TOLERANCE MANUAL

FOR PRECAST AND PRESTRESSED

CONCRETE CONSTRUCTION
MNL 135-00

PRECASTIPRESTRESSED
CONCRETE INSTITUTE
 TOLERANCES
FOR PRECAST AND PRESTRESSED CONCRETE
CONSTRUCTION
MNL-135-00

prepared by

PC/ Committee on Tolerances

Kim Sorenson, P.E., Chairman

Ted J. Gutt, P.E.

Michael W. LaNier, P.E.
Jagdish Nijhawan, P.E.
Jerald A. Schneider, P.E.
Helmuth Wilden, P.E.
 MNL 135-00
Copyright © 2000
By Precast/Prestressed Concrete Institute

All rights reserved.

This book or any part thereof may not be reproduced in any

form without the written permission of the Precast/Prestressed
Concrete Institute.

Substantial effort has been made to ensure that all data and
information in this manual are accurate. However, PCI cannot
accept responsibility for any errors or oversights in the use of
material or in the preparation of engineering plans. This publi-
cation is intended for the use by personnel competent to evalu-
ate the significance and limitations of its contents and able to
accept responsibility for the application of the material it con-
tains. Special conditions on a project may require more specif-
ic evaluation of practical engineering judgement.

While every effort has been made to prepare this publica-

tion as the national standards for the industry, it is possible that
there may be some conflicts between the material herein and
local practices.

First Edition, 2000

ISBN 0-937040-62-2

Printed in the United States of America

 Tolerances for Precast and Prestressed Concrete Construction
1.0 Preface to Tolerance Committee Report .. 1 8.2 Effects of Prestressing on Dimensions .. 21
1 .1 General .............................. 1 8.3 Effects of Time, Temperature, and
1.2 Need for Collaboration ................. 1 Shrinkage on Dimensions ............. 21
1.3 Responsibility for the Overall 8.4 Relation of Measuring
Project Tolerance System .............. 1 Techniques to Tolerances ............. 21
1.4 Specifying Responsibility 8.5 Tolerances for Blackouts
for Project Tolerances .................. 2 and Openings ....................... 22
1.5 Custom Nature of Building Construction . 5 8.6 Tolerances for Sweep or
Horizontal Alignment ................. 22
2.0 Introduction .......................... 6 8.7 Tolerances for Position of Tendons ..... 22
2.1 Groups of Tolerance Issues ............ 6 8.8 Tolerances for Handling
Product Tolerances .................... 6 Device Locations ..................... 22
Erection Tolerances ................... 6 8.9 Tolerances Considerations for
Interlacing Tolerances ................. 6 Camber and Differential Camber ....... 22
2.2 Tolerance Categories .................. 6 8.10 Tolerances for Squareness of Ends
Structural ............................ 6 or Variation From Specified End Skew .. 23
Feasibility ............................ 6 8.11 Tolerances for Position of Weld Plates .. 23
Visual ................................ 7 8.12 Tolerance on Tipping and Flushness
Economics ........................... 7 of Weld Plates ....................... 24
Legal ................................ 7 8.13 Tolerances on Haunches of
Contractual . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Columns and Wall Panels ............. 24
8.14 Tolerances on Location of
3.0 Responsibility for Project Sleeves Cast in Prestressed Products .. 24
Dimensional Control ................... 8 8.15 Tolerance on Reinforcing Steel
3.1 Handling a Pre-pour Tolerance Bending and Placement .............. 24
Discrepancy .......................... 8 8.16 Tolerance on Position of Strand
3.2 Handling a Post -Casting/Pre-Shipment Deflection Points ..................... 26
Tolerance Discrepancy ................. 8 8.17 Tolerance Effects of Warping, Bowing
3.3 Handling a Tolerance Discrepancy and Local Smoothness of Panels ....... 26
Discovered During Erection ............ 8
9.0 Special Tolerance Considerations ...... 29
4.0 Tolerance Acceptability Range .......... 9 9.1 Considerations for Tolerances
of Architectural Members ............. 29
5.0 Definitions of Tolerance Related Terms .. 10 9.2 Tolerance Considerations for
Visible Structural Members ............ 29
60 Relationships Among the Different 9.3 Tolerances for Structural Members ..... 29
Tolerance Groups .................... 17 9.4 Statistical Tolerance Concepts ......... 29
6.1 Relationship of Product Tolerances ..... 17 9.5 Tolerance Considerations for
6.2 Relationship of Erection Tolerances .... 17 Segmental Precast ................... 29
6.3 Relationship of Interlacing Tolerances .. 17
6.4 Project Economic Considerations ...... 18 10.0 Product Tolerance Listings ............ 31
6.5 Relationship of Form Tolerances 10.1 Architectural Wall Panels .............. 33
to Product Tolerances ................. 18 10.2 Solid or Insulated Flat Structural
Wall Panels .......................... 37
7.0 Product Tolerances ................... 19 10.3 Ribbed Structural Wall Panels ......... 39
7.1 Specification of Product Tolerances .... 19 10.4 Hollow-core Wall Panels .............. 41
10.5 Brick Faced Architectural Elements ..... 43
8.0 Overall Plan Dimension Tolerance 10.6 Double Tees (Untapped & Pretopped) .. 45
Considerations ...................... 20 10.7 Single Tees (Untapped and Pretopped) . 47
8.1 Effect of Forms on Dimensions ........ 20 10.8 Columns................... . ... 49
10.9 Building Beams and Spandrel Beams .. 51 13.0 Erection Tolerances for Mixed
10.10 I Beams (Girders) or Bulb Tee Girders .. 53 Building systems .................... 120
10.11 Box Beams .......................... 55 13.1 Connection Tolerances for
10.12 Poles ............................... 57 Mixed Building Systems ............. 120
10.13 Hollow-core Slabs .................... 59
10.14 Piling (Hollow and Solid) .............. 61 14.0 Clearance Considerations
10.15 Tee Joists/Keystone Joists ............ 63 in Product Manufacture .............. 121
10.16 Step Units ........................... 65 14.1 Effects of Product Tolerances
10.17 Sheet Piling ......................... 67 on Clearance Considerations ......... 121
10.18 Stadium Riser ....................... 69 14.2 Effects of Member Type on
10.19 Multi-Stemmed Bridge Units ........... 71 Clearance Considerations ............ 121
10.20 Modular Room Unit .................. 73 14.3 Effects of Member Size on
10.21 Prestressed Concrete Panels Clearance Considerations ............ 121
for Storage Tanks .................... 75 14.4 Effects of Member Location
10.22 Bridge Deck Units .................... 77 on Clearance Considerations ......... 121
10.23 Segmental Box Girder ................ 79 14.5 Effects of Member Movement
10.24 Pier Deck Units ...................... 81 on Clearance Considerations ......... 121
10.25 Box Culvert .......................... 83 14.6 Effects of Member Function
10.26 Prestressed Concrete on Clearance Considerations ......... 122
Railroad Ties ........................ 85 14.7 Effects of Erection Tolerances
10.27 Sills, Untels, Copings, Cornices, on Clearance Considerations ......... 122
Quoins and Medallions ............... 87 14.8 Procedure For Determination
10.28 Bollards, Benches and Planters ........ 89 of Clearance ........................ 122
10.29 Pavers .............................. 91 14.9 Clearance Examples ................ 123
14.10 Roof Member Clearance Example .... 123
11 .0 Erection Tolerances .................. 92 14.11 Bearing Wall Panel Joint
11.1 Recommended Erection Tolerances .... 92 Clearance Example ................. 125
11.2 Erection Tolerance Groups ............ 93 14.12 Cladding for High Rise Steel
11.3 Field Control of Erection Tolerances .... 93 Frame Building Clearance Example ... 127
11.4 Erection Tolerance Considerations
for Segmental Precast Projects ........ 94 15.0 Interfacing Tolerances ............... 129
15.1 Structural Requirements ............. 129
12.0 Erection Tolerance Listings ............ 95 15.2 Volume Change ..................... 129
12.1 Beam Erection Tolerances ............ 97 15.3 Exposure and Corrosion ............. 130
12.2 Floor and Roof Member 15.4 Waterproofing Requirements ......... 130
Erection Tolerances .................. 99 15.5 Drainage Requirements .............. 130
12.3 Column Erection Tolerances .......... 101 15.6 Architectural Requirements ........... 130
12.4 Structural Wall Panel Erection 15.7 Dimensional Considerations .......... 130
Tolerances ......................... 103 15.8 Vibration Considerations ............. 131
12.5 Architectural Walls/Spandrel 15.9 Fire-Rating Considerations ........... 131
Erection Tolerances ................. 105 15.10 Acoustical Considerations ............ 131
12.6 Stadium Riser Erection Tolerances .... 107 15.11 Economics ......................... 131
12.7 Room Module Erection Tolerance ..... 109 15.12 Manufacturing/Erection Considerations 131
12.8 Stair Unit Erection Tolerance .......... 111
12.9 Segmental Bridge Element 16.0 Design Approach for Two
Erection Tolerance .................. 113 Interfacing Tolerance Systems ........ 132
12.10 Circular Storage Tank Erection
Tolerances ......................... 115 17.0 Defining the Characteristics of
12.11 Pier Deck Erection Tolerances ........ 117 a Tolerance Interface ................ 134
12.12 Erection Tolerances for Bridge 17.1 Windows and Doors ................. 134
Deck Units ......................... 119 17.2 Mechanical Equipment .............. 134
17.3 Electrical Equipment ................ 134
17.4 Elevators and Escalators ............. 134 19.2 Clip Angle Supporting a
17.5 Architectural Cladding ............... 135 Precast Concrete Panel .............. 167
17.6 Structural Steel and 19.3 Precast Corbel with Steel
Miscellaneous Steel ................. 135 to Steel Bearing ..................... 168
17.7 Masonry ........................... 135 19.4 Effects of Beam Camber ............. 170
17.8 Roofing ............................ 135 19.5 Effects of Camber Variation on
17.9 Waterproofing ...................... 135 Top Flange Connections ............. 171
17.10 Interior Finishes-Floors, Walls, 19.6 Deflection of Supporting Elements .... 172
and Ceilings ........................ 135 19.7 Panel Supported by a Cantilever ...... 173
17.11 Interior Walls and Partitions ........... 136
20.0 References ......................... 174
18.0 Typical Tolerance Related Details ...... 137
Appendix A-Sample Specification Language . 176
19.0 Examples of Tolerance
Detailing Related Calculations ........ 166 Appendix B-Sample Contract Language ..... 180
19.1 Clip Angle for Lateral Restraint ........ 166
 FOREWORD
Precast concrete is a building system which de- and design of Precast and Prestressed Concrete
pends on a system of realistic and consistent toler- Products.
ances to meet the objectives of providing acceptable The Committee has designed this manual to com-
appearance, durability and economy. plement and support the PCI quality control manuals:
This document is the compilation of over 50 years MNL-116 Manual for Quality Control for Plants and
of Precast/Prestressed Concrete Industry experience Production of Precast and Prestressed Concrete
that defines this essential tolerance system for each Products, and MNL-117 Manual for Quality Control for
phase of the building project: design, production, Plants and Production of Architectural Precast Con-
erection and performance. This document also pro- crete Products. Together, these three documents
vides information on other building materials. form the basis of quality design and quality fabrication
Design information for engineers, architects and and erection for Precast and Prestressed concrete
building owners is presented to assist in the selection products.
 Tolerances For Precast and Prestressed Concrete
1.0 Preface To Tolerance Committee Report and erection for the precast concrete members and
all of the interfacing building systems.
1.1 General Contractual relationships which provide incen-
tives for cooperation among the building project team
This document is a working reference for the di- members, full exchange of information regarding the
mensional control of precast concrete products and needs of the various aspects of the project, and pro-
construction. It covers both plant-cast or site-cast active communication approaches, such as project
and precast and precast prestressed concrete. partnering, will help the building team successfully
The information contained herein should be used implement project tolerance plans.
by architects, engineers, general contractors, pre-
cast and precast prestressed concrete producers, 1.3 Responsibility for the Overall Project Tol-
erectors, quality control agencies, and other related erance System
or interfacing building trades.
The original tolerance committee report was pub- The concept of responsibility for specifying toler-
lished in the PC/ Journal in 1985. A supplement to the ances on precast concrete building projects has
original document was published in the Journal in been misunderstood and at times misused. The con-
1993. Portions of this document have been repub- sequences can be not only expensive, but damaging
lished in the Third, Fourth and Fifth Editions oflhe PCI to customer/client relationships. Consider the follow-
Design Handbook. MNL-116 Manual for Quality Con- ing. It is not uncommon for the published tolerances
trot for Plants and Production of Precast and Pre- for precast concrete products to be used as a tool for
stressed Concrete Products and MNL-117 Manual for rejection (or conversely, as a tool for advocating ac-
Quality Control for Plants and Production of Architec- ceptances), after a project has experienced tolerance
tural Precast Concrete Products have included por- related construction difficulties.
tions of the information published in 1985 for use in In some instances the architect/engineer may
the Plant Certification program. specify PCI documents MNL-116 or MNL-117 as a ref-
Since 1985, the PCI Committee on Tolerances has erence guide, believing thatthis will cover every situa-
listened to concerns, answered questions and con- tion. In other instances, building team members may
sidered the reported use (and misuse) of the pub- review the published product tolerances only after fit
lished tolerances. In response, this document ad- up problems become apparent in the field.
dresses some of the most frequently asked questions Depending on the nature of the contractual rela-
and concerns. tionships, the precast concrete manufacturer may fol-
Readers are encouraged to report any experi- low the specifications and use them as proof of mem-
ences, problems and concerns regarding tolerances ber tolerance compliance. In the event construction
for precast products and projects to the PCI technical problems arise, the architect/engineer may take the
staff. position that the precast manufacturer is responsible
for the proper fit of a precast member into the com-
1.2 Need for Collaboration pleted structure, regardless of whether or not the indi-
vidual members meet PCI tolerances.
The owner, architect/engineer, general contractor, The tolerances defined by the Committee were set
precaster and erector all have the same goal: a suc- to provide a suitable reference point. Each of these
cessful project. The overall building project involving tolerances was set based on current modern precast
precast concrete building members should be suc- concrete production techniques. They are based on
cessful from all points of view, namely, client satisfac- a standard of quality and craftsmanship that can be
tion, on time schedule performance, economy, aes- reliably accomplished by a PCI plant certified to pro-
thetics, constructability, and long term functional duce the various member types. The published toler-
durability. It is essential that the members of the build- ances are not intended to be an unyielding and rigid
ing team collaborate to provide an overall project tol- set of tolerances used only as a measure of accep-
erance system which will meet all of the project's tance or rejection. The intent of the Committee was
functional needs and allow economical fabrication to provide both a feasible and economically reason-
able set of starting tolerance tools that will enable the general concepts on the contract drawings and in the
party responsible for tolerances to develop an overall project specifications by the owner's architect/engi-
project tolerance plan that can be followed to create neer. In this case the architect/engineer of record may
a successful project. be defined in the contract as contractually responsi-
ble to specify the overall project tolerance plan.
1.4 Specifying Responsibility for Project Tol- Similarly, project circumstances between the two
erances extremes can be ill-defined with regard to the respon-
sibility for the overall project tolerance plan. In many
The 1985 PC/ Journal Tolerance Committee Re- areas of the country these project conditions of ill de-
port states: fined responsibility for project tolerances are the most
"While the detailed assignment of responsibility for prevalent.
the dimensional tolerancing and control of the various It should be noted that the precast member
members may vary, depending on the contractual ar- manufacturer may have no contractual control over
rangement for a particular project, it is very important the tolerances and the interface conditions created
that these responsibilities be clearly assigned and by other trades on the project. lfthis is the case, these
thatthese assignments be communicated to all mem- tolerances and interface conditions may best be han-
bers of the project team." dled by the architect/engineer of record, the general
In addition, it is important that the responsibility for contractor or other entity having the contractual au-
the overall project tolerance plan and the specifica- thority necessary to specify and control interfacing
tion of member dimensional tolerances and appropri- system procurement and the performance of all of the
ate interface details be specifically defined. The con- various project trades.
tractual relationships on a project and the associated There are definite advantages to having the re-
compensation for the effort involved should recog- sponsibilities for project tolerances defined prior to
nize the entity charged with the responsibility for the the purchase contract for the precast concrete. This
development and implementation of the overall proj- may prevent disputes over inappropriate or misun-
ect tolerance plan. derstood tolerance specifications after the start of
As a matter of actual practice on many projects, ei- precast production.
ther no entity is specifically designated with the re- See Appendix A for sample contract language re-
sponsibility to specify the required project tolerances garding responsibility for tolerances.
or the tolerances are too tightly defined. Figure 1.4.1 shows how different types of project
The first extreme, where responsibility has not tolerances fit into the overall project tolerance plan
been designated, may occur because the circum- and the subsequent implementation tasks. As indi-
stances of projects vary considerably. The construc- cated in this diagram "Special Project Tolerances",
tion team member in the best position to handle the which are different from the typical PCI tolerances,
development and implementation of the project toler- may be required. Figure 1.4.2 shows a possible con-
ance plan may change from project to project. On tractual relationship for the situation where the pre-
some projects the precast concrete manufacturer caster enters into a design-build contract to provide
may be contractually defined as the engineer of re- a building project directly to an owner. Figure 1.4.3
cord, possibly with only limited involvement of other shows a possible contractual relationship for the situ-
architects or engineers. On some projects the owner ation where the precaster bids members constructed
may not retain a design team to develop specifica- to specified tolerances to a general contractor who
tions or contract drawings. In situations like these the then erects the members.
precast concrete manufacturer may be contractually Figure 1.4.4 shows an example responsibility ma-
responsible for the development of the overall project trix for project tolerances where specific responsibili-
tolerance plan. ties for the various elements of the overall project tol-
The other extreme is the project that is tightly de- erance plan have been set forth in the project
fined by the owner's architect/engineer of record. contract. Appendix B contains a blank tolerance re-
Members may be accurately sized and located and sponsibility matrix that can be copied and filled out for
connections may be detail designed or defined in use on new projects.

