2 Electrical Ground Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8.3 Junction Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
8.4 Transient Protection Insurance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
8.5 Overview and Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
8.6 Trimming Individual Cells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
8.7 Trimming Paired Sections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8.8 Calibration with Test Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
© Rice Lake Weighing Systems. All rights reserved. Printed in the United States of America.
Specifications subject to change without notice.
August 13, 2014

ii Survivor®SR Siderail Truck Scale Assembly Instructions
Rice Lake continually offers web-based video training on a growing selection
of product-related topics at no cost. Visit www.ricelake.com/webinars.
9.0 Vehicle Scale Limited Warranty................................................................................................... 23
For More Information ............................................................................................................................. 24

Introduction 1
1.0 Introduction
This manual is intended for use by technicians responsible for installing and servicing the SR series truck scale.
You will find that the SR truck scale has been designed so that your on-site installation time is reduced as much as
possible. A well-organized, experienced installation crew should be able to install a typical 70’x 11’ truck scale in
one day.*
*These estimated times may vary.
This booklet covers all SR–Series truck scale installations. Use these instructions as general installation
guidelines unless the blueprints furnished with the specific scale ordered directly contradict this instruction
booklet. Blueprints furnished with the specific scale always take priority over these generic SR–Series
installation guidelines.
Refer to the blueprints furnished with the scale for all component numbering sequences.
Authorized distributors and their employees can view or download this manual from the Rice Lake
Weighing Systems distributor site at www.ricelake.com.
1.1 Sa fety
Safety Symbol Definitions:
Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.
Indicates a potentially hazardous situation that, if not avoided, could result in serious injury or death and
includes hazards that are exposed when guards are removed.
Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury.
Indicates information about procedures that, if not observed, could result in damage to equipment or
corruption of and loss of data.
General Safety
Do not operate or work on this equipment unless you have read and understand the instructions and
warnings in this manual. Failure to follow the instructions or heed the warnings could result in injury or
death. Contact Rice Lake Weighing Systems for replacement manuals. Proper care is your
responsibility.
Failure to heed may result in serious injury or death.
DO NOT allow minors (children) or inexperienced persons to operate this unit.
DO NOT operate without all shields and guards in place.
DO NOT use for purposes other than weight measurement.
DO NOT place fingers into slots or possible pinch points.
DO NOT use any load-bearing component that is worn beyond 5% of the original dimension.
DO NOT use this product if any of the components are cracked.
DO NOT exceed the rated load limit of the unit.
DO NOT make alterations or modifications to the unit.
DO NOT remove or obscure warning labels.
Keep hands, feet and loose clothing away from moving parts.
Note
DANGER
WARNING
CAUTION
Important
WARNING

2Survivor® SR Siderail Truck Scale Assembly Instrucitons
1.2 Installation
The individual components and modular sections of the SURVIVOR Siderail truck scales assemble smoothly
following a proven construction sequence. Some of the steps may change slightly depending on the lifting
equipment (crane or forklift) you have available. Assembling a single-platform gross weighing scale, or a
multi-platform axle weighing model, will require slightly different steps, but the general assembly order for all
scales will be roughly the same.
• Assemble siderails and cross beams loosely on 8" setting blocks
• Level and align frame to final position and tighten all bolts to final torque values
• Set mounts and load cells
• Install mount anchor bolts and grout beneath mount plates
• Install support bars, corrugated sheet metal, and rebar for concrete deck
• Pour and finish concrete deck
• Install conduit, cabling, and junction boxes
1.2.1 Foundation Slab Cure Period
Standard concrete reaches full strength after a 28-day cure. Note that
the concrete foundation slab must cure in a moist state for at least
seven days (three days for high-early concrete) before driving on it. At
seven days, standard concrete is at approximately 75% of its
maximum strength and can be driven on. Driving a loaded forklift on
the slab before it reaches 75% of maximum strength may damage the
foundation.
1.2.2 Delivery, Crane Rental, and Assembly Estimates
When scheduling scale delivery and crane/forklift rental for the unloading and frame placement, arrange a full day
and a crew of at least two assemblers. A two-man crew with crane or forklift can normally unload the scale and set,
align, and bolt all components in place on the first day.*
The next day, a crew of three or four can normally prepare the scale deck for concrete, pour and finish it before
evening.*
The third day, a crew of two can grout load cell base plates, run all conduit, make electrical connections, and
connect electronic equipment.*
When the concrete deck has cured, the scale can be corner-trimmed and calibrated with test weights and
placed into service.
*These estimated times may vary.
1.2.3 Recommended Equipment and Tools
• Crane with a minimum 6,000 lb capacity, or
• Forklift with 8' fork extensions
• Air compressor and impact wrench with 1"
drive
• 3/4" rotary hammer drill
• 3/4" x 36" masonry carbide bit
• Low-profile (8" ht.) 10-ton hydraulic jacks
• 8" setting blocks
• Chain winches (2) with 16' chains and hooks
• Torque wrench to 700 ft.lbs. with extension
handle
• Box end and 1" drive socket wrenches to 1
1/2"
• 4' bubble level or laser level
• Small torpedo level
• Chalkline
• 100' measuring tape
• 25' measuring tape
• Hammers and maul
• Hack saw, metal snips
• 1 1/2" rebar chairs and metal ties
• Rebar twist tie spinner tool
• Concrete vibrator (for deck concrete pour)
• Concrete trowels, edger, bull float, broom
• Hand tools for wiring and conduit installation

