Does anyone have a rule of thumb or chart for header size based on studs removed? I always get engineered plans when removing/altering a structural wall so I am really just looking for something I can use for quick and dirty estimates before engaging an engineer. I also (knowing it is overkill) like to frame any door or window openings in non-structural walls at least close to what they would be in a structural situation just in case someone were to say put a heavy load in the space above.
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Depends on the load it has to carry and span, has really nothing to do with studs removed. A header for a 6ft span on a gable end of a house on the 2nd floor is going to be different then a 6ft span on the 1st floor on the eaves side. If you live in the North with snow you'll have to figure the roof load for snow in the winter. Then there's what type of material your using, 2x and what type of pine, lvl or steel. There is no basic rule of thumb, you figure out the load it has to carry then look at a chart for what type of material your using and because it will probably fall somewhere in the middle of 2 different size headers you need to you pick the larger one.
Here's an article I found https://www.finehomebuilding.com/membership/pdf/16412/021162062.pdf
The Southern Pine Council used to have a handy pocket book span chart for headers, beams, joists and rafters.....
Perfect for the dashboard.
But there’s an online version.
https://www.southernpine.com/publications/
As the first comment suggested, there are many variables to consider... but this got me thinking. I checked some load tables (for Ontario, with SPF No. 2, so interpret that as you will) and came up with this rule of thumb (maybe good for costing... definitely not for building):
Exterior wall of 2-ply 2x header: max span in feet = actual header depth in inches if just supporting roof. Subtract 2' from span for each floor supported.
So 2-ply 2x8 header supporting roof only, max. span would be ~7.25'.
2-ply 2x12 header supporting roof and 1 floor, max. span would be (11.25' - 2')=~9.25'
Interior beams are similar, except 3-ply: max span in feet = actual depth in inches. Subtract 2' for each extra floor supported.
This is definitely not exact but will hopefully put you in the right ballpark... plus hopefully it is easy to remember!