2
Fig. 1.4.1 Relationship of Project Tolerances to Functional Requirements

rl Ty~~~~:~g:5uct
~
~ Project Des1gn
I
H ~
Typical Interface
Tolerai'"ICes

H
Product/Element
Design
I
H ~
Typical Erection

IDetermine Functional
Aequ1rements
~
Determine How to
Meet Functional
Requirements
Tolerances
Define Overall
Project Tolerance
Plan
H Fabricate Elements
I
H ~
Interface Tolerance
Details

H Erect Elements
I
H ~
Special Project
Tolerances

y Install Interface
Elements
I
y Special Project
Details
~

Fig. 1.4.2 Specifying Tolerances-Precaster Fig. 1.4.3 Specifying Tolerances-Design-Bid

Design-Build Contract Contract

Owne•

I Precaster's Plant
Architect/Engineer of
Record

Precaster Design-
Build Agreement r-- Engineering Desi~ns
Project and Speci ies
Tolerances

I I Precaster 81ds
Elements to
Specified Tolerances
Precaster Erects
and Controls Project Engineer of Record
Tolerances

3
 Fig. 1.4.4 Tolerance Responsibility*
Comments
Project Activity Owner Architect/ General Precast Precast Precast Erector Erection
Engineer Contractor Plant Man· Plant Plant Manage- Quality
agement Engineer- Quality ment Control
lng Control

p
Set Requirements

Determine How to Satisfy Requirements p

Define Overall Project Tolerance Plan A/A p I I

Specify Typical Product Tolerances p I

Specify Typical Interface Tolerances p I I

...
Specify Typical Erection Tolerances p I I

Select Interface Tolerance Details A/A p

ldenti'fy Special Project Tolerances p I

Accept Project Tolerances A/A A/A A/A

Confirm Product Tolerances Achieved p

;------
Confirm Erection Tolerances Achieved p

r--
Confirm Interface Tolerances Achieved p

Legend: P = Prime Responsibility A/A= Review and Approval Authority I= Input Required From

* The responsibility for various activities concerning tolerances varies from region to region and from project to project depending on differences in the contractual requ'1rements.
1.5 Custom Nature of Building Construction cial attention to the overall construction tolerances of
all of the elements of the construction project.
It should be noted that tolerance determination in Careful consideration of how the overall tolerance
building design and construction is substantially dif- system (product tolerances. interface tolerances,
ferent from the practices used in machine design and joint clearances, and erection tolerances) accommo-
assembly. Modern machine design relies on the abili- dates tolerance variations is necessary. The use of
ty to incorporate completely interchangeable close tolerance accommodating details, which in some
tolerance parts into the machine assembly. To ac- instances allow very significant tolerance variations to
complish this the machine industry has developed be appropriately handled, is also necessary in some
the concept of True Position Dimensioning which al- instances.
lows close tolerance mating parts to be produced in- Building construction principally involves custom
dependently with the assurance that if specified toler- work with relatively large dimensional tolerance varia-
ances are met the parts will fit properly 100 percent of tions. Thus even after appropriate member and erec-
the time. tion tolerances are specified and appropriate inter-
Precast concrete construction has moved toward face details are incorporated in the design, the
the machine design tolerance philosophy when building team members must be vigilant in the early
compared to most other large building element identification and resolution of out of tolerance situa-
construction methods. However, design practice and tions which may develop in any aspect of the overall
economical fabrication and erection tolerance reali- building system. By doing this, tolerance related re-
ties do not allow the same assurance of the 100 per- work will be minimized.
cent fit up 100 percent of the time, without giving spe-

5
2.0 Introduction Erection Tolerances

The tolerance information contained here has Erection tolerances are defined as those toler-
been developed for use primarily by precast and pre- ances which are required for the acceptable match-
cast prestressed concrete producers, erectors, quali- ing of the precast members after they are erected. Ar-
ty control agencies, architects and engineers and re- ticle 11 .0 provides a comprehensive discussion of the
lated or interfacing trades unless other tolerances are principles and considerations relative to precast con-
noted in the project drawings or specifications. crete erection tolerances. Additional information per-
In the event that the project tolerances are set by taining to erection tolerances that should be antici-
the precast producer, rather than the architect/engi- pated in the tolerance specification review and
neer, all involved parties agree in advance of any pro- construction of precast concrete structures is pro-
duction, what the project tolerances will be. If toler- vided in Article 12.0.
ances different from PCI standard tolerances are
used on a project. the specified tolerances on that
Interfacing Tolerances
particular project should be shown on the project
shop drawings and, as applicable, on the erection Interfacing tolerances are those tolerances which
drawings. In lieu of showing tolerances on each shop are associated with other materials or building sys-
drawing, a tolerance drawing for the project can be tems in contact with or in close proximity to precast
prepared to make the production personnel aware of concrete, both before and after precast erection. Ar-
the project tolerance requirements. ticle 17.0 provides guidelines for the proper dimen-
The producer's personnel should review the con- sional specification of interfacing materials in con-
tract documents and make sure that the specified tol- junction with precast product and erection
erances are appropriate to the individual compo- tolerances.
nents. If revisions are deemed necessary by the
review the architect/engineer should be notified by
the producer so that any proposed revisions can be
2.2 Tolerance Categories
approved and/or implemented by the architect/engi- There are six categories of tolerance issues for the
neer. three tolerance groups given above. The principal
concern of each category is as follows.
2.1 Groups of Tolerance Issues

Final component details for precast concrete Structural

products should conform to three groups of toler- To control the member dimensions and dimen-
ances which have been established as part of the pre- sional interface in order to assure that dimensional
cast concrete design process. These are product tol- variations do not change the loading configuration or
erances, erection tolerances and interfacing capacity of a member as assumed by the designer.
tolerances. Tolerances which are critical for structural perfor-
mance of members and or connections should be in-
Product Tolerances dicated as such by the architect/engineer on the proj-
ect design drawings.
Product tolerances are defined as those toler- The architect /engineer should also indicate the
ances related to the dimensions and dimensional tolerances that stem from the requirements of overall
relationships of the individual precast concrete mem- structural integrity.
bers. Article 10.0 provides a compilation of recom-
mended product tolerances for precast concrete
products. Articles 7.0 through 9.0 discuss the specifi- Feasibility
cation of these values and the methods of verifying To ensure acceptable performance of joints and in-
tolerances after casting. terfacing materials in the finished structure and to en-
Many times a control surface tolerance will control sure that designs and details are attainable with avail-
over a feature tolerance. This concept is discussed in able manufacturing and construction techniques.
detail in Article 6.0. The allowable variation for one The established tolerances or required perfor-
element of the structure should not be such that it will mance should fall within generally accepted limits
cause another element of the structure to exceed its and should not be made rnore stringent, and there-
allowable variations. fore more costly, than is absolutely necessary.

6
 Tolerances more restrictive than those discussed determine the most economical approach to han-
in this document should be brought to the attention dling the project tolerance requirements.
of the architect/engineer to ascertain that they are
compatible and that the proposed restrictions can be Legal
met. For example, a requirement which states that
"no bowing, warping, or movement is permitted" is To avoid encroaching on property lines and estab-
not practical or possible to achieve. lish a tolerance standard against which the work can
be compared in the event of a dispute.
Visual It is very important to agree on the project toler-
ances in writing, particularly with special tolerances
The variations in the finished product should be or in situations with critical visual aesthetics. Similarly,
controllable and result in an acceptable appearance. it is equally important to agree in advance how and
Tolerances related to visual effects or aesthetics may when these tolerances will be verified (with due con-
be significantly more stringent than those required for sideration for measurement methods, measurement
structural or functional reasons. Tolerances which locations, number of points to measure, support con-
are critical to project aesthetics should be indicated ditions, thermal conditions, and time of measure-
as such by the Architect/Engineer. ment).

Economics Contractual

To ensure a reliable and efficient rate of production To establish a known acceptability range and as-
and erection by having a known degree of accuracy sign responsibility for developing, achieving, and
in the dimensions of precast concrete products. The maintaining mutually agreed tolerances for the proj-
cost of working to tighter than standard product toler- ect. The producer's quality control staff should under-
ances should be evaluated for cumulative cost effects stand whatthe producer's contractual obligations are
at the project level. That is, one should evaluate both regarding project tolerances. The actual project tol-
the cost increases and cost savings for member fab- erances contractually agreed to may be different from
rication, interfacing with subsystems and erection to the charted values given here.

7
3.0 Responsibility for Project Dimensional assure that noted discrepancies have in fact been
Control corrected prior to concrete placement.

Once the tolerances for the various members have

3.2 Handling a Post-Casting/Pre-Shipment
been specified and contractually agreed to by the
Tolerance Discrepancy
producer, appropriate connection details which con-
sider those tolerances should be designed by or ap- An out of tolerance discrepancy discovered after
proved by the party responsible for the tolerances. the placement of concrete should be documented
Then the production ofthe members should be orga- and evaluated to determine what, if any, corrective ac-
nized to ensure that the specified tolerances are rec- tion is needed. The plant should have documented
ognized and tolerance compliance is verified during procedures regarding the manner in which post-pour
the member fabrication process. An organized quali- discrepancies noted by the quality control personnel
ty control program with a strong focus on dimensional are communicated for evaluation. The procedure
tolerance control is a necessary part of the production should outline which individual within the plant is au-
effort. thorized to evaluate the consequences of such dis-
While the detailed assignment of responsibility for crepancies.
the dimensional tolerance determination of the vari- These procedures should include a follow-up step
ous elements of the construction project may vary to assure that noted discrepancies have either been
(depending upon the contractual arrangement for a corrected or that other appropriate steps have oc-
particular project), these responsibilities should be curred, (such as notification of the field erection crew
clearly assigned and communicated to all members if the problem can be solved during erection). It is al-
of the project team. ways better to evaluate post-pour tolerance discrep-
In the erection phase of the project, the various ancies before the member is shipped to the construc-
elements must be assembled in accordance with the tion site. The producer's representative should
established erection tolerances. Erection quality as- evaluate whether or not the architect/engineer needs
surance plans will include a clear definition of respon- to be involved in the resolution of any specific discrep-
sibilities for tolerance verification and adjustment, if ancy.
necessary, of both the erected precast concrete
structure and any interfacing structure.
3.3 Handling a Tolerance Discrepancy Dis-
In the event that fast track approval of shop draw- covered During Erection
ings precludes use of formally "approved" shop Because tolerance discrepancies discovered in
drawings an alternative system should be developed
the field must be handled ·In the field, the precast engi-
to assure that the drawings in use by the production
neer should provide guidelines regarding the manner
staff are the correct version of the drawings. in which these sorts of problems are to be resolved.
The producer's representative should evaluate
3.1 Handling a Pre-pour Tolerance Discrep- whether notification of the design team regarding the
ancy problem is required. Adhere to any notification provi-
sions in the contract.
An out of tolerance discrepancy discovered in ad- In some cases it may be possible to substitute
vance of the placement of concrete should always be another similar piece and return the out of tolerance
corrected to nominal tolerance prior to the placement member to the plant for correction. In other instances
of concrete. a field repair crew may need to be deployed to the
The plant should have documented procedures field on an immediate basis to make necessary
regarding the manner in which pre pour discrepan- corrections. Because of the potential cost and sched-
cies noted by the quality control personnel are com- ule consequences of this situation the plant quality
municated to the production personnel for correction. control plan should be organized to minimize this oc-
These procedures should include a follow-up step to currence.

8
4.0 Tolerance Acceptability Range Engineer of Record is necessary to evaluate the
consequences of out of tolerance situations.
The tolerances shown in this document are guide-
lines for acceptability. Many projects involve situa- b. The member can be brought within project tol-
tions which require variation from the published toler- erance by structurally and architecturally satis-
ances. Only the recognized and agreed upon factory means. Repair methods used to correct
"project tolerances" govern the production of the pre- tolerance problems should not compromise
cast members. structural performance or long term durability.
Not all tolerances are critical in every case, particu-
larly when the structural or architectural performance c. The total erected assembly can be modified to
is not impaired. In some circumstances, the archi- meet all structural and architectural require-
tect/engineer may accept an out of tolerance member ments.
if it conforms with any of the following:
Modification of erection activities to accommodate
a. Exceeding the project tolerances does not af- out of tolerance members requires close coordination
fect the structural integrity; or architectural per- between the producer's representative and the erec-
formance of the member. Often the input of the tor.

9
5.0 Definitions of Tolerance Related Terms Bowing-An overall out-of-planeness condition
which differs from warping in that while two edges of
The following definitions should apply to toler- the panel may fall in the same plane, the portion of the
ances tor precast and precast prestressed concrete plane between the edges is out of plane. (See Warp-
products: ing.) Bowing tolerance is usually most important in
Accuracy of measurement-Conformity with the wall panels that are exposed to view. Bowing can oc-
cur in more than one direction.
actual value of the measurement.
Accuracy is not necessarily associated with the Building survey datum-The local survey datum
notion of close conformity with the true value, which established for the global erection of the building to
is a measure of precision. the design plan layout and elevations.
Architect of Record-The individual design pro- Camber- (1) The deflection that occurs in pre-
fessional responsible for, among other things, speci- stressed concrete members due to the net bending
fying the appearance of the finished structure. It may resulting from stresses associated with the effects of
be necessary to gain the approval of the Architect of the prestress force (not including dimensional inac-
Record for any proposed tolerance repair methods curacies); and (2) a built-in curvature to improve ap-
which will be visible in the completed structure. pearance.
Camber control is generally more of a concern in
Architectural precast concrete-- A precast con-
crete product with a specified standard of uniform ap- long prestressed members where there is increased
potential for differential camber in adjacent members.
pearance, surface details, color, and texture.
Tolerances for architectural precast products are Groups and Categories of Products-The PCI
generally more stringent than for structural products Plant Certification Program is focused around four
because of the increased importance of appearance. groups of products and categories within those
This class of product generally is associated with a groups designated as indicated in Table 5.0.1.
premium cost.

Table 5.0.1 Product groups and categories

Group A-Architectural Products
Category A1-Architectural cladding and load bearing members
Category AT-Precast concrete architectural trim
Group 8-Bridge Products
Category B1-Bridge products, not prestressed
Category B2-Bridge products prestressed, excluding bridge beams
Category B3-Bridge superstructure using straight prestressing
Category B4--AII products in Category B plus draped strand bridge superstructure
Category BA-Bridge elements with special finishes
Group C-Commercial (Structural)
Category C1-Commercial products, not prestressed.
Category C2-Prestressed hollow-core and similar products
Category C3-Commercial products using straight prestressing
Category C4--Commercial products using draped prestressing
Category CA-Commercial structural elements with special finishes
Group G-Giass Fiber Reinforced Concrete Products

10
 Products in Group A are subject to architectural ishes that require uniformity and detailing more de-
tolerances. Products in groups B, C, are subject to manding than the typical requirements for structural
structural tolerances. Categories CA and BA are sub- products.
ject to structural tolerances unless they are specified The surface finish requirements for these mem-
category A1 with Special Project Tolerances which bers should be clearly specified and verified with ap-
may be a combination of specially defined structural propriate samples and mockups. Included in this
and architectural tolerances. category are parking deck structural spandrels with
a special finish. Typically these members are used on
Group A-Architectural Products. These are projects for reasons of economy. They are fabricated
products produced in accordance with the require- to structural tolerances unless Special Project Toler-
ments of MNL-117. Within Group A, products in cate- ances are specified, which may be a combination of
gories A1- architectural cladding and load bearing structural and architectural tolerances.
members, and AT- architectural trim units are gener-
ally considered subject to architectural tolerances. Group G-Giass Fiber Reinforced Concrete.
This group includes concrete building elements all of These products are reinforced with glass fibers that
which are exposed to view. are randomly dispersed throughout the products and
are made by spraying a glass fiber, cement, and sand
Category A1 is architectural cladding and load slurry mixture into molds. This produces thin walled
bearing members. This category includes concrete lightweight cladding panels. Products are manufac-
building elements such as exterior cladding, load tured according to the quality requirements of MNL-
bearing and non-load bearing wall panels, spandrels,
130.
beams, mullions, columns, column covers. Category
AT is precast concrete architectural trim units, prod- Clearance-Interface space (distance) between
ucts with a high standard of finish quality and of rela- two elements. Clearance is normally specified to al-
tively small size that can be installed with equipment low for the effects of product and erection tolerances
of limited capacity. Included in this group are sills, lin- and for anticipated movement such as deflection, vol-
tels, coping, cornices, quoins, bollards, medallions, ume change movement, etc.
benches, planters, and pavers.
Clear distance-The least distance between the
Group B Bridges-This group includes all bridge surface of the reinforcement and the referenced sur-
products. The group is subdivided into B1, B2, B3, face. The referenced surface may be the form, adja-
and B4 categories. These products are considered cent reinforcement, embedments, concrete surface,
structural products. Category B1 products are typi- or other surfaces.
cally not prestressed, B2 products are prestressed
bridge related products excluding bridge beams, B3
Concealed surface-Surface not visible during
products are superstructure members using straight normal use of the member.
prestressing strand, B4 includes all products in B1 Tolerances for concealed surfaces may not be as
through B3 plus draped strand bridge members. critical as for surfaces which are exposed to view in
Category BA includes products fabricated using the finished structure.
forms and techniques common to the production of Connection-Device for the attachment of pre-
structural members (Group B) and having specified cast concrete members to each other, to the building
surface finishes that require uniformity and detailing or to the structure. Connection design must often ac-
more demanding than the typical requirements for count for the cumulative effects of all allowed toler-
structural products. ance variations.
Group C Commercial (Structural)-This group Contract documents-General conditions, proj-
includes all commercial products. The category is ect specifications and design drawings issued on be-
subdivided into C1, C2, C3, and C4 categories. These half of the owner by the design professionals of re-
products are considered structural products. Cate- cord (architect/ engineer) and from which the project
gory C1 products are typically not prestressed, C2 shop drawings and production drawings are devel-
products are prestressed hollow-core and similar re- oped.
petitive products, C3 products are prestressed mem- It is good practice to initially review the contract
bers using straight strands, C4 are products using documents to see if tolerances for the precast mem-
draped prestressing strands. Category CA, this cate- bers have been specified. If not, amend the contract
gory includes products fabricated using forms and to include specific definition of the planned approach
techniques common to the production of structural to project tolerances. Blanket reference to this docu-
members (Group C) and having specified surface fin-