Introduction 3
1.2.4 Determine Frame Assembly Sequence
The scale assembly sequence can be done in either of two ways: side-to-side or
end-to-end. Analyze your site access, equipment, and manpower to determine
which is better for you. The truck has been loaded in a way that avoids
double-handling beams on site. Main side rail beams and components can be
unloaded and set directly in place on the scale foundation in the order they will
be used. See the truck loading diagram on the first page of this manual.
If using a crane, park the crane beside and parallel to the scale foundation, with
the loaded truck parked on the other side of the crane.
If using a forklift to unload and set beams, you’ll need access to both sides of the truck to unload beams in order to
avoid double handling.
The first assembly step —unloading and setting the first row of side rail beams on one side of the scale—is the
same in both side-to-side or end-to-end assembly sequences.
Assemble Reference Beams on One Side
Main siderails on one side are placed on 8" setting blocks in their final
position on the far (least accessible) side of the scale. The end side rail
is set 1.5" from the concrete approach. If the next side rail is to be
bolted to the end one, set it directly adjacent and bolt it. If any side rail
is to be the start of a separate section, leave a 1" end gap to separate
independent platforms. The final end section is set 1.5" from the other
concrete approach. These beams are aligned straight with a string line
and squared with the foundation approaches. This line of side rail
beams becomes the reference line to which the other side rail and all
cross beams are aligned.
Side-to-Side Assembly Sequence
With this method, the side rail beams on the second side
are next set into position parallel but about 2" wider
than they will be in the final scale. This extra width
allows clearance for the cross beams to be lowered into
position with a sling on either a crane or
extension-boom forklift as shown at right.
Lower all cross beams into place on the side rail beam flanges and bolt them only to the first line of side rail beams
you set—the reference line side. When all cross beams are bolted to the reference side rail, check the straightness
of the side rail again with a string line to be certain it hasn’t moved. If it hasn’t, you can start bringing in the
siderails on the second side. Any siderails on the second side that will be end-bolted into a multi-module section
should not be bolted together at the ends yet—they will be too heavy and awkward to move in the required 2" if
combined now.
Begin bolting the cross beams to the siderails on the second side starting at one approach end. Use chain winches
(“comealongs”) to bring in the second side rail beam the extra 2" as you tighten the cross beam bolts. Keep
repositioning the chain winches on the siderails as you bolt down the line of cross beams from the approach end
through all scale sections.
A forklift can be used to slide each side rail section into place rather than step-by-step with chain winches. Your
forklift operator must have a delicate touch though or your reference side rail can be pushed out of alignment.