11
mentwithout specifying specific tolerances should be nal 8 ft. [2.44 m] wide double tee wall panel is de-
avoided. signed to have a nominal% in. [19 mm] wide joint on
either side, the working dimension for the member
Control surfaces-The following are several dif- width would be 7ft. 11 V. in. [4.42 m].
ferent categories of surfaces relevant to precast con-
crete tolerance control and erection. Discrepancy-Indicates the difference between
planned dimension and actual dimension. The exis-
Alignment face-The face of a precast member tence of a discrepancy frequently reveals the need for
which is to be set in alignment with the faces of adja-
closer monitoring. Less precise measurement tech-
cent members or features. The alignment face is usu-
niques tend to obscure problems that more precise
ally a primary control surface. This is the member face
techniques may reveal.
that is usually exposed to view in the final structure.
Draft-The taper given to features of a mold or
Primary control surface--A surface or feature on form to allow the precast piece to be removed from
a precast member, the dimensional location of which
the mold or form without damage. Draft can result in
is specifically set and controlled in the erection pro- different feature dimensions between the front and
cess. Primary control surfaces are generally associat- back of a piece.
ed with the key dimensional features of the structure.
(for example a column haunch support surface) Engineer of Record-The design professional le-
gally responsible for the overall structural design of a
Secondary control surface--A surface or feature building or facility, for determining and setting the
on a precast member, the dimensional location of load requirements, and for coordinating the designs
which is dependent on the location tolerance of the
performed by a speciality engineer with the overall
member primary control surfaces plus the member system. Generally this is the individual who has
feature tolerances. An example would be the eleva- sealed the contract design drawings (not the precast
tion of a second-story corbel on a multistory column shop drawings) with his or her professional engi-
whose first-story corbel elevation is selected as the neer's stamp.
primary elevation control surface.
Errors in measurement-The following are differ-
Cover-The distance between the surface of the ent types of errors in measurement which must be
reinforcement and the nearest concrete surface. considered.
Creep-Dimensional change, usually shortening Systematic error-An error that invariably has the
or camber change, which takes place as result of sus- same magnitude and the same sign under the same
tained compression loading and prestress force on given conditions. Thus a cloth tape that has been
concrete elements. The magnitude and rate of creep stretched about 5 percent by overuse will consistently
depends on various factors including concrete char- measure a 40 in. dimension as just over 38 in.
acteristics and the level of compression loading.
Natural errors-Systematic errors that arise from
Dimensions-The following are several different natural phenomena. They are really the effects of cer-
categories of dimensions relevant to precast con- tain influences that operate to prevent the observer
crete fabrication. from seeing or reading directly the quantity being
Actual dimensions-The measured dimension of sought. Two instances are the refraction of light rays
the precast member after casting. and the thermal variation of measuring devices. (for
The actual or as-built dimension may differ from example thermal length changes in metal measuring
the working dimension due to construction and mate- tapes).
rial induced variation. Instrumental errors-Are the systematic effects
Basic dimension-The dimensions shown on the of imperfections in the construction or adjustment of
contract drawings or called for in the specifications. instruments used in making measurements.
The basic dimension applies to size, location, and rel- Instances include the lack of concentricity of transit
ative location. It may also be called the "nominal" di- circles, graduation errors in scales, and maladjust-
mension. ment of the bubble tubes of levels.

Working dimension-The planned dimension of Personal errors-This systematic error depends

the precast member obtained from its basic dimen- on the physical limitations and also on the habits of
sion the necessary joint or clearance dimensions, the observer. Some observers may have a slight ten-
and other adjustments. dency to observe to the right or left in estimating
It is to this planned working dimension that the tenths, or have poorly coordinated vision. The
product tolerance is applied. For example, if a nomi- amount of such error is usually small, though erratic.

12
 Accidental Errors-These errors of observation Lateral alignment-The location relative to a spe-
are random; they are usually small and then have a cified horizontal line or point in a horizontal plane.
tendency to be mutually compensating. The appear-
Level alignment-The vertical location relative to
ance of discrepancies in a series of measurements is
a specified horizontal plane.
one example.
When applied to roadways, bridge decks, slabs,
Flatness-The degree to which a surface approxi- ramps, or other nominally horizontal surfaces estab-
mates a plane. See Smoothness. This tolerance is lished by elevations, level alignment is defined as the
most important in wall and slab members. vertical location of the surface relative to the specified
profile grade and specified cross slope.
Formed surface-A concrete surface that has
been cast against form work. Match casting-A precast concrete fabrication
procedure whereby a segment is cast against the pre-
Hardware-Items used in connecting precast ceding segment thereby producing a matching inter-
concrete members or attaching or accommodating face that will permit re-establishment of the cast ge-
adjacent materials or equipment.
ometry at the time of erection. Match-casting may be
Generally suppliers of hardware can provide infor- accomplished by either the short line casting method
mation regarding required placement tolerances for or the long line casting method.
their hardware products.
Hardware is normally divided into the following Short line match casting-The method of casting
three categories: segments one at a time on the casting bed utilizing a
fixed or movable bulkhead. The first segment is cast
Contractor's hardware-Items to be placed on or between bulkheads.
in the structure in order to receive the precast con- Successive segments are cast, one at a time,
crete members, e.g., anchor bolts, angles, or plates against the bulkhead on one end and the reposi-
with suitable anchors.
tioned, previously cast segments on the other end.
Since the precast members must interface with
this hardware, it is important to understand the toler- Long line match casting-The method of casting
ance to which these elements are to be installed. Con- segments on a casting bed of sufficient length to per-
firm the as-built location of this hardware in advance mit the cumulative casting of segments for the entire
of the precast erection activities. length between field closure pours without reposition-
ing the segments on the casting bed. With this meth-
Plant hardware-Items to be embedded in the od, the first segment is cast between bulkheads and
concrete members themselves, either for connec-
successive segments are cast between a movable
tions and precast concrete erector's work, or for other
bulkhead on one end and the previously cast seg-
trades, such as mechanical, plumbing, glazing, mis-
ment on the other end.
cellaneous iron, masonry, or roofing trades. The
placement tolerances for this hardware often must PCI quality manuals-MNL-116 Manual for Quali-
consider the installation requirements of the systems ty Control for Plants and Production of Precast and
the hardware must interface with. Prestressed Concrete Products. This is the docu-
ment prepared by PCI as a guideline for quality assur-
Erection hardware-All loose hardware neces- ance of all precast concrete except architectural pre-
sary for the installation of the precast concrete mem-
cast and glass fiber reinforced concrete (GFRC).
bers.
MNL-117 Manual for Quality Control for Plants and
Jig-A template or device to align parts of an as- Production Of Architectural Precast Concrete Prod-
sembly, usually for pre-assembling reinforcing steel ucts. This is the document prepared by PCI as a
and hardware cages and positioning of anchor bolts guideline for quality assurance of architectural pre-
on site, with a minimum of measurement to attain con- cast concrete. MNL-130 Manual for Quality Control for
sistent accuracy from one casting to the next. The use Plants and Production of Glass Fiber Reinforced Con-
of templates in the plant and the same or matching crete. This is the document prepared by PCI as a
template for placement of the contractor's hardware guideline for quality assurance of glass fiber rein-
in the field is a good way to assure fit-up of mating forced concrete products.
connection elements.
Post-tensioning-A method of prestressing con-
Jog in alignment-The difference in elevation of crete whereby the tendon is kept from bonding to the
the top or bottom of one wall panel relative to the adja- plastic (wet) concrete, then stressed and anchored
cent wall panel measured at the mating edges of the directly against the hardened concrete, imparting
panels. stresses through end bearing at an anchorage. Post-

13
tensioning has the effect of shortening a member in the specific project specifications and for specifying
the direction axial to the post-tensioning and may re- items not covered in this document.
sult in camber. This shortening and the effects of
camber should be included in the length tolerance Quality-The appearance, strength, durability,
considerations. and dimensional conformance which is appropriate
for the specific product, its particular application and
Precast Engineer-The person or firm who de- its expected performance requirements. Quality also
signs precast concrete members for specified loads refers to the totality of features and characteristics of
and who may also direct the preparation of the shop a product that bear on its ability to satisfy stated
drawings. The responsibility for the design of the pre- needs.
cast members and of the overall structure (including
the overall tolerance plan) is determined by contract Quality assurance (QA)- All those planned or
and should be specifically defined in the project con- systematic actions necessary to ensure that the final
tract. product or service will satisfy given requirements for
quality; and performance of intended function. Typi-
Precast linear member-Beam, column, or simi- cally, the quality assurance effort will focus on the re-
lar member. quirements of the overall project. thus identifying the
tolerance quality control requirements for member
Precast planar member-Wall panel, floor panel fabrication.
or similar member.
Quality control (QC)-Those planned actions .
Precision of measurement-A measure of the which provide a means to measure and control the
closeness of conformity with the actual value. Preci-
characteristics of members and materials to predeter-
sion is related to the degree of care and refinement
mined quantitative criteria.
employed in making a measurement.
Accuracy of measurement is descriptive of the cor- Relative alignment-The distance between two
rectness of the result of the measurement. or more elements in any plane, or the distance be-
tween adjacent elements, or the distance between an
Pre-tensioning-A method of prestressing con- element and a defined point or plane.
crete whereby the tendons are elongated, and then
anchored while the concrete in the member is cast Set-up-The process of preparing molds or forms
around the tendons. The tendons are then released for casting, including installation of materials (rein-
when the concrete is strong enough to receive the forcement and hardware) prior to the actual placing
forces from the tendon through bond. of concrete. The set-up process is second only to the
Once the prestress force is transferred to the con- mold or form construction in its importance in the
crete member the member will shorten and possibly achievement of specified member tolerances.
camber. These dimensional changes need to be con-
sidered in the product tolerances, the erection toler- Shrinkage-The volume change in precast con-
ances, and the interface tolerances. crete members caused by drying that normally oc-
curs during the curing and initial life of concrete mem-
Pre-topped systems-A construction approach, bers. The expected shrinkage must be subtracted
such as may be used for the floor system in parking from the form set up dimensions to determine the as-
garages, in which the flange for the floor member, cast dimensions of a member.
often a double tee, is constructed to its final thickness
in the plant, resulting in no cast-in-place topping be-
Shop drawings-(1) Collective term used for
erection drawings, production drawings and hard-
ing required in the field. This approach can be very ef-
ficient in that it reduces the amount of field construc- ware details; and (2) Diagrams of precast concrete
members and their connecting hardware, developed
tion work. It does however. require closer control of
tolerances such as differential camber, flange con- from information in the contract documents. Shop
drawings show information needed for both field as-
nector placement and overall member depth.
sembly (erection) and manufacture (production) of
Project specifications-The building or facility the precast concrete members.
specifications which define specific requirements for
the elements of the project. Specifications can
Erection drawings-Those drawings which show
the relationship of the precast members and their
employ PCI tolerance recommendations by refer-
connections in the erected structure and which pro-
ence to specific tolerances given in this document.
vide such information as is necessary to properly
The specifications serve as the instrument for making
erect and connect the various members.
mandatory and optional selections available under

14
 Production drawings-A set of instructions in the bers is secondary to their structural requirements.
form of diagrams and text which contain all the infor- The fabrication techniques used for structural precast
mation necessary for the manufacturer to produce concrete (for example, long line casting in forms with
the precast member. These documents are usually movable bulkheads), limit some of the dimensional
produced by or under the direction of the precast precision possibilities with this type of manufacturing
plant engineering department or by a party hired by process.
the producer to do this.
Sweep-A global variation in member horizontal
Hardware details-Those drawing details which alignment. This can sometimes be caused by hori-
are used for the fabrication or procurement of hard- zontally eccentric prestress in narrow members.
ware which is used either in the production of the pre-
cast member or in its erection and connection. Tendon-A high strength steel element consisting
of one or more wires, strands, or bars or a bundle of
Smoothness-The absence of local irregularity or such elements, which are stressed and used to im-
roughness. It does not refer to the overall shape ofthe part prestress to the concrete.
member. In prestressed products the position of the ten-
dons is one of the most important of all tolerances, as
Speciality Engineer-A licensed engineer, not variation in tendon location affects the structural ca-
the Engineer of Record, who performs structural engi-
pacity of the element.
neering functions necessary for the structure to be
completed. He has shown experience and/or training Theoretical casting curve-The curve of casting
in his specialty. geometry followed at the casting bed for segmental
precast members to achieve the theoretical profile of
Specially finished structural precast con- the completed structure after final deformations have
crete-A product fabricated using forms and tech-
taken place. This calculated curve takes into account
niques common to the production of structural mem-
deformations resulting from the sequence of erection
bers and having specified surface finishes that and loads applied during erection.
require uniformity and detailing more demanding
than the typical requirements for structural members. Tolerance-Specified permissible variation from
These surface finishes and any special tolerance specified requirements such as dimensions, location
requirements for this class of member should be and alignment such as:
clearly specified and verified with appropriate sam- • the permitted variation from a basic dimension
ples and mockups. These products are defined as or quantity, as in the length, width, and depth
Groups CA or BA if they use structural tolerances and of a member.
Group A 1 if they use architectural tolerances. • The range of variation permitted in maintaining
a basic dimension, as in an alignment toler-
Statistical tolerance control concepts-A math-
ance.
ematically valid approach of sampling and monitoring • A permitted variation from location or align-
tolerances on projects which have large numbers of ment.
identical pieces made using industrial tolerance con-
trol methods. Architectural tolerances-The tolerances given
in Article 10.1 for architectural panels define architec-
Step in face-The dimensional difference be-
tural tolerances. Member finish and color are sepa-
tween the edges of the planar surfaces of two adja- rate issues which are often important in the produc-
cent wall panels measured atthe mating edges ofthe tion of architectural concrete members. Architectural
two panels. The more perfectly the panels match di-
dimensional tolerances can be applied to other prod-
mensionally at the edges the less the step in face.
uct types as special project tolerances. There is no in-
Strand-A group of wires laid helically over a cen- tent to split tolerances between structural and archi-
tral-core wire. A seven-wire strand would thus consist tectural tolerances on the basis of finish or color.
of six outer wires laid over a single wire core. High Finish and color are separate issues related to project
strength steel strand is typically used to prestress aesthetic requirements.
concrete.
Structural tolerances-The tolerances given in
Structural precast concrete-Precast concrete Article 10.0 with the exception of the architectural tol-
members that are intended to support external struc-
erances given in Article 10.1, architectural trim toler-
tural loads in addition to their own weight. They are
ances given in Articles 10.29, 10.30 and 10.31 for ar-
fabricated using methods which are optimized to eco-
chitectural trim elements and Article 10.28 for railroad
nomically produce members with specified structural
ties. These tolerances apply to structural precast
properties. Appearance requirements for these mem-

15
concrete members that are fabricated using methods Erection tolerances-Those allowable variations
designed to produce economically feasible members in dimensions of member placement in the com-
with specified structural properties. pleted structure required for acceptable matching of
Finish and color are usually less important for precast members alter they are erected.
members governed by structural tolerances. When Erection tolerances are a characteristic of how the
the finish and or color of structural members are im- individual members are positioned both globally nnd
portant to the project, this should be specifically relative to one another in the overall structure.
noted in the contract documents, as special mea-
sures may be required to achieve the desired result. Interfacing tolerances-Those allowable varia-
tions in dimensions associated with other materials or
Project tolerances-The required tolerances for systems in contact with or in close proximity to pre-
a specific project. If the specified tolerances differ cast concrete.
from the tolerances given in this document for a spe- Interface tolerances could include the tolerances
cific product group or category, it is in the interest of of cast-in-place concrete footings, structural steel or
all parties to agree in writing to the project tolerances. cast-in-place concrete frames, and subsystems like
windows, doors, heating and ventilating system ele-
Special project tolerances-Specially required ments, and the like.
tolerances, different from standard PCI tolerances
given in this publication which are required to meet True position dimensioning-A system of dimen-
specific project requirements. sioning used in the machine design industry to assure
Tolerances different from those listed in this docu- that close tolerance parts are universally interchange-
ment may be agreed to for a specific project. These able. Some of the concepts of this tolerancing system
tolerances could be either less stringent or more strin- may be of interest to the precast producer for special
gent than the tolerances listed here. situations. See the reference section for publications
It should be noted that the requirement for special which address this tolerance system.
project tolerances may have a significant impact on
project price and schedule.
Variation-The difference between the actual and
the basic dimension. Variations may be either nega-
Product tolerances-Those allowable variations tive (less) or positive (greater).
in dimensions relating to individual precast concrete
members.
Vertical alignment-The location relative to a spe-
cified vertical plane or a specified vertical line or from
Control surface tolerance-Tolerances which a line or plane reference to a vertical line or plane.
are related to element control surfaces that are set or When applied to battered walls, abutments or other
aligned to be within the specified project erection tol- nearly vertical surfaces, vertical alignment is defined
erances. as the horizontal location of the surface relative to the
specified profile.
Feature tolerance-The allowable location or di-
mensional variation of a feature, such as a corbel or Warping-Twisting of a member, resulting in over-
a blackout, with respect to overall member dimen- all out-of-plane curvature of surfaces characterized
sions. Feature tolerances are a characteristic olthe in- by non-parallel edges.
dividual precast members. Warping is most often a concern in panel mem-
bers, although it can occur in other types of members.

16
6.0 Relationships Among the Different Toler- Erection tolerances and product tolerances for
ance Groups some features of a precast concrete member may be
directly additive while others are not. This fact should
The relationship among the different tolerance be communicated to production, quality control and
groups must be consistent in order to avoid tolerance erection personnel and may be shown on the erection
related rework of building members. A careful review drawings if relevant to the erection activity. Knowing
of which tolerances are primary and which secondary which member surfaces are the primary erection con-
and a review of how product and erection tolerances trol surfaces is important to the erection effort.
relate on a particular building project will determine If special project tolerances, other than standard
which tolerances are cumulative and which are not. PCI tolerances are used, in lieu of showing the erec-
tion tolerances for each piece, a tolerance drawing for
6.1 Relationship of Product Tolerances each erection situation can be used to convey the re-
quired project tolerances to the erection personnel.
Product tolerances define the limits of the size and In instances where the tolerance of both primary
dimensional precision of the individual precast mem- and secondary control surfaces must be controlled
bers comprising the building or structure. The prod- during erection, the design should be reviewed by the
uct tolerance also controls the location of the member producer and erector to assure that the details in-
features as they relate to the overall member dimen- clude provisions for secondary control surface ad-
sions. justment. If revisions are indicated by the review, the
In lieu of showing the member tolerances on each architect/engineer should be notified, as problems in
shop drawing. a project tolerance drawing can be the tolerancing system are easier to resolve before
used to convey the required project tolerances to the the pieces are produced.
production personnel. The producer should review
project specifications and design drawings to deter·
6.3 Relationship of Interfacing Tolerances
mine if surface and feature dimensional control re-
quirements are clearly outlined. If clarifications are Interfacing tolerances are those associated with
needed the architect/engineer should be notified. other materials or systems which interface with the
precast concrete members. Interfacing tolerances
6.2 Relationship of Erection Tolerances apply whether the interfacing system is erected prior
to or following precast erection.
Erection tolerances define the location and place- For interfacing situations which involve multiple
ment of the individual precast members in the as- members, both product and erection tolerance ef-
sembled structure. The individual precast member is fects may have to be accommodated within the inter-
erected and positioned so that its primary erection face tolerance.
control surface is in conformance with the established Product tolerances, erection tolerances and inter-
erection tolerances. face tolerances together determine the dimensions of
See Articles 11.0 and 12.0 for further discussion of the completed structure. If it is critical to the project,
erection tolerances. the system tolerances which take precedence on the
During precast panel installation, priority is gener- given project should be reflected in the contract docu-
ally given to aligning the exterior face of the precast ments and should also be indicated on the project
panels to meet aesthetic requirements. This may re- shop drawings.
sult in the interior precast panel face not being in a See Article 17.0 for a discussion of interfacing tol-
true plane. erances.
Product tolerances for member primary control As written, American Concrete Institute (ACI) doc-
surfaces are not additive to the erection tolerances ument 117 "Standard Tolerances for Concrete
which govern the setting of the member primary erec- Construction and Materials" applies primarily to rein-
tion control surfaces. forced concrete construction. Similarly the American
The secondary control surfaces of a member (for Institute for Steel Construction (AISC) code of stan-
example the surfaces of a blackout) usually are not di- dard practice applies only to structural steel construc-
rectly set during the erection process. Thus, the tion. Neither of these standards addresses toler-
product tolerances for secondary control surfaces ances for buildings of composite construction (i.e.
and features of the member are additive to the erec- concrete floor slabs carried by steel columns or steel
tion tolerances for the member. To ensure a trouble frames with precast concrete cladding) Nor are toler-
free installation, generally, the product tolerances ances for fireproofing and masonry controlled by ref-
must not conflict with the erection tolerances. erencing these standards. The producer should re-

17
view the contract documents to assure that the by the producer, as these require early decisions
location of all such materials contiguous to the pre- based on overall project economics. Once these de-
cast concrete members have been controlled within cisions about forming, fabrication methods, and erec-
tolerances which are, at most, no less stringent than tion procedures have been made, they should be re-
those specified in ACI 117. Notify the architect/engi- flected on the project shop drawings.
neer if revisions to the contract documents are indi-
cated by this review.
6.5 Relationship of Form Tolerances to Prod-
uct Tolerances.
6.4 Project Economic Considerations
Product tolerances are directly dependent on form
The precedence of product and erection toler- manufacturing tolerances, the flexibility of the form,
ances raises questions of project economics. The tol- and the precision with which the variable features of
erance requirements and other costs associated with the form can be adjusted.
the connection details should be reviewed by the pro- In some cases, when long production runs of
ducer in conjunction with the erector. close tolerance members are required, the invest-
When accepted by the producer and/or erector as ment in very rigid, close tolerance premium form work
contractual requirements, special tolerance require- may be the best investment that can be made. This
ments, details, and procedures should be clearly will serve to minimize any tolerance related problems
spelled out in the project shop drawings. Special tol- and the associated costs.
erances or construction procedures should be noted

18
7.0 Product Tolerances ling authority. If a specifying agency has tolerances
more restrictive than PCI tolerances in the project
Product tolerances are a measure of dimensional specification, the more restrictive agency tolerances
accuracy of the individual members and ensure, prior will govern the production of the project members.
to delivery to the job site, the high probability that the
member will fit into the structure without requiring tol-
erance related rework. See Article 10.0 for a listing of
7.1 Specification of Product Tolerances
product tolerances. See Appendix A for sample specification language
The applicable product tolerances should be con- regarding product tolerances. Project tolerances for
sidered in the overall project tolerance plan, along
manufacturing precast members and other interfac-
with the appropriate erection tolerances and the re- ing systems are standardized throughoutthe industry
quired interfacing tolerances. and should not be made more rigid and therefore
Product tolerances are needed in any manufactur-
more costly, unless absolutely necessary. The pro-
ing process. They are determined by economics, ducer should review the contract documents to as-
practicality, function and appearance. Product toler-
sure that the architecVengineer has specified project
ances are applied to physical dimensions of precast product tolerances within a generally accepted range
members such as thickness, length, width, square- or has defined special measures to achieve a different
ness, and location and size of member features.
level of tolerance. The requirement for such special
At times, the user of a precast concrete product
measures should be defined in the project contract
will specify special project tolerances for a particular documents.
project or member type. For example railroad author- The per unit cost of the preparations and actions
ities or governmental bridge authorities may often
necessary to manufacture members to close toler-
specify the necessary tolerances for products that
ances usually decreases with increasing repetition in-
they incorporate into their infrastructure. Therefore, volved on projects which consist of many similar pre-
the designer should consider PCI tolerances in con- cast members.
junction with the tolerances specified by the control-

19
8.0 Overall Plan Dimension Tolerance Con- which should be taken into account in the selection
siderations of the types of forms to be used is the precision of di-
mensional tolerance specified for the member.
The two most important considerations in achiev-
ing specified product tolerances are the effects of
formwork and the measuring techniques used to set Effects of Rigid Forms
the forms and assess the various product dimen-
Rigid forms are those which have all the sides of
sions.
the form rigidly and permanently fixed, thus ensuring
When considering the effects of product toler-
a higher degree of dimensional accuracy than other
ances the following items are significant: When new,
form types, in both the length and width directions.
relocated, or modified forms are used, the initial mem-
Rigid forms are often used in the fabrication of cus-
ber cast should be carefully measured to assure that
tomized products such as architectural precast pan-
all features are correctly formed and that all member
els, where appearance or function dictates the need
tolerances are met. This process should be repeated
for closer tolerances. Large runs of repetitive use of
when there is any reason to believe that the condition
forms can make the higher initial cost economically vi-
of the form may have changed.
able.
Length or width dimensions and straightness of a
Side forms for rigid forms should have suitable
member will all affect the joint clearance dimensions,
draft. Draft is the slope or taper required on the forms
opening dimensions between members, and poten-
to permit stripping of the precast member from the
tially the overall length of the structure which incorpo-
form.
rates the member. Thickness variation of the precast
concrete panel member becomes critical when interi-
or surfaces are exposed to view. A non-uniform thick- Effects of Semirigid Forms
ness of adjacent members will cause offsets of the
front or rear faces of the panels. Semi-rigid forms are those which have two sides
rigidly and permanently fixed. The other sides typical-
ly are made by using end dividers for long line casting
8.1 Effect of Forms on Dimensions or removable side forms to allow dimensional differ-
ences in individual pieces.
Forms are generally one of three types: rigid, semi-
In semi rigid forms the end dividers or removable
rigid, or flexible. See Fig. 8.1.1. The tolerances to
side forms are not permanently rigidly attached to the
which the forms are made and the tolerances to which
form, and thus must be set to the proper dimension
they can reliably be adjusted are an important deter-
for each panel casting. Because they must be set with
minant of the ability to achieve specified member tol-
each new casting length, they have the potential to
erances. The proportion of the product tolerance vari-
move slightly during the placement and vibration of
ation which results from form manufacturing
the concrete. This results in a lesser degree of achiev-
tolerances or adjustment precision should be consid-
able precision in linear plan dimensions than when
ered in the plan to achieve specified member toler-
rigid forms are used.
ances. One of the most important considerations

Fig. 8.1.1 Types of precast concrete formwork

RIGID SEMIRIGID FLEXIBLE

~~ ,;,d "" Removable s1de

20
Effects of Flexible Forms er modulus at release) when compared with mem-
bers cast during the week and detensioned the next
Flexible forms have no permanent rigidly fixed morning after casting (more camber because of lower
sides. The typical product using such forms is a modulus at release).
double tee with blocked-out flanges, or a flat wall pan- If particular members within a project require high
el on a project having many different sized wall pan- levels of dimensional stability over time, this require-
els. Of the three types of forms discussed here, flex- ment should be brought to the attention of the precast
ible forms result in the least degree of achievable plan designer so that the prestress can be designed tore-
dimensional precision in both length and width. duce the potential effects of creep. Since this may in-
volve the addition of more total prestress, it may have
8.2 Effects of Prestressing on Dimensions economic effects and this requirement should be
treated as a special project tolerance.
The effects of prestressing can have a significant The effects of differential temperature from one
effect on member dimensions and should be consid- side of a member to another can cause the member
ered in the plan to meet specified tolerances. The pro- to bow or camber. Similarly in long members the ef-
ducer should assure that the effects of prestressing fect of lengthening and shortening due to wide ex-
have been accounted for in determining the form set- tremes of temperature can be important to the overall
up dimensions for member casting. length tolerance of members.
It is very important to agree in advance on the con- Solar heating of members stacked in the yard may
ditions under which the tolerances of a member will cause sweep and camber variations due to differen-
be checked. (e.g. the agreed support conditions for tial temperature. These deformations may not be
measuring sweep of a long slender precast pile). In present in the completed structure if it is enclosed.
instances where stringent tolerances are required Because of this it may be important to measure cam-
make sure that the affect of prestressing on member ber and sweep in the members at times when thermal
dimensions is clear within the project team. Put this effects in the piece are minimal. The opposite can oc-
agreement in writing prior to fabrication. cur with members that are exposed to thermal effects
The prestress effects result in length changes, in the completed structure. The potential for undesir-
member camber, and end rotation all of which should able deformation due to significant thermal effects
be taken into account when determining the casting should be brought to the attention of the precast de-
length for the member. The application of prestress sign engineer for evaluation.
force to the member can affect the overall length of Shrinkage and differential shrinkage of the con-
the member in two ways. First, there is an axial short- crete members can also have an effect on the dimen-
ening of the member as result of the applied axial sional tolerances of precast concrete members. Al-
compressive force of the prestress and second, the though the great majority of the concrete shrinkage
ends of the member may rotate in elevation as a result takes place during the initial curing of the member, its
of the member camber caused by prestress eccen- effect, particularly on large members, can be signifi-
tricity. cant and should be accounted for in the tolerance
control of the member. Differential shrinkage, particu-
8.3 Effects of Time, Temperature, and Shrink- larly in members which have different mixes with dif-
age on Dimensions ferent shrinkage characteristics, can result in mem-
ber bowing, warping, or camber. Differential
Because of concrete's tendency the creep under shrinkage of face and back up concrete mixes in ar-
applied load or prestress, the shape and dimensional chitectural members or in different mixes which may
tolerance of a member has the potential to change be used for the interior and exterior wythes of insu-
over time. This is more of a concern for members lated panels is something that should be assessed
which have high levels of eccentric prestress which with regard to the effect on member bowing and
can lead to changes in member camber or sweep warping tolerances.
over time.
Since the modulus of elasticity of concrete varies 8.4 Relation of Measuring Techniques to Tol-
proportionally to its strength, the strength (and result- erances
ing modulus) of the concrete at the time of transfer of
prestress may have an effect on member camber Accurate measuring devices and methods with
which can be significant enough to consider in the the precision capability appropriate to the tolerance
overall dimensional control program. This may be no- being controlled should be used for both setting and
ticeable, for example, in differential camber of long checking product, interface, and erection tolerances.
cambered members which are cast on Friday and de- Typically, the precision of the measuring technique
tensioned on Monday (less camber because of high- used to verify a dimension, either pre or post casting,

21
should be capable of reliably measuring to a preci- tion, the architect/engineer should be notified for pos-
sion of one-third the magnitude of the specified toler- sible design revisions.
ance.
The most common measuring method used in
8. 7 Tolerances for Position of Tendons
precast plants is the use of metallic measuring tapes
graduated in feet, inches and fractions of a inch. (me- Tolerance for position of prestressing tendons is
ters and millimeters) For economic and functional one the key tolerances affecting the structural capac-
reasons, the use of more sophisticated measuring in- ity of the member. If tighter or less stringent tolerances
struments, such as surveying instruments, may be on strand location than given in this document are re-
justified in some instances. To maximize accuracy, quired by the contract documents, they should be
members should not be measured in increments in a specifically noted on the project shop drawings.
manner which creates the possibilttyof cumulative er- Strand position tolerance is usually more important in
ror. (For example, use a tape long enough to measure shallow beam members than it is in deep beam mem-
the entire length of a member.) The degree of accura- bers.
cy in using measuring tapes depends on the particu- It is common practice to use% in. [16 mm] diame-
lar dimension of the member being measured. To at- ter holes in end dividers (bulkheads, headers) for all
tain greater precision in the linear dimensions of long strand sizes Y, in., 'A' in., 'Ia in., [13, 11, and 9.5 mm
members measuring tape slope, tape sag, tape ten- diameters]. This is done because it is costly to switch
sion, and temperature effects should betaken into ac- to new end dividers for different strand diameters.
count. Thus, in most plants, more precision in strand loca-
tion is achieved when using larger diameter strands.
8.5 Tolerances for Blackouts and Openings
8.8 Tolerances for Handling Device Loca-
A tolerance, consistent with the eventual function, tions
size and location of the block out should be indicated
on the shop drawings. In lieu of showing block out tol- The relative importance of placing tolerances on
erances on each shop drawing, typical block out tol- handling device locations in different directions
erances can be shown on a tolerance drawing for the should be indicated by tolerances shown on the proj-
overall project. For example, the tolerance on a win- ect shop drawings, especially in thin or narrow sec-
dow blackout, into which a prefabricated window tions.
frame will fit, should be more precise than a block out For example, closer lateral tolerances are neces-
through which a field-installed piping system will be sary to ensure the minimum required cover around
placed. The possible need for draft on the sides of lifting devices embedded in the stems of tees. In lieu
blackouts should also be considered. of showing the tolerance for handling devices on each
Another special case which should be shown on shop drawing they may be shown on a tolerance
the shop drawings is the set of required tolerance for sheet for the project.
dimensions controlling the matching of open shaped
panels. These tolerances may have to be tighter than
8.9 Tolerances Considerations for Camber
the standard dimensional tolerances by 50 to 75 per-
and Differential Camber
cent in some cases to assure a visually acceptable
match up. The producer should review these types The importance of camber and differential camber
of situations with the architect/engineer so that any between adjacent prestressed concrete members of
anticipated tolerance problems can be solved in the similar design will vary depending on the project re-
design of the panel interfacing prior to fabrication. quirements. If differential cambers exceed recom-
mended tolerances, additional effort is often required
to erect the members in a manner satisfactory for the
8.6 Tolerances for Sweep or Horizontal intended use.
Alignment The effects of differential camber on member to
member connection details and overall function in
Horizontal alignment deviation can occur as result pretopped systems should be considered in deter-
of form tolerances and member width tolerances. It mining appropriate differential camber specifications.
can also result from the effects of prestressing which The final installed differential elevation tolerance
has a lateral eccentricity, thus causing a sweep (later- between two adjacent cambered members erected in
al camber) in the member. If prestressed induced the field may be the combined result of member differ-
sweep is noted to create an out of tolerance condi- ential cambers, variations in support elevations, and

22
any elevation adjustments made to members during c. Creep differences resulting from differing con-
erection. cretes or differing stress conditions within the
Member camber measurements should be per- member.
formed in a consistent manner in order to understand d. Shrinkage effects due to differences in expo-
the actual differences in camber. It is very important sure, humidity, or curing differences.
to maintain uniformity at the time of camber measure- e. Strand relaxation which increases somewhat
ment both with regard to member temperature and with time.
solar exposure during the day and with regard to the f. Thermal effects that vary with time.
age and support conditions of the member since g. Extent of member flexural cracking.
casting.
For example, the camber measured on the top
Effects of Curing Methods on Camber Tolerances
member of a stack of double tees in the mid afternoon
on a hot sunny day will be considerably different from If special curing methods are needed to achieve
the measured camber of the bottom member of the member camber tolerances this should be noted on
stack on the same day (or of the same top piece on the project shop drawings. Curing methods can influ-
a cold cloudy day}. Similar camber measurement dif- ence concrete strength (and consequent modulus of
ferences will occur with long wall panels with one side elasticity and resulting camber effects} at the time of
exposed to the sun and the other side in the shade. prestress transfer to the member.
The most consistent results are obtained by measur-
ing camber in the early hours of the day, before the
sun has begun to differentially heat the members. Storage Configuration Effect on Camber Tolerance
Control of differential camber of adjacent mem- If special storage configurations are required to
bers in pre-topped systems may require more strin-
achieve product camber tolerances this should be
gent tolerances to meet functional requirements.
noted on the project shop drawings.
When this is the case, special design and production The following storage related issues can have an
measures may be required to achieve special project
effect on member camber.
tolerances for differential camber. Some adjustment
a. Member support locations while in storage.
to design floor elevations may be necessary when
b. Member position with respect to the sun.
working with pre-topped systems.
c. Member position in the storage stack and its ef-
If variation in camber in excess of the specified tol-
fect on the storage loading of the member.
erance is observed, the plant quality control inspector
should look for the cause and inform the architect/en-
gineer, who will determine the effects of the variation 8.1 0 Tolerances for Squareness of Ends or
on member performance. Note that variations from Variation From Specified End Skew
expected design camber may indicate strand slip-
page after release of prestress. The type of forms selected for a project should
consider the tolerance precision requirements for the
Some of the factors affecting camber variation and
subsequent differential camber are: of squareness of member ends. Out of square panels
and other members can cause tapered joints be-
tween adjacent panels and make the adjustment of
Time-Dependent Effects on Camber adjacent members difficult.
A member end skew which is not 90 degrees will
Since member camber can vary over time, the require special procedures during form set-up and
point in the life of the camber critical member to which during as-built measurement verification to assure
the camber tolerance applies to should be defined in
that tolerances are met.
the contract documents.
Checking all members at the same prescribed age
since casting is important for consistent camber mea- 8.11 Tolerances for Position of Weld Plates
surement results.
When selecting the positioning and installation
The following are time related influences on cam-
ber. methods for weld plates, consider the tolerance re-
quirements on these items. In general, plates can be
a. Modulus of elasticity variations due to curing
positioned to closer tolerances when the plates are
duration differences can result in different cam-
embedded in the bottom of the member (or against
bers for members of similar design.
b. Different age at release, ages of adjacent mem- the side form} than can plates cast into the top of the
member.
bers, age at time of erection, age at addition of
superimposed load.