4Survivor® SR Siderail Truck Scale Assembly Instrucitons
End-to-End Assembly Sequence
This method requires more setting blocks, but no chain winches. More driving
on the slab is necessary, but the assembly can be done by a forklift with standard
length tines.
Begin by setting one row of side rail beams on 8" setting blocks as in the
previous method. If access is limited to one side, drive across the pad and
position these on the limited-access side. Align these reference siderails with a
string line and square with the approaches. Bolt adjoining siderails together
where needed to final torque settings.
Bring the cross beams onto the pad one at a time starting at one approach end.
Position each cross beam at its final location with one end resting on the side rail
flange. Bolt the cross beam to the side rail. Rest the other end of the cross beam
at a right angle to the side rail on a setting block 2" higher than your 8" blocks.
Repeat for all cross beams of the module.
When all cross beams for the first module are set and bolted to the reference side
rail, move the opposite side rail for the open side into position with the forklift.
With the cross beams resting on the side rail flange, raise the side rail and cross
beams enough to allow the cross beam setting blocks to be removed. Lower the
side rail onto two 8" setting blocks. Bolt the cross beams to this side rail so it
pulls into final position. Do not disturb the reference side rail positioning. Align
and square this completed section with the reference line and approaches.
Combined Modules: If a second module is to be bolted together into a
multi-module platform, move the second set of cross beams into position and
perform the same steps. When these cross beams are bolted to the reference side
rail, bring the opposite side rail into position. Lift the side rail and cross beams,
remove the 2" setting blocks, and align the side rail with the adjoining side rail
so the six holes in the adjoining end plates align. Bolt the siderails together.
Check alignment and square with the reference line and approaches.
Independent Modules: If the next module is not to be bolted to the first, set the
side rail 1" from the adjoining side rail. The final side rail will end 1.5" from the
approach.

Assemble Frame Siderails and Cross Beams 5
2.0 Assemble Frame Siderails and Cross Beams
Whichever assembly sequence you chose, observe the following details.
• Use 8" high setting blocks so the deck frame will nearly match the level of the approaches.
• Don’t torque down cross beam assembly bolts tightly until the module is aligned and squared.
• Use a taut string line to align side rails.
• Measure diagonals with a 100' tape to assure frame is square within 1/4".
• Refer to the blueprints furnished with the scale for all component numbering sequences.
2.1 Connecting Siderails into Multi-Module Sections
A load cell mount sits directly under each multi-module joint splice and bears on both
siderail beams. The mount requires a flat surface at the joint to bolt to. Because of
material variances from the mill, the two beams may not be exactly the same height.
Always align the bottom of the beams when bolting together to create a flat surface for
the mounts top plate. Let any extra height protrude at the top of the siderail joint.
The six bolts connecting the two side rails must be torqued to 640 ft/lb. This cannot be
done with an impact wrench—a large torque wrench with extension handle will be
required.
2.2 Siderail Beam Identification and Positioning
The following sections outline the positioning and numbering of the SR truck scale siderail beams.
2.2.1 Siderail Positioning Set all side rails with the cut-outs for the load cell mount down and the uncut
flange up. The headed anchor rods (Nelson studs) that will be encased in the
concrete deck face inward.
Gusset plates at the ends of single side rails which form an independent section
are solid.
Gusset plates at the end of side rails which bolt together to form a longer section
have three holes in each plate for these bolts as shown at left.
2.2.2 Siderail Numbering
All side rails are clearly marked with large numerals keyed to the final assembly drawing. Preview the drawing
before beginning to unload the truck. You will note that some side rails are interchangeable, while others are not
and must be placed exactly as the assembly drawing shows.
The truck will be loaded such that you can unload the side rails in order and set them directly into position on the
foundation without double handling. See the truck loading diagram for your scale model included with this manual.
2.3 Cross Beam Identification and Positioning
The following sections outline the positioning and numbering of the SR truck scale cross beams.
2.3.1 Cross Beam Positioning
Set all cross beams with the flush end of the drain tube up. The 3/8" threaded studs that attach the sheet metal
support bars should be near the bottom of the cross beam web.

6Survivor® SR Siderail Truck Scale Assembly Instrucitons
2.3.2 Cross Beam Numbering
Cross beams are marked with numbers 5, 6, or 7 on the web near the drain tube.
Number 5 cross beams attach on the ends of a scale section. The welded plate
and angle extension face to the end of the section. The headed anchor rods face
inward where they will be encased in the concrete deck.
Number 6 cross beams are set adjacent to a load cell mount. Two extra 3/8"
threaded studs near each end of #6 beams hold short support bars over the load
cell area to support the corrugated metal there when the deck is poured. Position
#6 beams so the extra end studs are over the load cell mount.
Number 7 cross beams make up the rest of the beams in the middle area of each module. Short modules may have
only one or two #7 cross beams, while longer modules may have four or more. The #7 beams are similar to #6
beams, but don’t have the extra 3/8" threaded studs near their ends. Any #7 beam can be reversed end-for-end so
drain tubes can be staggered from side to side for even drainage from the deck.
Figure 2-1. Beam Positions
6
5
7
77
1
2
1
2
3
3
7
6
6
7
7
7
7
66
7
7
7
7
6
5
70'
23' 4"
23' 4" 23' 4"

Level and Align Frame, and Bolt Tightly 7
3.0 Level and Align Frame, and Bolt Tightly
The following sections cover the steps in aligning and leveling the SR truck scale deck.
3.1 Align and Square Deck
Align the siderails with a string line and square the entire frame by measuring diagonals with a 100' tape. As the
siderails may not be perfectly vertical, measuring diagonals across the top flanges of the siderails may not reflect
the true squareness of the deck. The most accurate measurement will be diagonally from the center web of the
siderails at the level of the deck top.
If adjustments are necessary, a fork lift or crane can be used to nudge the frame into alignment.
3.2 Level Frame
If the concrete foundation pad has been sloped for water drainage, add the appropriate amount to the 8" setting
blocks on the low side to level the frame. Begin leveling the frame at one end of a section at the approach. With
hydraulic jacks, raise the ends of the siderails until the end #5 cross beam is at the same level as the approach.
Insert metal shims (large washers work well) on the setting blocks to maintain this level.
Move down the scale toward the other end, jacking and shimming until the entire deck is level in both directions.
When the entire deck frame is level, torque down all cross beam bolts to 260 ft. lb.

8Survivor® SR Siderail Truck Scale Assembly Instrucitons
4.0 Set Load Cell Mounts
This section covers the steps in setting the load cell mounts on the SR series truck scale.
4.1 Attach Mount Chair
The mounts may be attached in any order. Begin each mount by removing the
girder chair and four bolts from the mount box and bolting the chair on the
bottom of the siderail at a mount cut-out. Turn each bolt into the threaded hole in
the girder chair and tighten each of the four bolts to 260 ft.lb.
4.2 Prepare Baseplate and Load Cell
Lift the baseplate and four leveling screws out of the box. Set the plate upside
down and turn the four leveling screws into the baseplate so about 2" extends
beyond the bottom surface as shown at right.
Each load cell must be fitted with a 90° threaded LB conduit adapter. Install an
adapter on each load cell now before the cell goes into the mount. Orient the
adapter so the cable will point toward the outside of the scale when mounted.
4.3 Set Baseplate
Set the baseplate, load cell, and link beneath the chair as shown. Only one of the
load cell screws is inserted into the cell now as shown at right. Leave the other
screw out until the link is placed onto the load cell and raised in the next step.
4.4 Raise Link and Load Cell
Place the link into position around the load cell. Insert the second load cell
screw. Raise the link and load cell until both ends of the load cell are on the
supports and the load cell screws can be started.

Set Load Cell Mounts 9
4.5 Tighten Load Cell Screws
Turn in and tighten both load cell screws to 50 ft.lb. minimum.
You can now tell if the baseplate is directly under the chair by how the top
convex surface of the link is aligning with the concave bearing surface of the
chair. If necessary, slide the baseplate sideways to improve the alignment. The
final alignment will be done when the baseplate is raised in the next step.
4.6 Raise Mount into Final Position
Turn the leveling screws to raise the mount until the link is centered in the chair
bearing and lightly touching. Level the plate in both directions.When the
baseplate is directly under the chair, the link will be hanging exactly vertical
when centered in the chair. Approximately 1/4" of link should protrude beyond
each side of the chair. If adjustment is necessary, tap baseplate edges lightly with
a hammer to slide the entire mount sideways.
4.7 Attach Flexible Conduit Sections
A 30" section of flexible conduit is included for each load cell. One end is
threaded for mating with the LB connector at the load cell. The other end adapts
to 3/4" galvanized rigid conduit. Thread the load cell cable through the flexible
section and turn the threaded end into the LB connector.
To maintain level of scale deck, don’t remove shims and blocks beneath siderails
until all mounts are set. When all are set, jack siderails at each mount location
just enough to remove shims and blocks. Gently lower the siderail onto the load
cell at each mount.
1/4"