23
 The main reason for this difference in placement 8.15 Tolerance on Reinforcing Steel Bending
precision is that bottom and side plates can be held and Placement
in position by fastening directly to the form, and hence
are less susceptible to movement which may be Reinforcing steel placement tolerances should be
caused by the placement and vibration of the con- shown on the project shop drawings. Similarly, rein-
crete. Plates cast into the top of the member are usu- forcing bar bend tolerances should be shown on the
ally supported by some type of frame which must be bar list for the precast members. In lieu of showing
positioned on the form before casting. these tolerances on each shop drawing, they may be
given on a project tolerance drawing.
Reinforcing steel used in precast prestressed
8.12 Tolerance on Tipping and Flushness of
products is controlled by two tolerances. The first is
Weld Plates
the bar length and bending tolerance, and the second
The tipping and flushness tolerance is also impor- is the bar placement tolerance, which is to an extent
tant when selecting the plate positioning method also dependent on the bar bending tolerance.
Flushness is the relationship of the weld plate surface Reinforcing bar bending and length tolerances as
to the concrete surface. For the same reasons as out- well as reinforcement placing tolerances are gov-
lined above, plates cast on the top of members will erned by the American Concrete Institute standards.
tend to tip out of plane more than bottom plates. The section on concrete feature tolerances (Section
Another reason for tolerance difference between 2.2. from ACI 117-90 Standard Tolerances for Con-
top and bottom plates is that bottom plates get uni- crete Construction and Materials) is reproduced be-
form bearing from the form surface whereas top low in Table 8.15.1. See the current issue of ACI117
plates must be supported by removable positioning for reinforcement bending and placing tolerances.
fixtures which often are not an integral part of the In situations where reinforcement embedded in
form. and extending from a precast member must interface
with other members, special measures are often re-
quired when planning the tolerances for the reinforce-
8.13 Tolerances on Haunches of Columns ment and in the fabrication of the members. The
and Wall Panels achievable reinforcement bar bending tolerances
possible with available bar bending equipment
Measures taken to assure maintaining tolerance
should be taken into consideration. This is especially
on haunch location dimensions which are also prima-
important if hooked bars are used.
ry erection control surfaces should consider the toler-
The overall tolerance plan for members with em-
ance requirements of the type of connection used at
bedded reinforcement should consider the detailed
the base of the member. Since a panel or other mem-
clearances between adjacent reinforcing bars and
ber base connection often allows some positioning
the potential maximum tolerance variation possible in
flexibility, it is often more important to control dimen-
the location of the reinforcement extending from each
sions from haunch to haunch in multistory columns or
of the interfacing elements. This is necessary to as-
walls rather than to maintain tight control of actual
sure that adequate clearances exist throughout.
haunch location dimensions from the end of the
Where the reinforcement extends out from the mem-
member.
ber, be sure to evaluate the position of the reinforce-
ment relative to the features it must interface with.
8.14 Tolerances on Location of Sleeves Cast through all of the angles of motion involved in the
in Prestressed Products erection process.
In special situations where complex reinforcement
The sleeve location tolerance should be secon- patterns must be interfaced during erection, steps
dary to the location tolerance of the strands unless should be taken to assure that the proposed arrange-
otherwise noted on the project shop drawings. The ments are workable. A common error is to lay out a
tolerance on sleeves may be affected by slight reloca- reinforcement clearance plan using reinforcing bar
tion of the sleeves necessitated by the location of pre- centerline to centerline dimensions and not appropri-
stressing strands within the member. ately considering the consequences of the bar diam-
For horizontal and vertical sleeve location toler- eter or the consequences of hook bending and length
ances, consideration should be given to the location tolerances. This is more of a consideration with larg-
of both straight and deflected prestressed strands, er diameter reinforcing bars which are relatively
the function of the sleeve, and its proximity to other closely spaced.
sleeves.

24
 If a producer subcontracts the reinforcing bar ACI specified bending tolerances is not suitable to
bending to an outside supplier, early and frequent meet the tolerance requirements of member fabrica-
checks of bending accuracy should be made. Addi- tion. For this reason some producers bend their own
tionally, in some instances special bar bending toler- bars or require their suppliers to work to bending tol-
ances may have to be specified in the contract with erances that are more stringent than those pre-
the bar bending fabricator. scribed by ACI.
Note that for some types of precast members, pro-
ducers find that reinforcement bent to conform with

Fig. 8.15.1 Selected* Tolerances

ACI117-90 Item Tolerance Tolerance
Section No. (ln.) (mm)t
3 Foundations
3.2 Lateral alignment
3.2.1 Footings
As cast to the center of gravity as specified; 0.02 times the width of the footing in the di- 2 50
rection of misplacement, but not more than
Supporting masonry '(, 13
3.3 Level alignment
3.31 Footings
3.3.1.1 Top of footings supporting masonry '(, 13
3.3.1.2 Top of other footings +%, -2 +13,-50
4 Cast-in-Place Concrete for Buildings
4.1 Vertical Alignment
4.1.1.1 For Heights less than 100 ft. ]30m]
Lines, surfaces, arrises 25
Outside corner of exposed corner columns and control joint grooves in concrete exposed '(, 13
to view
4.1.2 For heights greater than 100ft. [30 m)
Lines, surfaces and arrises 1/1 000 times the height but not more than 6 150
Outside corner of exposed corner columns and control joint grooves in concrete, 1/2000 3 75
times the height but not more than
4.2 Lateral alignment
4.2.1 Members 25
4.2.2 In slabs, center line location of openings 12 in. [300 mm] or less and edge location of •;, 13
larger openings
4.2.3 Sawcuts, joints, and weakened plane embedments in slabs 19
4.3 Level alignment
4.3.1 Top of slabs
4.3.1.1 Elevation of slabs on grade 19
4.3.1.2 Elevation of top surfaces of formed slabs before removal of supporting shores 19
4.3.2 Elevation of formed surfaces before removal of shores 19
4.3.3 Lintels, sills, parapets, horizontal groves and other lines exposed to view 13
* See Standard Specifications for Concrete Construction and Materials, ACI117-90, or current edition, for full listing.
t Metric conversions shown are "soft" (e.g. rounded to appropriate values).

25
8.16 Tolerance on Position of Strand Deflec-
tion Points
Fig. 8.17 .1 Warping Definitions for Panels
Strand hold-downs and other strand deflection de-
vices frequently have their positions dictated by the
requirement that they be fixed, either to the form itself
or to the form support, so that suitable strand hold-
down structural capacity is achieved. Often these
hold down locations are on a lattice grid that may
have a spacing as great as 40 in. [1020 mm] between
location points.
These casting bed structural conditions affecting
strand hold down location can frequently result in
available hold down positions being as much as ± 20
in. [±51 0 mm] from the specified location. If hold
down locations are specified closer than this, the ar- ADJACENT CORNER
chitect/engineer should be contacted prior to revision
of any specified hold down tolerance.
Special strand hold down location tolerances may
be required for cantilevers and other special condi-
tions. More precise placement of strand deflection
points will increase the cost of these members. The
vertical position of the hold-down is usually more im-
portant than the horizontal position.

8.17 Tolerance Effects of Warping, Bowing Bowing and Warping Tolerances

and Local Smoothness of Panels
Differential temperature effects and differential
Panel warping and bowing tolerances are often moisture absorption between the inside and outside
important aspects of panel visual features, and also faces of a panel, the effects of possible prestress ec-
influence the ease of erection and functional perfor- centricity, and differential shrinkage between face
mance of panel connections and panel interface ele- and back-up concrete mixes can all contribute to pan-
ments. el bowing and warping.
Warping tolerances are stated in terms of the mag- Note that bowing and warping tolerances are of in-
nitude ofthe corner variation, as shown in Fig. 8.17.1. terest primarily at the time the panel is erected. Care-
This tolerance is usually stated in terms of the allow- ful attention to pre-erection storage of panels is nec-
able variation per foot of distance from the nearest ad- essary, since storage conditions can be an important
jacent corner with a not-to-exceed maximum value of factor in achieving and maintaining panel bowing and
corner warping. warping within tolerances.
While warping and bowing occur in both structural Differential bowing is a consideration for panels
and architectural members, it is architectural mem- which are viewed together on the completed struc-
bers that usually demand special consideration. ture. If convex bowing is positive ( +) and concave
Warping and bowing tolerances have an important in- bowing is negative (-), then the magnitude of differ-
fluence on the visual effects relating to edge match up entia! bowing for adjacent members can be deter-
during erection and on the visual appearance of the mined by subtracting the bowing values.
erected panels, both individually and when viewed to- For example in Fig. 8.17.3, if the maximum bowing
gether. Several possible bowing conditions are of Panel 3 were + V. in. [ +6 mm] and the maximum
shown in Fig. 8.17.2. bowing of Panel4was- '!.in. [ -6 mm] then the differ-
Bowing and warping tolerances should be ential bowing between these two adjacent panels is
compared against panel global erection tolerance re- y, in. [13 mm].
quirements which may be driven by tolerance re- A special appearance related tolerance require-
quirements for panels as installed, with reference to ment may be necessary for honed or polished flat
joint widths, jog in alignment, and step in face toler- concrete walls where bowing or warping tolerances
ance. Compliance with these global requirements for may have to be made more stringent by 50 percent
some panel sizes and shapes may create more strin- to 75 percent of the bowing tolerances given in Article
gent requirements than the specific bowing and 11.0 in order to avoid possibly objectionable joint
warping tolerances. shadows.

26
Fig. 8.17.2 Definition of Bowing for Panels

Length of bow Length of bow

Exposed face ~
I
Max. bowing 0)
Max. bowing 0)

CROSS SECTION CONVEX BOWING CROSS SECTION CONCAVE BOWING

Bowing
(cross section)

Exposed face
(convex)
Bowing 0)
(elevation)
Exposed face
(concave)
Length of
bow
(elevation)
Max. bowing 0)

Precast
concrete
panel

Length of bow
(cross section)

PANEL BOWED IN BOTH ELEVATION &

ELEVATION CROSS SECTION

27
Fig. 8.17.3 Differential Bowing of Panels Panels which are relatively thin in cross section,
when compared to their overall plan dimensions, are
more likely to warp or bow as a result of a number of
design, manufacturing, and environmental condi-
tions.
To reduce the potential of panel warping or bowing
(i) 0 0 0 ® ® after erection, consideration should be given by the
architect/engineer for panel length, shape and the
===,== number and location of tie back connection points.
The producer and the architect/engineer should
L PRECAST
CONCRETE
collaborate in the decisions regarding maintaining or
PANELS relaxing bowing and warping tolerances. Appear-
ance requirements, the required type and spacing of
CROSS SECTION OF FACADE connections, and the experience of the local precas-
ter regarding overall economic and construction fea-
sibility of panels with various levels of bowing and
warping tolerance should be discussed with the ar-
chitect/engineer.
Similarly, panels which are manufactured using
large aggregate concrete mixes (above% in. [19 mm]
aggregate) or members which are fabricated from
non homogeneous materials such as two significant-
Surface Out of Planeness Tolerance ly different concrete mixes, special veneers, insulat-
ing mediums, etc., require more careful consideration
Surface out of planeness, which is not a character-
of all aspects of fabrication, storage, and handling
istic of the entire panel shape, is defined as a local
with regard to bowing and warping.
smoothness variation rather than a bowing variation.
Examples of local smoothness variation are shown in
Fig. 8.17.4.
The tolerance for this type of variation is usually ex- Fig. 8.17.4 Local Smoothness Variations
pressed in inches deviation from a 10ft. [3m] straight
10' (3 m )
edge. The tolerance should be checked with a 10ft. Exposed sur-
[3m] straightedge or the equivalent, as shown in Fig. face of pre-
r- Variation in local cast concrete
8.17.4 unless other methods are specified or agreed smoothness
to. Fig. 8.17.4 also shows how to determine if a sur-
/
v panel

face meets a tolerance of V. in. [6 mm] as measured

beneath a 10ft. [3m] straightedge. A y, in. [6 mm]
diameter by 2 in. [50 mm]long roller should fit any- I I I I lfiiiiTlllll 'I I I I I I II
I
where between the straight edge and the member
surface being measured when the straightedge is %" shim (1yp.) (9 \!.'' roller (1yp.) (6 mm) (fi1s
mm) anywhere)
supported at its ends on 3!a in. [9 mm] shims as
shown. A '12 in. [13 mm] diameter by 2 in. [50 mm]
long roller should not fit between the surface and the
straightedge. _ Variation in lo::: straight~dge (1y1p.) (J m)
smoothness
Panel Size to Thickness Ratio Effects on Tolerance

lithe producer has concern about the likelihood of

a panel to bow or warp in excess of the specified toler- I' I I I 1m I I I I I I I I Ill I ITI I I II
ances, the architect/engineer should be notified. The I I
%" shim (1yp.) 'li' roller (1yp.) (12 mm)
design of the panel and its relative stiffness or ability (9 mm) (won't fit anywhere)
to resist deflection as a plate member must be consis-
tent with the bowing and warping tolerances speci- MEASURING LOCAL SMOOTHNESS
fied. VARIATIONS ANY SURFACE

28
9.0 Special Tolerance Considerations 9.4 Statistical Tolerance Concepts

The function of members within the building or Any special measuring or record keeping meth-
structure and the employment of special manufactur- ods specified in the contract documents should be
ing techniques used to produce certain members observed by the plant quality control personnel. An
may warrant special tolerance considerations which understanding of statistical methods as they apply to
should be discussed by the producer with the archi- dimensional control can be helpful in developing proj-
tect/engineer. ect tolerance control plans which account for mem-
For example groups of inserts or cast-in items ber product tolerances, interface tolerances, and
which must be located in close relative tolerance to erection tolerances.
each other should not be separated onto two different While statistical concepts may not be commonly
panels by a joint unless special measures are taken employed in the dimensional control of precast prod-
to achieve the desired relative tolerances. ucts, it may be advantageous for producers to con-
sider this approach in certain circumstances for at
least two reasons: First, a random sampling of specif-
9.1 Considerations for Tolerances of Archi-
tectural Members ic measurements and subsequent statistical analysis
of these measurements can create quality control re-
In the context of tolerances, "architectural panel or lated economies on projects which have a large num-
member" refers to the class of tolerances specified ber of identical pieces with stringent tolerance re-
and not necessarily to the members' use in the final quirements. Concrete railroad tie production and
structure. Article 10.1 of this document defines archi- close tolerance interlocking tunnel liner elements are
tectural tolerances for typical architectural panels. Ar- examples of such instances.
chitectural panels, for example, require more strin- Second, statistical concepts can be used as a tool
gent tolerances due to the visual considerations in developing the tolerance control requirements for
which apply to the final construction. specific production operations. By proper sampling
and analysis, one can determine more precisely
which types of member features require more atten-
tion in the fabrication process and this can be imple-
9.2 Tolerance Considerations for Visible
mented in the production and quality control pro-
Structural Members
gram. For information regarding this type of statistical
Double tees and hollow-core slabs are often used approach to dimensional control, one should refer to
for wall panels which are exposed as visible elements appropriate publications as listed in the references for
of a building. If more stringent special project toler- this document.
ances are specified and required for these products
when used as visual elements, special production
methods and tolerance verification methods will be 9.5 Tolerance Considerations for Segmental
required. The same high degree of dimensional preci- Precast
sion associated with purely architectural panels
should generally not be specified for double tee or Segmental precast projects are, by definition, spe-
hollow-core panels since the manufacturing tech- cial projects from the tolerance point of view. These
niques for the product when used as a visible element projects will have unique tolerance requirements and
is generally the same as for the structural product for will require consideration of tolerances at all levels of
which these elements are more commonly used. the project, including design, member fabrication,
erection, and sub system installation.
For precast segmental construction using short
line forming techniques, precision surveying systems
9.3 Tolerances for Structural Members
should be provided so that levels and horizontal align-
Unless otherwise specified on the shop drawings, ment are measured to the very high levels of accuracy
tolerances for structural members should be as out- unique to each project using this construction meth-
lined in Article 10.0 of this document for the members od. For all other types of segmental construction,
designated as "structural members" (excluding Ar- surveying should be provided to an accuracy of ± 1/a
ticle 10.1 and Articles 10.29, 10.30, and 10.31 which in. [3 mm].
give architectural tolerances).

29
 For precast segmental construction using match- casting a new segment. In addition to the computed
cast segments, careful checks of both measure- as-built casting curves for vertical and horizontal
ments and computations of geometry should be deflections, a cumulative twist curve should be com-
made before moving segments from their casting puted using the measured cross slopes ofthe individ-
position. Dimensions from segment to segment ual units as a check on the extrapolated deflections.
should be adjusted to compensate for any deviations In computing set up elevations in the match-cast pro-
within a single segment so that the overall alignment cess, priority should be given to correcting twist er-
of the completed structure will conform to the dimen- rors by proper counter-rotation. The segment in the
sions shown on the plans. Computed as-built coordi- match cast position should not be subjected to
nates of all sections cast should be completed before stressing that would induce twist.