10 Survivor® SR Siderail Truck Scale Assembly Instrucitons
5.0 Install Anchor Bolts and Grout
Each mount requires two anchor bolts to prevent lateral motion or uplift. 7" x 3/4"
anchor bolts with expansion heads as shown at right are supplied with the scale.
After anchor bolts are set, epoxy/cement grouting is required to distribute the
baseplate load evenly to the foundation.
5.1 Anchor Bolts
Use an industrial hammer drill with a 3/4" carbide masonry bit at least 36" long to drill
anchor bolt holes. This long bit allows the drill body to clear the siderail so the hole can be
drilled nearly vertical. Hold the bit as close to vertical as possible and drill a 3/4" hole at least
6" into the concrete beneath each anchor bolt slot on both sides of the baseplate.
Place a washer and nut on each anchor bolt to protect the threads and drive anchors into
drilled holes until washer is solid against baseplate. Tighten nuts until the heads expand and
the bolts are solidly anchored.
5.2 Grouting
Erect temporary dams around each baseplate and inject 9,000 psi non-shrinking,
epoxy/cement grout. Take care not to leave air voids; the baseplate must have
even support from continuous grout contact.

Install Support Bars, Corrugated Metal, and Deck Rebar 11
6.0 Install Support Bars, Corrugated Metal, and Deck Rebar
6.1 Support Bars
2" x 3/16" steel bar stock bolted between cross beams support the corrugated sheet metal that forms the bottom
surface for the concrete deck pour. Several different lengths of support bars are necessary for most scale lengths.
See the attached blueprint of the scale to determine where each of the different lengths are located in the frame.
Unload the support bars from the hardware box on the truck. Each group
of similar-length bars is bundled separately and marked. Keep equal
length bars together in separate piles.
Install all support bars onto the 3/8" threaded studs per locations shown in the
blueprint. Turn a hex nut onto each stud and tighten securely.
At each load cell mount location, the bottom flange of the 24" siderail I-beam
has been cut out for the load cell window. To support the sheet metal where the
flange is gone, a short support bar is installed next to the load cell window as
shown at left.
6.2 Corrugated Metal Sheeting
Lay in 28 gauge, 3/4" corrugated galvanized panels (1-1/4" wide corrugations) to support the concrete deck pour.
Lay the panels parallel to the cross beams so they are resting on the support bars and the I-beam flanges. Overlap
adjoining panels at least 9" or three full corrugations. Overlap ends at least 12".
Do not use galvanized panels lighter than 28 gauge, or with corrugations more than 1-1/4” wide!
Panels must fit closely to vertical webs of all I-beams to prevent concrete runout
during the deck pour. Cut out accurate slots in the corrugated metal for clearance
around the vertical gussets in the siderail beams and around the drain tubes on
the cross beams. A metal-cutting snips is the best tool for this work.
Cut out clearance sections in the panels for drain tubes where necessary. Slide
the main panel into place, then make a larger overlapping panel section with a
slot cut out for the drain tube. Slide the overlapping panel into place aligned with
corrugations of the main panel. Use duct tape to seal the panel for the concrete
deck pour
Important

12 Survivor® SR Siderail Truck Scale Assembly Instrucitons
6.3 Deck Rebar
Reinforcing for the concrete deck consists of #5 rebar tied on 8" centers, see Section 7.1. Long rebars are first tied
to the bottom of the Nelson studs on each cross beam, which locates them approximately 1.5" above the corrugated
metal. The shorter rebars perpendicular to the cross beams are then tied to the top of the long rebars. It is important
that all rebar be positioned 1.5" - 2" from the corrugated metal for maximum deck strength. 1.5" rebar “chairs” are
available at construction equipment suppliers and are strongly recommended to hold the rebar 1.5" above the
corrugated panels.
Begin laying the rebar gridwork by tying long rebars parallel to the cross beams
under the Nelson studs on each cross beam (Rebar ties and spinner tools are
available at most contractor supply outlets).
Tie rebar parallel to the siderails under the Nelson studs on each siderail. Using
these rebars along the siderails for support, set and tie long rebars each 8"
parallel to the cross beams.
Tie the second rebar layer perpendicular to the cross beams and on 8" centers.
Tie the two rebar layers together at intersections where necessary to prevent
shifting during the concrete pour.
Insert and tie 1.5" concrete chairs beneath rebar intersections where necessary to prevent sagging and maintain the
minimum 1.5" distance from the top of the corrugated metal.