30
10.0 Product Tolerance Listings the location of multiple embedments should always
be measured from the appropriate control surface,
The following pages give dimensional require· rather than measuring some from a member edge
ments for a range of standard precast concrete and and others from intermediate embedments. The
precast, prestressed concrete products. These toler· member diagrams in this section show the location of
ances are guidelines only and each project may have features to which the tolerances apply. They are not
project tolerances specified which are different from intended to show the most appropriate reference lea·
those shown. Article 10.1 defines architectural panel ture for measurement. The appropriate dimensioning
member tolerances. Articles 10.2 through 10.25 de· system to achieve the desired tolerances should be
fine tolerances for structural members. Article 10.26 established by the engineer and shown on the pro·
Railroad nes, is a special product tolerance. Articles duction drawings.
10.27 through 10.29 defme tolerances for architectur· Camber tolerances have special considerations.
al trim elements. For members with a span-to-depth ratio at or exceed·
During the pre and post pour check of precast ing 25, the camber tolerance given herein may not ap·
member dimensions, the quality control inspector ply. If the application requires control of camber to the
should have the approved version of shop drawings listed tolerance in beams with high span-to-depth ra·
for reference. Any discrepancies found should be tio, special production measures may be required.
noted on the post pour record and transmitted to The precaster should be consulted regarding this re·
management or engineering for evaluation and reso- quirement.
lution, which may include design of any structural or Prediction of camber in a prestressed member is
appearance revisions which may be necessary. based on empirical formulas. The accuracy of these
Product tolerances are necessary in any manufac- estimates decreases with time. Measurement of cam·
turing process. They are normally determined by ber for comparison to predicted design values should
function and appearance requirements, and by eco- be completed within 72 hours of transfer of prestress·
nomic and practical production considerations. Toler- ing force.
ances for manufacturing precast products are stan- Temperature variation across a member section
dardized throughout the industry and should not be can have a significant impact on the measured cam·
reduced, and therefore made more costly, unless ab- ber. Camber should be evaluated under conditions
solutely necessary. that minimize the effect of temperature variation due
The tolerances listed herein are the minimum ac- to solar radiation, such as early in the morning.
ceptable criteria in the absence of other specifica- When the finished floor or deck surface is created
tions. Projects under the control of special authori- by the precast elements as erected (pretopped), the
ties, such as state highway departments for bridges, overall depth of the member becomes a primary con-
will often have a full set of tolerances specified. In trol feature and the deck surface becomes a primary
these situations, the tolerances specified by the con- control surface for both fabrication and erection. In or-
trolling authority may govern. der to achieve the desired tolerances on the overall
For products not specifically listed, select the ap· floor or deck it may be necessary to use special pro·
propriate tolerances from the listed type (or types) duction measures to control camber and differential
that most closely matches the function of the product. camber among the adjacent elements.
A dimensional layout and measurement plan is Refer to Article 8.17 for a definition and discussion
needed to control the production of precast elements of bowing, warping, and local smoothness toler·
so that the measurement process does not result in ances.
unintended accumulation oftolerances. For example,

31
Fig. 10.1.1 Architectural Wall Panels

.,

Allowable angle
~tationl 4

r- I
~
~ [/ I-:; .2
)
~+
~

'f-. I / ~

_, ~

I
I

a,
~

Arch1tet.iurally 1
exposed surface

Architectural panels

32
10.1 Architectural Wall Panels*

a1 = Overall height of unit measured at the face exposed to view:

Up to 10ft. [3m] .............................................. ±Vain. [±3 mm]
10 to 20ft. [3 to 6 m] .. .. .. .. .. .. .. .. .. . .. .. .. . .. .. + 'Ia in., - 31is [ +3 mm, -5 mm]
20 to 40ft. [6 to 12m] .......................................... ±'I• in. [±6 mm]
Greater than 40ft. [12m] ..................... ±V•s in. per 10ft. [±1.5 mm per 3m]
a2 Overall height of unit measured at the face not exposed to view:t
Up to 10ft. [3m] . . . . . . . . . .. . . . . . . . . . . .. . . . . . . .. .. . . . . . . . . . . . . . ±'I• in. [±6 mm]
10to20ft. [3to6m] .................................. +'/•in., -% [+6, -10mm]
20 to 40ft. [6 to 12m] ......................................... ±%in. [±10 mm]
Greater than 40ft. [12m] ....................... ±Vain. per 10ft. [±3 mm per 3m]
b = Overall width of unit measured at the face exposed to view:
Up to 10ft. [3m] .............................................. ± 1/a in. [±3 mm]
10to20ft. [3to6m] .............................. +Vain., - 31is[+3mm, -5mm]
20 to 40ft. [6 to 12m] .......................................... ±'I• in. [±6 mm]
Greater than 40ft. [12m] ..................... ±'lis in. per 10ft. [±1.5 mm per 3m]
b1 Rib width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±Vain. [±3 mm]
b2 = Distance between ribs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±Vain. [±3 mm]
b3 = Ribtoedgeofflange ........................................... ±Vain. [±3mm]
b8 = Overall width of unit measured at the face not exposed to view:
Up to 10ft. [3m] .............................................. ±V. in. [±6 mm]
10to20ft. [3to6m] ............................... +'!.in., -%in. [+6, -10mm]
20to40ft. [6to12m] ......................................... ±%in. [±10mm]
Greater than 40ft. [12m] ....................... ± 1/a in. per 10ft. [±3 mm per 3m]
c = Total thickness ....................................... + v. in., -Vain.[ +6, -3 mm]
c1 = Flange thickness ..................................... + v. in., -Vain. [ +6, -3 mm]
c2 Dimensions of haunches ........................................ ±'I• in. [±6 mm]
e = Variation* from square or designated skew ......... ±'Ia in. per 6ft., ±'12 in. minimum
[±3 mm per 2m, ±13 mm minimum]
h = Local smoothness, unconcealed surfaces ........... 'I• in. per 10ft. [±6 mm per 3m]
Bowing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ± Length/360, to a maximum of 1 in. [25 mm]
Warp (from adjacent corner} .................... 'lis in. per ft. [1.5 mm per 300 mm]
Location of weld plates ......................................... ±1 in. [±25 mm]
Tipping and flushness of plates .................................. ±'I• in. [±6 mm]
Allowable rotation of plate, channel insert, electrical box . . . . . . . . . . . . . . . . . . 2 degrees
............................ 'I• in. [6 mm] maximum measured at perimeter of insert
Haunch bearing surface tipping and flushness of bearing plates ..... ±Vain. [±3 mm]
Difference in relative position of adjacent haunch bearing
surfaces from specified relative position .......................... ±'I• in. [±6 mm]
Location of opening within panel ................................. ±'I• in. [±6 mm]
Length and width of blackouts and openings within one unit ±'I• in. [±6 mm]
Location and dimensions of blackouts hidden from
view and used for HVAC and utility penetrations .................. ±%in. [±19 mm]

33
 0 = Position of sleeve ............................................ . ± 1l2 in. [±13 mm]
p Position of insert .............................................. ±'12 in. [±13 mm]
q = Position of handling devices ........................... . ±3 in. [±75 mm]
r1 = Location of bearing surface from end of member . . . . . . . . . . . . . . . . . . ± 114 in. [±6 mm]
s1 = Reinforcing steel and welded wire reinforcement:
Where position has structural implications or affects concrete cover .. ±'/4 in. [±6 mm]
Otherwise .................................................... ±'12 in. [±13 mm]
s3 = Reinforcing steel extending out of member ....................... ±'12 in. [±13 mm]
s4 = Location of strand:
Perpendicular to panel........................... . . . . . . . . . . . . . . . ±%in. [±6 mm]
Parallel to panel ............................................... ±1 in. [±25 mm]

t1 Dimensions of architectural features and rustications . . . . . . . . . . . . . . . ±'Ia in. [±3 mm]

t2 = Location of rustication joints ..................................... ±'Is in. [±3 mm]

Wj = Location of flashing reg lets ...................................... ±'/4 in. [±6 mm]

w2 Location of flashing reglets at edge of panel ....................... ±'Ia in. [±3 mm]

w3 = Size of reglets for glazing gaskets ................................ ± 11a in. [±3 mm]
z Electrical outlets, hose bibs, etc ................................. ±'12 in. [±13 mm]

* Units shall be manufactured so that the face of each unit which is exposed to view after erection
complies with the following dimensional requirements.
t Unless joint width and fit-up requirements demand more stringent tolerance.
<Applies to both panel and to major openings in panel. Tolerances apply to the difference of the two
diagonal measurements.

34
This page is intentionally left blank.

35
Fig. 10.2.1 Solid or Insulated Flat Structural Wall Panels

c, i
-------------------------.- Cj t

Cross section
w
a

q, 10'

I:
'~
!3 h~
I
- - i
----+
~~ -B-j
-~
f----

I
;0
I n2
~IL
I
I i il1 '2

+~
I -®----
I
--EJ-
I
I
L
~
r-
I
i
n,
9 4

- n,
p

Plan

,,
Elevation

Solid or Insulated flat wall panels

36
10.2 Solid or Insulated Flat Structural Wall Panels

a = Length ....................................................... ±'12 in. [±13 mm]

b = Width (overall) ................................................. ±%in. [±6 mm]
c = Depth (overall) ................................................. ±'I• in. [±6 mm]

c1 = Wythe thickness .............................................. ±'Ia in. [±10 mm]

d = Variation from specified plan end squareness or skew
........................................ ± 1/a in. per 12 in. width, ±'12 in. maximum
[±3 mm per 300 mm width, ±13 mm maximum]
e = Variation from specified elevation end square ness or skew . . . . . . . . . . ± 'Ia in. per 12 in.
[±3 mm per 300 mm]
f Sweep ........................................ ± 1/a in. per 20ft., ±%in. maximum
[±3 mm per 6 m, ±10 mm maximum]
h Local smoothness of any surface ....................... V. in. in 10ft. [6 mm in 3 m]
= Bow ...................................................... Length/360 maximum
i1 = Differential bowing between adjacent panels of the same design ....... '12 in. [13 mm]
Warp (from adjacent corner) ................... 1As in. per foot [1.5 mm per 300 mm]

k1 = Location of strand perpendicular to plane of panel ................. ±'/• in. [±6 mm]

k2 Location of strand parallel to plane of panel ........................ ±1 in [±25 mm]

11 Location of embedment ........................................ ±1 in. [±25 mm]
12 Tipping and flushness of embedment . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±'I• in. [±6 mm]
13 Concrete surface between embedments to receive
continuous ledger, relative to plane of embedments . - v. in., +0 in. [- 6 mm, +0 mm]
n1 Location of blockout ............................................ ±1 in. [±25 mm]
n2 = Size of blockouts ............................................. ±'12 in. [±13 mm]
p = Location of inserts for structural connections ..................... ±'12 in. [±13 mm]

q1 Location of handling device parallel to length of panel ............. ±6 in. [±150 mm]
q2 = Location of handling device transverse to length of panel ........... ±1 in. [±25 mm]
r1 Location of haunch bearing elevation from end of panel ............ ±'/• in. [±6 mm]
r2 = Transverse distance between haunches . . . . . . . . . . . . . . . . . . . . . . . . . . ±'I• in. [±6 mm]

r3 Variation from specified haunch bearing surface slope

............................................. ±'Is in. per 18 in., ±'/• in. maximum
[±3 mm per 450 mm, ±6 mm maximum]
t1 = Size of architectural feature ..................................... ± 1/a in. [±3 mm]
t2 Location of architectural feature .................................. ± 1/a in. [±3 mm]
w Location of flashing reglet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±'I• in. [±6 mm]

37
Fig. 10.3.1 Ribbed Structural Wall Panels

~L
Cross section

----a---

J
p

Plan

'I I,
/f"\.. ~
I
I
I
L

jl ,,

Elevation

38
1 0.3 Ribbed Structural Wall Panels

a =Length ........................................................ ±'12 in. [±13 mm]

b = Width (overall) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±'!.in. [±6 mm]

b1 = Stem width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ± 11a in. [±3 mm]

b2 = Distance between stems ........................................ ±Vain. [±3 mm]

b3 = Stem to edge of top flange ...................................... ±Vain. [±3 mm]

c = Depth (overall) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±'!.in. [±6 mm]

c1 = Flange depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . + v. in., -Vain. [ +6 mm, -3 mm]

d = Variation from specified plan end squareness or skew
........................................ ± 11a in. per 12 in. width, ±V2 in. maximum
[±3 mm per 300 mm width, ±13 mm maximum]
e = Variation from specified elevation end squareness or skew
.......................................... ±Vain. per 12 in. [±3 mm per 300 mm]
f = Sweep, for member length:
Up to 40ft. [12m] ............................................. ±'I• in. [±6 mm]
40ft. [12m] or greater ........................................ ±'Ia in. [±10 mm]
h = Local smoothness of any surface ....................... v. in. in 10ft. [6 mm in 3m]
Bow ...................................................... Length/360 maximum
i1 = Differential bowing between adjacent panels of the same design ....... '12 in. [13 mm]
= Warp ........................................ 1As in. per foot [1.5 mm per 300 mm]

k = Location of strand .............................................. ±'I• in. [±6 mm]

11 Location of embedment ........................................ ±1 in. [±25 mm]
12 = Tipping and flushness of embedment ............................ ±V. in. [±6 mm]
13 Concrete surface between embedments to receive
continuous ledger, relative to plane of embedments . - v. in., +0 in. [ -6 mm, +0 mm]

n1 = Location of blackout ............................................ ±1 in. [±25 mm]

n2 = Size of rough opening .......................................... ±1 in. [±25 mm]

n3 = Size of finished opening ....................................... ±%in. [±13 mm]

p = Location of inserts for structural connections ..................... ±V2 in. [±13 mm]

q1 = Location of handling device parallel to length of panel ............. ±6 in. [±150 mm]

q2 = Location of handling device transverse to length of panel ........... ±1 in. [±25 mm]
r1 Location of haunch bearing elevation from end of panel ............. ±V.in. [±6 mm]

r2 = Transverse distance between haunches .......................... ±'!.in. [±6 mm]

r3 = Variation from specified haunch bearing surface slope
.............................................. ± 11a in. per 18 in., ±V. in. maximum
[±3 mm per 450 mm, ±6 mm maximum]
w = Location of flashing reglet ....................................... ±V. in. [±6 mm]

39
Fig 10 ..
41 Hollow-core Wall Panels

I.
b

c,~
~-

CC .O.GJ.u.O.C.Ow
c:T
0.
k1 f k
k

Cross section

d
n,

ll I. 10· •

1
ht
I --1
~
-

I n,[---tffi----
I
I
I
~
I
~ --~--_1
-;T i -;J
I,

Plan

l----- --- ---------------

= l-~=----d
~L Elevation

40
10.4 Hollow-core Wall Panels

a = Length ....................................................... ±V2 in. [±13 mm]

b = Width (overall) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±V.. in. [±6 mm]
b1 = Web width:
The total web width defined by the sum of the actual measured values of "b 1" shall not
be less than 85 percent of the sum of the nominal web widths "b 1, nomina!"
c = Depth (overall) ................................................. ±V. in. [±6 mm]
c1 = Top flange depth:
Top flange area defined by the actual measured values of average "c 1" x "b" shall not be
less than 85 percent of the nominal area calculated by "c1, nomina!" x "b nomina!"
c2 = Bottom flange depth:
Bottom flange area defined by the actual measured values of average "c2" x "b" shall not
be less than 85 percent of the nominal area calculated by "c2, nomina!" x "b nomina!"
d = Variation from specified plan end squareness or skew ............ ±'/'in. [±13 mm]
e = Variation from specified elevation end squareness or skew
.......................................... ±'AI in. per 12 in. [±3 mm per 300 mm]
Sweep ....................................................... ±'Ia in. [±10 mm]
h = Local smoothness of any surface ....................... 'I• in. in 10ft. [6 mm in 3 m]
= Bow ...................................................... Length/360 maximum

i1 = Differential bowing between adjacent panels of the same design ....... %in. [13 mm]
Warp ........................................ •;,, in. per foot [1.5 mm per 300 mm]
k Center of gravity (CG) of strand group ............................ ±V• in. [±6 mm]

k1 = Location of strand perpendicular to plane of panel ................ ±V2 in. [±13 mm]
Minimum cover .................................................. '~• in. [19 mm]

k2 Location of strand parallel to plane of panel ...................... ±%in. [±19 mm]

minimum cover .................................................. %in. [19 mm]
11 = Location of embedment* ....................................... ±1 in. [±25 mm]
12 = Tipping and flushness of embedment ............................ ±V. in. [±6 mm]
n1 Location of blackout ............................................ ±1 in. [±25 mm]
n2 = Size of blackouts ............................................. ±V2 in. [±13 mm]
X Weight:
Actual measured value shall not exceed 110 percent of the nominal published unit weight
used in the design.

*Some hollow-core production systems do not permit the incorporation of embedments. Contact
local producers for suitable alternate details if embedments are not practical.

41
Fig. 10.5.1 Brick Faced Architectural Elements

e c

=+== =4
Section A-A

42
10.5 Brick Faced Architectural Elements

a Alignment of mortar joints:

Jog in alignment ................................................. 'Ia in. [±3 mm]
Alignment with panel centerline ................................... ±'Ia in. [±3 mm]

b Variation in width of exposed mortar joints ......................... ±'Ia in. [±9 mm]

c ~ Tipping of individual bricks from the panel

plane of exposed brick surface . . . . . . . . . . . . + v,, in., - 'I• in, s depth of form liner joint
[+1.5 mm, -6 mm]

d ~ Exposed brick surface parallel to primary

control surface of panel .......................... . +'14 in., - 1.1! in.[+6 mm, -3 mm]

e ~ Individual brick step in face from panel

plane of exposed brick surface . . . . . . . . . . . . + v,, in., - V. in, s depth of form liner joint
[+1.5mm, -6mm]

Note: See other panel tolerances in Fig. 10.1.1.

43
Fig 10..
61 Double Tees (Untapped & Pretopped)

l I _:1
"'"'~'
~
w
-t-----! if+.,
-t-
I
r
lr b2
b-4J

I
L
b3

Cross Section

q2
r -
I.
10'

.I
-T
h!
~
.I - - - -

~~2
I I
I
~
'
=--1
'
- -
I '
' ~
l r- +
'

~T
J p

I,

n,
Plan

12

1\= ]
I
- - I • -

I
I
m2
I
t-r ' I

J k,

a
.I 9

.I .,j J
Elevation

44
10.6 Double Tees (Untapped & Pretopped)

a ; Length ........................................................ ±1 in. [±25 mm]

b Width (overall) ................................................. ±'I• in. [±6 mm]
b1 ; Stem width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±Vs in. [±3 mm]
b2 ; Distance between stems ........................................ ±V. in. [±6 mm]
b3 ; Stem to edge of top flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±V. in. [±6 mm]
c ; Depth (overall) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±'I• in. [±6 mm]
C1 ; Flange thickness................................ + 'I• in., -'h in. [ +6 mm, -3 mm]
d Variation from specified plan end squareness or skew
........................................ ±'Ia in. per 12 in. width, ±'12 in. maximum
[±3 mm per 300 mm width, ±13 mm maximum]
e ; Variation from specified elevation end squareness or skew:
24 in. [600 mm] or less depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±'I• in. [±6 mm]
Greater than 24 in. [600 mm] depth .............. ±Vs in. per 12 in., ±'12 in. maximum
[±3 mm per 300 mm, ±13 mm maximum]
f ; Sweep, for member length:
Up to 40ft. [12m] ............................................. ±V.in. [±6mm]
40 to 60ft. [12 to 18m] ........................................ ±'h in. [±10 mm]
Greater than 60ft. [18m] ...................................... ±'12 in. [±13 mm]
g ; Camber variation from design camber ............ ±'I• in. per 10ft.,±% in. maximum
[±6 mm per 3m, ±19 mm maximum]
g1 ; Differential camber between adjacent untapped members
ofthe same design to receive topping ............... 1J, in. per 10ft.,% in. maximum
[6 mm per 3m, ±19 mm maximum]
g2 Differential camber between adjacent pretopped members of the same design
.................................................. 'h in. per 10ft., 3h in. maximum
[3 mm per 3m, ±10 mm maximum]
h Local smoothness of any surface ....................... 'I• in. in 10ft. [6 mm in 3 m]
k Location of strand:
Individual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±'I• in. [±6 mm]
Bundled ..................................................... ±'12 in. [±13 mm]
k1 Location of harp points for harped strands from design location ... ±20 in. [±51 0 mm]
11 Location of embedment ........................................ ±1 in. [±25 mm]
12 ;
Tipping and flushness of embedment ............................ ±'I• in. [±6 mm]
m1 ;
Location of bearing assembly .................................. ±'l2 in. [±13 mm]
m2 ;
Tipping and flushness of bearing assembly ....................... ± 1/a in. [±3 mm]
n1 ; Location of blackout ............................................ ±1 in. [±25 mm]
n2 ; Size of blackouts ............................................. ±'12 in. [±13 mm]
o Location of sleeves cast in stems, in both horizontal and vertical plane ±1 in. [±25 mm]
o1 Skew of sleeve ends, vertical or horizontal, end to end* ........... ±'12 in. [±25 mm]
p ; Location of inserts for structural connections ..................... ±'12 in. [±13 mm]
q1 ; Location of handling device parallel to length of member .......... ±6 in. [±150 mm]
q2 ; Location of handling device transverse to length of member ......... ±1 in. [±25 mm]
* If skew tolerance of sleeves cast in stems is important for the function or other reason, it should be
treated as a special project tolerance.

45
Fig 1o. 7 1 Single Tees (Untapped and Pretopped)

Cross section

n,

Plan

12
r
I~
- 12 ]
I - I + -
I
m2L I
J
II
k,
rgr T
I
I

mj t--
0

a
.I
Elevation

46
10. 7 Single Tees (Untapped and Pretopped)

a = Length ........................................................ ±1 in. [±25 mm]

b = Width (overall) ................................................. ±'I• in. [±6 mm]
b1 = Stem width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±V. in. [±6 mm]
b2 = Stem to edge of top flange ...................................... ±'I• in. [±6 mm]
c = Depth (overall) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±'I• in. [±6 mm]
C1 Flange thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . + V. in., - 'Ia in. [ +6 mm, -3 mm]
d Variation from specified plan end squareness or skew
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ± 'Ia in. per 12 in. width, ± '12 in. maximum
[±3 mm per 300 mm width, ±13 mm maximum]
e = Variation from specified elevation end squareness or skew:
Greater than 24 in. [600 mm] depth .............. ±'Ia in. per 12 in., ±'12 in. maximum
[±3 mm per 300 mm, ±13 mm maximum]
24 in. [600 mm] or less depth ................................... ±'I• in. [±6 mm]
f = Sweep, for member length:
Up to 40ft. [12m] ............................................. ±'I• in. [±6 mm]
40to60ft. [12to18m] ........................................ ±'hin. [±10mm]
Greater than 60ft. [18m] ...................................... ±'12 in. [±13 mm]
g Camber variation from design camber ............ ±V. in. per 10ft., ±%in. maximum
[±6 mm per 3m, ±19 mm maximum]
g1 = Differential camber between adjacent untopped members of the same
design to receive topping . . . . . . . . . . . . . . . . . . . . . . . . . . V. in. per 10ft., %in. maximum
[6 mm per 3m, ±19 mm maximum]
g2 Differential camber between adjacent pretopped members of the same
design ............................................ 'Ia in. per 10ft., 'h in. maximum
[3 mm per 3m, ±10 mm maximum]
h = Local smoothness of any surface ....................... v. in. in 10ft. [6 mm in 3 m]
k = Location of strand:
Individual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±V. in. [±6 mm]
Bundled ..................................................... ±'12 in. [±13 mm]
k1 Location of harp points for harped strands from design location ... ±20 in [±510 mm]
11 = Location of embedment ........................................ ±1 in. [±25 mm]
12 = Tipping and flushness of embedment ............................ ±'I• in. [±6 mm]
m1 = Location of bearing assembly .................................. ±'12 in. [±13 mm]
m2 = Tipping and flushness of bearing assembly ....................... ±'Ia in. [±3 mm]
n1 = Location of blockout ............................................ ±1 in. [±25 mm]
n2 = Size of blockouts ............................................. ±'12 in. [±13 mm]
0 = Location of sleeves cast in stems, in both horiz. and vertical planes .. ±1 in. [±25 mm]
01 = Skew of sleeve ends, vertical or horizontal, end to end* ........... ±'12 in. [±25 mm]
p = Location of inserts for structural connections ..................... ±'12 in. [±13 mm]
q1 = Location of handling device parallel to length of member .......... ±6 in. [±150 mm]
q2 = Location of handling device transverse to length of member ......... ±1 in. [±25 mm]
*If skew tolerance of sleeves cast in stems is important for the function or other reason, it should be
treated as a special project tolerance.

47
Fig. 10.8.1 Columns

Cross section

,,

!
-------~~~~I'L_@~~PL_~-==~~hj~----~~~1
JL
I
LJ
JL
Ll z

-- I I-- 1
~ e

Plan

lr lz + 'lr
I
I
qzl o
t I
I
I
L
j
I
,T
Elevation

48
10.8 Columns

a = Length ....................................................... ±'/'in. [±13 mm]

b = Width ......................................................... ±'!.in. [±6 mm]
c = Depth ........................................................ ±'/• in. [±6 mm]
d = Variation from specified plan end squareness or skew
.............................................. ±Vs in. per 12 in., ±%in. maximum
[±3 mm per 300 mm, ±10 mm maximum]
e = Variation from specified elevation end squareness or skew
.............................................. ±Vs in. per 12 in., ±'Is in. maximum
[±3 mm per 300 mm, ±10 mm maximum]
f = Sweep ........................................ ±'h in. per 10ft., ±V2 in. maximum
[±3 mm per 3m, ±13 mm maximum]
h = Local smoothness of any surface ....................... V. in. in 10ft. [6 mm in 3m]
k = Location of strand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±V. in. [±6 mm]
11 = Location of embedment ........................................ ±1 in. [±25 mm]
12 = Tipping and flushness of embedment . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±V. in. [±6 mm]
p Location of inserts for structural connections ..................... ±V2 in. [±13 mm]
q1 = Location of handling device parallel to length of member .......... ±6 in. [±150 mm]
q2 = Location of handling device transverse to length of member ......... ±1 in. [±25 mm]
r1 = Location of haunch bearing elevation from end . . . . . . . . . . . . . . . . . . . . ±V. in. [±6 mm]
r2 Variation from specified haunch bearing surface slope
.............................................. ±'h in. per 12 in., ±%in. maximum
[±3 mm per 300 mm, ±10 mm maximum]
z = Base plate overall dimensions ................................... ±V. in. [±6 mm]