Pour and Finish Concrete Deck 13
7.0 Pour and Finish Concrete Deck
With a concrete crew of three experienced workers, a 70'-90' scale 14' wide can
be poured and finished in approximately three hours. Access to only one side of
the scale is necessary as most concrete trucks carry extension chutes at least 16'
long. If possible, order concrete in front-unloading trucks. The truck will be
moving slowly while filling each bay and the improved driver-visibility with
front-unloading makes that process faster and more accurate.
To protect against unsightly concrete splatters on the inside of the siderail beams,
you may want to tape 4-6 mil plastic against the inside surface of the siderails
starting at the finished deck level (top of cross beams) and running up the siderail several inches. If applied
carefully, the bottom tape strip can serve as a screed guide for the concrete deck surface against the siderails.
Rather than rest the weighbridge on the load cells, you may wish to raise the
siderails a fraction of an inch and rest them on temporary blocks as shown at
right. This is rarely necessary, but may prevent damage from a concrete redi-mix
truck accidentally backing into the scale frame and damaging the load cells with
a large lateral shock force.
With as little water added by the driver on-site as possible, mix the concrete in
the truck for a standard 4" slump.
Position the unloading chute at the far side of the scale over the first bay. Begin
filling the first bay, having the truck slowly move away from the scale to fill the
bay uniformly.
To ensure concrete flowing evenly into beam cavities and encasing all Nelson
studs and rebar, a concrete vibrator is highly recommended. These units are
available for rent at most construction equipment rental sources. They work very
quickly to level concrete, settle out surface stones, and leave a stone-free
“cream” layer at the top surface to make finishing easier.
After vibrating to approximate level, screed the concrete to the level of
the cross beams with a 2x4 board cut to the appropriate length. As this
first bay is too narrow to use a wide bull float, the final surface leveling
should be done with a magnesium hand float.

14 Survivor® SR Siderail Truck Scale Assembly Instrucitons
With the bay level and floated, finish against the siderails with either a
magnesium float or steel trowel for a neat deck line level with the exposed cross
beams. If you have taped plastic-film splatter guards on the siderails, the bottom
tape strip will serve as a guide for the finished deck level between cross beams.
When the first bay has been floated with a magnesium float and has set enough
for finishing, use a radius edger to finish the metal/concrete joint at each cross
beam.
Move to the next section and pour and vibrate that section.
Use a screed board cut to the appropriate length for this section. This
section will be wide enough to use a bull float to assure a level surface.
Finishing the edge along the siderail can be done from outside the scale to
eliminate using kneeboards on the fresh concrete.
Continue with each section in the same manner. As a general guideline, a 90' x
14' deck 8" thick should require approximately 30-32 cubic yards of concrete,
necessitating two or possibly three concrete trucks. A short break between trucks
will allow time to finish float and edge poured sections while waiting for the
next concrete truck. Don’t forget to clean out concrete from the drain tubes on
each bay.
For a non-skid surface, use a stiff bristle broom for a brushed finish when the
concrete has set enough for final finishing.
Curing the Completed Concrete Deck: The concrete deck must be maintained in a moist state for at least seven
days for a satisfactory cure. If the top surface of the deck is allowed to dry out during this time, the finished surface
will be prone to unsightly spalling and be weakened from surface cracking.
A moist surface can be maintained by covering the entire deck with a continuous 4-6 mil sheet of polyethylene
plastic turned up and dammed at the ends and kept filled with 1" of water. Alternately, an epoxy-based concrete
curing solution can be sprayed or rolled onto the deck surface immediately after final finishing and while the
concrete surface is still moist. As the epoxy curing solution will also seal in concrete stains on the exposed beams,
clean off stains with a damp sponge before applying the curing solution to the deck. Epoxy-based concrete curing
products are available at contractor-supply companies. Do not use the petroleum-based or paraffin-based
waterproofing agents advertised for wood decks and concrete patios available at hardware stores or lumberyards.
These products are not curing agents, and will allow the deck surface to rapidly dry out.

Install Conduit, Cabling, and J-Boxes 15
8.0 Install Conduit, Cabling, and J-Boxes
Load cells are supplied with 60' cables. Since each cell is temperature-compensated for the supplied cable length,
do not change any cable length. There will be room to coil excess cable inside the junction box after making final
connections.
All cabling must be enclosed in 3/4" weatherproof conduit from the load cell to the junction box in accordance with
applicable electrical codes. NEMA 4 junction boxes are supplied from the factory with 30" sections of flexible
conduit and waterproof conduit adapters where necessary to maintain NEMA 4 integrity.
Figure 8-1. J-Box Wiring and conduit Runs for a Four Section/Three Module Scale
Load Cell
Cable to
Connector
Pocket 1 Conduit
Pocket 8 Conduit
Pockets 1, 2, 3, 4
Conduit runs to J-Box
Pocket 5 Conduit
Module A Module B
Pocket 3 Conduit
1
8
2
7
SI - Green
SI - White
EX - Red
EX - Black
SHD - Shield
+
-
+
-
+SI
-SI
+EX
-EX
SHD
+SI
-SI
+EX
-EX
SHD
+SI
-SI
+EX
-EX
SHD
+SI
-SI
+EX
-EX
SHD
J3
J4
J7
J8 J6
J5
J2
J1
+SI
-SI
+EX
-EX
SHD
+SI
-SI
+EX
-EX
SHD
+SI
-SI
+EX
-EX
SHD
+SI
-SI
+EX
-EX
SHD
Load Cell #1 Load Cell #3
Load Cell #8 Load Cell #6
Load Cell #2 Load Cell #4
Load Cell #7 Load Cell #5
+SI
-SI
+EX
-EX
SHD
-SEN
+SEN
SHD - Shield
+SI
-SI
+EX
-EX
SHD
-SEN
+SEN
Indicator/J10
Expansion/J9
Cable to Indicator SI - Green+SI - White-
EX - Red+
EX - Black-SEN - Yellow-
SEN - Blue+
Pocket 4 Conduit
Pocket 6 Conduit
6
3
Pocket 4 Conduit
Pocket 5 Conduit
5
4
Module C

16 Survivor® SR Siderail Truck Scale Assembly Instrucitons
Figure 8-1. J-Box Wiring and Conduit Runs for a Five Section/Four Module Option
Pocket 1 Conduit
Pockets 1 and 2
Conduit runs to J-Box
Pocket 3 Conduit
Pocket Conduit for J-Box 2
cable to Expansion Slot in J-Box 1
Pocket 5 Conduit
Load Cell
Cable to
Connector
Pocket 9 and 10
Conduit runs to J-Box
SI - Green
SI - White
EX - Red
EX - Black
SHD - Shield
+
-
+
-
+SI
-SI
+EX
-EX
SHD
+SI
-SI
+EX
-EX
SHD
+SI
-SI
+EX
-EX
SHD
+SI
-SI
+EX
-EX
SHD
J3
J4
J7
J8 J6
J5
J2
J1
+SI
-SI
+EX
-EX
SHD
+SI
-SI
+EX
-EX
SHD
+SI
-SI
+EX
-EX
SHD
+SI
-SI
+EX
-EX
SHD
Load Cell #1
Load Cell #2 Load Cell #9
Load Cell #3
Load Cell #10
Load Cell #8
+SI
-SI
+EX
-EX
SHD
-SEN
+SEN
SHD - Shield
+SI
-SI
+EX
-EX
SHD
-SEN
+SEN
Indicator/J10
Expansion/J9
Cable from J-Box 2
SI - Green+SI - White-
EX - Red+
EX - Black-SEN - Yellow-
SEN - Blue+
Pocket 10 Conduit
Module C Module B Module AModule D
Pocket 4 Conduit
3
8
2
1
10 9
5
4
Section 1B
Section 1A
Section 2B
Section 2A
Section 3B
Section 3A
Section 4B
Section 4A
Section 5B
Section 5A
6
7
Pocket 5 and 6 Conduit
J-Box 2
J-Box 1
Load Cell
Cable to
Connector SI - Green
SI - White
EX - Red
EX - Black
SHD - Shield
+
-
+
-
+SI
-SI
+EX
-EX
SHD
+SI
-SI
+EX
-EX
SHD
J3
J4 J2
J1
+SI
-SI
+EX
-EX
SHD
+SI
-SI
+EX
-EX
SHD
Load Cell #4 Load Cell #7
Load Cell #5 Load Cell #6
+SI
-SI
+EX
-EX
SHD
-SEN
+SEN
SHD - Shield
+SI
-SI
+EX
-EX
SHD
-SEN
+SEN
Indicator/J10
Expansion/J9
Cable to J-Box 1 SI - Green+SI - White-
EX - Red+
EX - Black-SEN - Yellow-
SEN - Blue+
Detail A Detail B
SHD - Shield
Cable to Indicator SI - Green+SI - White-
EX - Red+
EX - Black-SEN - Yellow-
SEN - Blue+
J-Box 1 - Detail A
J-Box 2 - Detail B