49
Fig 10..
91 Building Beams and Spandrel Beams

b, b,

:' :'
SJ t
1
n n
,---

~~~
c

k+ 1 ~-~-l3
- b,r n
-+13
c

LJ i
I. b .I
Cross sections
u
q,

0
.----
n q=-l
~-
/
I.
-
10'

"'
.I
----~
ht
t
I
~~
I

I --$- -rt~- -----{2

I
~
l +- ,T-+
_Jd - I,

Plan

s,

I,
SJ
lr !'''

-----
!I

II--- - ~
I
I
I
~
- - r-r+ -------- ~

m, I

Jl k, .I g
m, 1J
I~ Elevation
a

50
10.9 Building Beams and Spandrel Beams

a = Length ....................................................... ±%in. [±19 mm]

b = Width (overall) ................................................. ±V. in. [±6 mm]

b1 = Stem width .................................................... ±V. in. [±6 mm]

b2 = Ledge width ................................................... ±V. in. [±6 mm]

c = Depth (overall) ................................................. ±'I• in. [±6 mm]

Cj = Ledge depth .................................................. ±'I• in. [±6 mm]

d Variation from specified plan end squareness or skew

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ± 'Ia in. per 12 in. width, ± '12 in. maximum
[±3 mm per 300 mm width, ±13 mm maximum]
e = Variation from specified elevation end squareness or skew
........................................ ±'h in. per 12 in. depth, ±'12 in. maximum
[±3 mm per 300 mm, ±13 mm maximum]
f = Sweep, for member length:
Up to 40ft. [12m] ............................................. ±'I• in. [±6 mm]
40 to 60ft. [12 to 18m] ........................................ ±'l2 in. [±13 mm]
Greater than 60ft. [18m] ...................................... ±%in. [±16 mm]
g = Camber variation from design camber . . . . . . . . . . . . ± 'Ia in. per 10ft., ±% in. maximum
[±3 mm per 3m, ±19 mm maximum]
h = Local smoothness of any surface ....................... V. in. in 10ft. [6 mm in 3 m]
k = Location of strand:
Individual ..................................................... ±'I• in. [±6 mm]
Bundled ..................................................... ±'12 in. [±13 mm]
k1 Location of harp points for harped strands from design location for member length:
30ft.[9m]orless ............................................ ±6in.[±150mm]
Greater than 30ft. [9 m] ...................................... ±12 in. [±300 mm]

11 Location of embedment ........................................ ±1 in. [±25 mm]

12 = Tipping and flushness of embedment ............................ ±V. in. [±6 mm]

m1 = Location of bearing assembly .................................. ±'l2 in. [±13 mm]

m2 = Tipping and flushness of bearing assembly ....................... ±'Ia in. [±3 mm]
0 = Location of sleeves cast in stems, in both horiz. and vertical planes .. ±1 in. [±25 mm]
p = Location of inserts for structural connections ..................... ±'12 in. [±13 mm]
q1 = Location of handling device parallel to length of member ......... ±12 in. [±300 mm]

q2 = Location of handling device transverse to length of member ........ ±'12 in. [±13 mm]
Sj Longitudinal spacing of stirrups .................................. ±2 in. [±50 mm]
s2 = Longitudinal spacing of stirrups within distance "c" from member ends
.............................................................. ±1 in. [±25 mm]
S3 = Stirrup projection from beam surface ............. + V. in., - 'l2 in. [ +6 mm, -13 mm]

51
Fig. 10.10.1 I Beams (Girders) or Bulb Tee Girders

Cross section Cross section

10"

1· ~
·1 h~

I -~
/
"-- t
I q2
~- -t_~- ~~- -~-- - - - --f~

1- •J p

I. 11
.I
Plan
LJ

''
'''
' ' I

J I: ----~----~f·r-------;;, .,J_~

Elevation

52
10.10 I Beams (Girders) or Bulb Tee Girders

a Length ................................... ±'I• in. per 25ft. length, ±1 in. maximum

[±6 mm per 7.5 m length, ±25 mm maximum]
b = Width (overall) ................................... +'Ia in., -'I• in. [10 mm, -6 mm]
b1 = Web width .................................... +'Ia in., -'I• in. [+10 mm, -6 mm]
c Depth (overall) ................................. +'l2 in., -'I• in. [+13 mm, -6 mm]
c1 Flange depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±'I• in. [±6 mm]
d Variation from specified plan end squareness or skew
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±'Is in. per 12 in. width, ± '12 in. maximum
[±3 mm per 300 mm width, ±13 mm maximum]
e = Variation from specified elevation end squareness or skew
........................................ ± 3!1s in. per 12 in. depth, ±1 in. maximum
[±5 mm per 300 mm, ±25 mm maximum]
Sweep . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 'h in. per 10ft. length
[3 mm per 3 m length]
g Camber variation from design camber ............ ±'Is in. per 10ft. [±3 mm per 3m]
................................. 'l2 in. [13 mm] maximum up to 80ft. [24 m]length
........................ 1 in. [25 mm] maximum for length greater than 80ft. [24m]
h = Local smoothness of any surface ....................... V. in. in 10ft. [6 mm in 3 m]
k = Location of strand*
Individual ..................................................... ±'I• in. [±6 mm]
Bundled ..................................................... ±'12 in. [±13 mm]
k1 Location of harp points for harped strands from design location ... ±20 in. [±510 mm]
k2 = Location of post-tensioning duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±'I• in. [±6 mm]
11 = Location of embedment ........................................ ±1 in. [±25 mm]

12 Tipping and flushness of embedment ............................ ±'I• in. [±6 mm]

m1 = Location of bearing assembly .................................. ±'Ia in. [±16 mm]

m2 = Tipping and flushness of bearing assembly ....................... ±'Ia in. [±3 mm]
p Location of inserts for structural connections ..................... ±'12 in. [±13 mm]

q1 = Location of handling device parallel to length of member .......... ±6 in. [±150 mm]

q2 Location of handling device transverse to length of member ......... ±1 in. [±25 mm]
s1 = Longitudinal spacing of stirrups .................................. ±2 in. [±50 mm]

s2 = Longitudinal spacing of stirrups within dist. "c" from member ends ... ±1 in. [±25 mm]

s3 Stirrup projection from beam surface ............. ±V. in., -'12 in. [±6 mm, -13 mm]

• The location of harped strand at the end of the beam may be controlled to ±'12 in. [±13 mm] provid-
ing that calculations show that such a variation will not result in unacceptable stresses at any design
load condition.

53
Fig. 10.11.1 Box Beams

•••••• ·-1---_I

c2

Cross section

.,
10"

1· ·1
~ --~- ~---~ --- ----
L.._-J/1----1--1- - + - - -~- 1' II

pc*- p
~-------
-----------1----,~--0~-0~
__ II _ _ _ _ }
J-
d I,

Plan

s,

12
s2 ~ II
T T T

I t I i I l
~-----
I -- - ~-=+-
I I I

-- -
-:J_.

I
I
-
I - -~ 02
l_:_J I

I I
gr
J .I ~r "'J~
:
k,

Elevation

54
10.11 Box Beams
a = Length ....................................................... ± 3/4 in. [±19 mm]

a1 = Lengthofvoidform ........................... +1 in., -6in. [+25mm, -150mm]

b = Width (overall) ................................................. ±'I• in. [±6 mm]

b1 = Web width ................................................... ±'Ia in. [±10 mm]

c = Depth (overall) ................................................. ±'!.in. [±6 mm]

c1 = Top flange depth .............................................. ±'12 in. [±13 mm]

~ = Bottom flange depth . . . . . . . . . . . . . . . . . . . . . . . . . . . + '12 in., -'Ia in. [ + 13 mm, -3 mm]

d = Variation from specified plan end squareness or skew

........................................ ± 1h in. per 12 in. width, ±'12 in. maximum
[±3 mm per 300 mm width, ±13 mm maximum]
e = Variation from specified elevation end squareness or skew ......... ± 112 in. [±13 mm]
f Sweep, for member length:
Up to 40ft. [12m] ............................................. ±'!.in. [±6 mm]
40 to 60ft. [12 to 18m] ........................................ ±'Ia in. [±10 mm]
Greater than 60ft. [18m] ...................................... ±'12 in. [±13 mm]
g Camber variation from design camber ............ ±'Ia in. per 10ft., ±'12 in. maximum
[±3 mm per 3m, ±13 mm maximum]
g1 = Differential camber between adjacent members of the same design
................................................. 'I• in. per 10ft.,% in. maximum
[6 mm per 3m, 19 mm maximum]
h = Local smoothness of any surface ....................... 'I• in. in 10ft. [6 mm in 3 m]
k Location of strand (individual and bundled)* ...................... ±'I• in. [±6 mm]
k1 = Location of harp points for harped strands from design location ... ±20 in. [±51 0 mm]
k2 = Location of post-tensioning duct ................................ ±'!.in. [±6 mm]
11 Location of embedment ........................................ ±1 in. [±25 mm]
12 = Tipping and flushness of embedment . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±'I• in. [±6 mm]

m1 = Location of bearing assembly .................................. ±'Is in. [±16 mm]

m2 Tipping and flushness of beam seat bearing surface ............... ± 11a in. [±3 mm]

01 = Location of sleeve at connection to support . . . . . . . . . . . . . . . . . . . . . . ±'Is in. [± 16 mm]

02 = Location of tie-rod sleeve (horizontal) ............................ ±'12 in. [±13 mm]

Vertical ...................................................... ±'Ia in. [±10 mm]
p Location of inserts for structural connections ..................... ±'12 in. [±13 mm]

q1 = Location of handling device parallel to length of member .......... ±6 in. [±150 mm]

q2 = Location of handling device transverse to length of member ......... ±1 in. [±25 mm]

51 = Longitudinal spacing of stirrups .................................. ±1 in. [±25 mm]

52 Stirrup projection from beam surface ............. +'!. in., -'12 in. [+6 mm, -13 mm]
u = Location of void relative to design center location . . . . . . . . . . . . . . . . . ± '12 in. [ ± 13 mm]
From end of beam .............................. +3 in., -1 in. [675 mm, -25 mm]
• The location of harped strand at the end of the beam may be controlled to ± '12 in. [± 13 mm] if cal-
culations show that the variation will not result in unacceptable stress at any design load.

55
Fig. 10.12.1 Poles

b, b, b,
_:1
r
c

b3
0

Sections

n p o,
t+-
I ·- J ·-
t-
I
I
t • •
I
I [g) 0 0
I
I
j
L
f t
d,J - o,

Elevations

56
10.12 Poles

a = Length ............................. ±Vain. per 10ft. or ±2 in., whichever is greater

[±3 mm per 3m or ±50 mm, whichever is greater]

b1 = Width, static cast poles

Less than 24 in. [600 mm] width ................................ ±%in. [±10 mm]
24 to 36 in. [600 to 900 mm] width .............................. ±%in. [±13 mm]
Greater than 36 in. [900 mm] width ............................. ±'Ia in. [±16 mm]

b2 Diameter, spun poles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±'I• in. [±6 mm]

b3 = Wall thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±'!.in. [±6 mm]

or + 20, -1 0 percent of nominal thickness, whichever is greater

c = Depth, static cast poles:

Less than 24 in. [600 mm] width ................................ ±%in. [±10 mm]
24 to 36 in. [600 to 900 mm] width .............................. ±V2 in. [±13 mm]
Greater than 36 in. [900 mm] width ............................. ±'Ia in. [±16 mm]

c1 = Flange thickness ............................................... ±V• in. [±6 mm]

d = Variation from specified plan end squareness or skew

Top .......................................................... ±'/.in. [±6mm]
Bottom ...................................................... ±1 in. [±25 mm]

e = Variation From Specified Elevation End Squareness or Skew

Top .......................................................... ±V. in. [±6 mm]
Bottom ...................................................... ±1 in. [±25 mm]

f = Sweep ............................ ±V• in. per 10ft. or ± 1/2 in., whichever is greater
[±6 mm per 3m or ±13 mm, whichever is greater]

k = Location of strand .............................................. ±'I• in. [±6 mm]

n Location of blockout ............................................ ±1 in. [±25 mm]

01 = Location of sleeve .............................................. ±1 in. [±25 mm]

02 Location of sleeve for matching hardware pattern . . . . . . . . . . . . . . . . . . ± 'h in. [ +3 mm]

p = Location of insert for matching hardware pattern ................... ±'h in. [ +3 mm]

X = Weight ............................................. ±8 percent of nominal weight

57
 .
Fig 10 13.1 Hollow-core Slabs

I c, ~ I

f/.O.W.U.G.Q.O.~l
i cJ k,
k2

Cross section

d 10'

ll I. .I 11_
I,

- L
I
I
- - ~

~r-- I
I,

I
-t-- -

I
I
I
I ~
n
I>KI
f
+--- ~

I I_ n,
I
a

Plan

12

-- -- -
- ----- -
-
- -
--
1------ - --I

J~
Elevation

58
10.13 Hollow-core Slabs

a = Length ....................................................... ± 112 in. [±13 mm]

b = Width (overall) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±'/• in. [±6 mm]
b1 = Web width:
The total web width defined by the sum of the actual measured values of "b1" shall not
be less than 85 percent of the sum of the nominal web widths "b1, nomina!"
c = Depth (overall) ................................................. ±'/• in. [±6 mm]
c1 = Top flange depth:
Top flange area defined by the actual measured values of average "c1" x "b" shall not be
less than 85 percent of the nominal area calculated by "c1, nomina!" x "b nomina!"
c2 = Bottom flange depth:
Bottom flange area defined by the actual measured values of average "c2" x "b" shall not
be less than 85 percent of the nominal area calculated by "c2. nomina!" x "b nominal"
d = Variation from specified plan end squareness or skew ............ ±'12 in. [±13 mm]
e = Variation from specified elevation end squareness or skew
.............................................. ±Vein. per 12 in., ±'12 in. maximum
[±3 mm per 300 mm, ±13 mm maximum]
Sweep ....................................................... ±'Is in. [±10 mm]
g = Applications requiring close control of differential camber between adjacent members
should be discussed with the producer to determine applicable tolerances.
h = Local smoothness of any surface ....................... v. in. in 10ft. [6 mm in 3m]
k = Center of gravity (CG) of strand group . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±V. in. [±6 mm]
k1 = Location of strand perpendicular to plane of panel ................ ± 112 in. [±13 mm]
Minimum cover ................................................... %in. [19 mm]
k2 Location of strand parallel to plane of panel ...................... ±%in. [±19 mm]
Minimum cover ................................................... %in. [19 mm]
11 = Location of embedment* ....................................... ±2 in. [±50 mm]
12 = Tipping and flushness of embedment . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±V• in. [±6 mm]
n1 = Location of blockout ............................................ ±2 in. [±50 mm]
n2 Size of blockouts ............................................. ± 112 in. [±13 mm]
X = Weight:
Actual measured value shall not exceed 110 percent of the nominal published unit weight
used in the design.

• Some hollow-core production systems do not permit the incorporation of embedments. Contact
local producers for suitable alternate details if embedments are not practical.

59
Fig. 10.14.1 Piling (Hollow and Solid)

b b b
.I
~~
•
w
----- _ _j
J
·0·
~ bd

Cross sections

/f--- ----------------- -j---- ---------------

/ f-- - - - - - - - - - - - - - - - - - - - - - - -r_-------------
~-

d.J L
L --
--
1. h t10'
.I
Side

60
10.14 Piling (Hollow and Solid)

a = Length* ....................................................... ±1 in. [±25 mm]

b = Width or diameter ............................................. ±'Is in. [±10 mm]

b1 = Wall Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . + '12 in., - V. in. [ + 13 mm, -6 mm]

c = Depth ....................................................... ±'Is in. [±10 mm]

d = Variation from specified plan end squareness or skew

.............................................. ±V• in. per 12 in., ±V2 in. maximum
[±6 mm per 300 mm, ±13 mm maximum]

e = Variation from specified elevation end squareness or skew

.............................................. ±V• in. per 12 in., ±V2 in. maximum
[±3 mm per 300 mm, ±13 mm maximum]

f = Sweep ........................................ ±Vain. per 10ft. [±3 mm per 3m]

h = Local smoothness of any surface ....................... v. in. in 10ft. [6 mm in 3m]

k = Location of strand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±V. in. [±6 mm]

q = Location of handling device .................................... ±6 in. [±150 mm]

s Longitudinal spacing of stirrups or spiral reinforcement ........... ±%in. [±19 mm]

z = Location of driving tip .......................................... ±V2 in. [±13 mm]

• Controlling pile length to +6 in., -2 in. [+150 mm, -50 mm] is acceptable in most cases.

61
Fig. 10.15.1 Tee Joists/Keystone Joists
b

_ q,::). 'L __ L
q2 /- ~ =========-1 =====-· 4=== ·-=
'=~------E-----+-------
L ------- ~T---=_T---------~==f===
cJ 11 1J J at --,, 10" .I hT-
0

Plan

51
1/ 521
rrr___j

Elevation

62
10.15 Tee Joists/Keystone Joists

a = Length ........................................................ ±1 in. [±25 mm]

b = Width (overall) ................................................. ±'I• in. [±6 mm]

b1 = Stem width .................................................... ± 1/a in. [±3 mm]

c = Depth (overall) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±'I• in. [±6 mm]

c1 = Flange thickness................................ + 'I• in., - 1/a in. [ +6 mm, -3 mm]

d = Variation from specified plan end squareness or skew
........................................ ±V• in. per 12 in. width, ±V' in. maximum
[±6 mm per 300 mm width, ±13 mm maximum]
e = Variation from specified elevation end squareness or skew
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ± 'I• in. per 12 in. height, ± Y, in. maximum
[±6 mm per 300 mm height, ±13 mm maximum]
f = Sweep, for member length:
Up to 40ft. [12m] ............................................ ±%in. [±10 mm]
40to60ft. [12to18m] ........................................ ±'lain. [±16mm]
Greater than 60ft. [18m] ...................................... ±%in. [±19 mm]
g Camber variation from design camber .............. ±'I• in. per 10ft.,% in. maximum
[±6 mm per 3m, 19 mm maximum]
h = Local smoothness of any surface ....................... v. in. in 10ft. [6 mm in 3m]
k = Location of strand
Individual ..................................................... ±V. in. [±6 mm]
Bundled ..................................................... ±V, in. [±13 mm]

k1 = Location of harp points for harped strands from design location ... ±20 in [±510 mm]
11 = Location of embedment ........................................ ±1 in. [±25 mm]
12 = Tipping and flushness of embedment . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±'I• in. [±6 mm]
m1 = Location of bearing assembly .................................. ±V2 in. [±13 mm]
m2 = Tipping and flushness of bearing assembly ....................... ±Vain. [±3 mm]
0 = Location of sleeves cast in stem, in both horiz. and vertical plane ±1 in. [±25 mm]
p = Location of insert for structural connections .................. . ±Y, in. [±13 mm]

Q1 = Location of handling device parallel to length of member .......... ±6 in. [±150 mm]
q2 = Location of handling device transverse to length of member ......... ±1 in. [±25 mm]
51 = Longitudinal spacing of stirrups .................................. ±2 in. [±50 mm]
52 Stirrupprojectionfrombeamsurface ............. +'/•in., -Y,in. [+6mm, -13mm]

63
F"IQ. 10.16 ·1 Step Units

a d

- I l
I
I
I

b I-
,, I
I
~
I
I
j I

~
I

I I, I ~
I

!
Plan

Elevation

64
10.16 Step Units

a = Length ....................................................... ±Y, in. [±13 mm]

b = Width (overall) ................................................ ± 3/8in. [±10mm]

b1 = Individual tread width (not cumulative) . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±'I• in. [±6 mm]

c = Depth (overall) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±'I• in. [±6 mm]

c1 Individual riser depth (not cumulative) ............................ ± 3As in. [±5 mm]

c2 = Riser variation from specified plane ................ + '18 in., -0 in. [ +3 mm, -0 mm]

c3 = Differential height between adjacent risers* . . . . . . . . . . . . . . . . . . . . . . . ±V. in. [±6 mm]

d = Variation from specified plan end squareness or skew

........................................ ±Vs in. per 12 in. width, ±V2 in. maximum
[±3 mm per 300 mm width, ±13 mm maximum]

e = Variation from specified elevation end squareness or skew . . . . . . . . . . ±V. in. [±6 mm]

Warp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±'I• in. [±6 mm]

11 = Location of embedment ........................................ ±1 in. [±25 mm]

12 = Tipping and flushness of embedment . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±'Is in. [±3 mm]

p = Location of inserts for structural connections ..................... ±%in. [±10 mm]

* Local building codes may restrict the maximum height differential between risers. The building
code shall govern.

65
Fig. 10.17.1 Sheet Piling

JL
Elevation

Section

.---- ,..--~=-=-=--=------_--_--_-_--_-_--_-_-------------~..L_-_--_-_--_--_-_--_-_--_-_--_-+-.....:-=--=-=-=~.....,
•
I I
I
n 1 Stirrups
n I A
I I/
~----t-t-1~
i I
I I
I I
I I
I I

-------------------------------------------------------1-------L __ l____
I I

l
I

Plan

66
10.11 Sheet Piling

a = Length ........................................................ ±1 in. [±25 mm]

b = Width ........................................................ ±%in. [±10 mm]

c = Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±'I• in. [±6 mm)

c, = Flange depth ................................................. ±'l2 in. [±13 mm]

d = Variation from specified plan end squareness or skew

.............................................. ±'I• in. per 10ft.• ±'12 in. maximum
[±6 mm per 3m. ±13 mm maximum)

e = Variation from specified plan end squareness or skew .............. ±'I• in. [±6 mm]

= Sweep ........................................ ±'AI in. per 10ft. [±3 mm per 3m)

h = Local smoothness of any surface ....................... v. in. in 10ft. [6 mm in 3 m]

k, = Location of strand perpendicular to plane of panel ................. ±'I• in. [±6 mm]

k2 = Location of strand parallel to plane of panel ....................... ±1 in. [±25 mm]

n = Location of blockout ............................................ ±1 in. [±25 mm)

q, = Location of handling device parallel to length of member .......... ±6 in. [±150 mm]

q2 = Location of handling device transverse to length of member ........ ±'12 in. [±13 mm]

q3 = Projection of handling device ................................... ±'l2 in. [±13 mm)

s = Longitudinal spacing of stirrups ................................. ±%in. [±19 mm]

u, = Transverse location of voids .................................... ±'12 in. [±13 mm]

U2 = Vertical location of voids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±'I• in. [±6 mm]

u3 Longitudinal location of voids ................................... ±'12 in. [±13 mm]

67
Fig. 10.18.1 Stadium Riser

Single riser section

~
I
""' r 1
I

a m2 __J m 1• r--
Elevation

r Centerline of hole at
connection to support a

Plan

Relative warp over

length of riser

Multi-riser section A Multi-riser section B

68
10.18 Stadium Riser

a = Length ....................................................... ±'12 in. [±13 mm]

b = Width (overall) ................................................. ±V. in. [±6 mm]

b1 = Stem width .................................................... ±Vain. [±3 mm]

b2 = Individual tread width (not cumulative) . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±Vs in. [±3 mm]

c = Depth (overall) ................................................. ±V• in. [±6 mm]

C1 = Flange thickness ................................................. + v. in., - Va in.

[ +6 mm, -3 mm]
c2 = Individual riser depth (not cumulative) . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±Vain. [±3 mm]
c3 = Riser variation from specified plane ................ + Va in., -0 in. [ +3 mm, -0 mm]
d = Variation from specified plan end squareness or skew
........................................ ±Vain. per 12 in. width, ±V. in. maximum
[±3 mm per 300 mm width, ±6 mm maximum]
e = Variation from specified elevation end squareness or skew
....................................... ±V. in. per 12 in. height, ±V2 in. maximum
[±6 mm per 300 mm height, 13 mm maximum]
f = Sweep .................................. ±'I• in. per 40ft. length, ±%in. maximum
[±6 mm per 12m length, 10 mm maximum]
g Camber variation from design camber
.............................................. ±V. in. per 10ft., ±'12 in. maximum
[±6 mm per 3m, 13 mm maximum]
g1 = Differential camber between adjacent units of the same design
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v.
in. per 10ft., '12 in. maximum
[6 mm per 3m, 13 mm maximum]
h = Local smoothness of any surface ....................... 'I• in. in 10ft. [6 mm in 3 m]

= Warp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±V. in. [±6 mm]

k = Location of strand .............................................. ±'I• in. [±6 mm]
11 = Location of embedment ........................................ ±1 in. [±25 mm]

12 = Tipping and flushness of embedment ............................ ±'I• in. [±6 mm]

m1 = Location of bearing assembly .................................. ±'12 in. [±13 mm]

m2 Tipping and flushness of bearing assembly ....................... ±Vs in. [±3 mm]

n1 = Location of blockout ............................................ ±1 in. [±25 mm]

n2 = Size of blockouts .............................................. ±1 in. [±25 mm]

0 Location of sleeves at connection to support ..................... ±'12 in. [±13 mm]
p = Location of inserts ............................................ ±'12 in. [±13 mm]

q1 = Location of handling device parallel to length of member .......... ±6 in. [±150 mm]

q2 = Location of handling device transverse to length of member ......... ±1 in. [±25 mm]

69
Fig. 10.19.1 Multi-Stemmed Bridge Units

b
~--

c, ~ I I I i I "l
t- r. I

I
I

I'
I

I
!

I
J -i
c,

c
kL.
~~
m3L
I I
I
I
I
I
I
- I
'
b,
i il
b '--:-
I I ::_l_.JI'--

Cross section

- ---- ------------- __rj_-- ------ ---------~----

n, I
- i •
q,
-
I
I
I

~~
Jn, i b

I
I
I
I

- 1 -
L

Plan

q,
r---,
I I
''L - i
I
h
I

I
I I
I
I
I
i I
I
I
I
I

,f - - - - - ------ -
I
. . .
- -- -- ----o·-
.

--=~=~l~=-=:.-=-~=~=---
I
0
I
I m,l
I
L - -

I--
gi k,
i __jm, 1--
a

Elevation

70
10.19 Multi-Stemmed Bridge Units

a = Length ....................................................... ±%in. [±19 mm]

b = Width (overall) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±'I• in. [±6 mm]

b1 = Stem width .................................................... ±'I• in. [±6 mm]

b2 = Distance between stems ........................................ ±'AI in. [±3 mm]

b3 = Stem to edge of top flange ...................................... ±V. in. [±6 mm]

b4 = Shear key width ............................................... ±'I• in. [±6 mm]

c = Depth (overall) ................................................. ±'I• in. [±6 mm]

C1 = Flange thickness ................................ + y, in., -'AI in. [ +6 mm, -3 mm]

c2 = Shear key depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±V. in. [±6 mm]

d Variation from specified plan end squareness or skew ............. ±%in. [±19 mm]

e = Variation from specified elevation end squareness or skew ......... ±%in. [±19 mm]

f Sweep, for member length:

Up to 40ft. [12m] ............................................. ±V. in. [±6 mm]
40 to 60ft. [12 to 18m] ........................................ ±'Ia in. [±10 mm]
Greater than 60ft. [18m] ...................................... ±'12 in. [±13 mm]
g = Camber variation from design ................... ±V• in. per 10ft., ±%in. maximum
[±6 mm per 3m, ±19 mm maximum]
g1 = Differential camber between adjacent units of the same design
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V. in. per 10ft., 31• in. maximum
[6 mm per 3m, 19 mm maximum]
k = Location of strand:
Individual ..................................................... ±'I• in. [±6 mm]
Bundled ..................................................... ± 1l2 in. [±13 mm]

k1 = Location of harp points for harped strands from design location .... ±6 in [±150 mm]

11 = Location of embedment ........................................ ±1 in. [±25 mm]

12 = Tipping and flushness of embedment . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±V. in. [±6 mm]

m1 = Location of bearing assembly .................................. ±'12 in. [±13 mm]

m2 Tipping and flushness of bearing assembly . . . . . . . . . . . . . . . . . . . . . . . ±'Ia in. [±3 mm]

m3 = Differential elevation of bearing surface between stems ............. ±'/16 in. [±2 mm]

n1 Location of blackout ............................................ ±1 in. [±25 mm]

n2 = Size of blackouts .............................................. ±1 in. [±25 mm]

0 = Location of sleeves cast in stems, in both
horizontal and vertical plane . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . ± '12 in. [ ± 13 mm]
p = Location of inserts for structural connections ..................... ±'/2 in. [±13 mm]

q1 = Location of handling device parallel

to length of member ........................................... ±6 in. [±150 mm]

q2 = Handling device location transverse to member length ............. ±1 in. [±25 mm]
s = Longitudinal spacing of stirrups .................................. ±1 in. [±25 mm]

71
Fig. 10.20.1 Modular Room Unit

a a,

,--c,
'
I,

---~--t D
I
: ----r~r--=-----.-----~
I \
I I z I

c
.---~~-+~--
\ I D ~I\
I I ;-73 n
'21--q--~ :
z 1

j I n L
Elevation

I I I

r-----------, r------
-
: : 1
I
l J
--- ~~,,,
/
/
/
/
/

a ) r
I I I Recess
I I I
I I I
I b I I
,____ 1 I I
I I I
I I I
I I I
L--------------~ L------r---
________ 1_ __

a,
I- ----~~~============= -------
:r-- 12
:----=
I
/1
/ I
I
'-----L------------' L _ _ _ __ I
I

L___ -.1 --=----b ~

I

Plan Tilt

72
10.20 Modular Room Unit

a Length ....................................................... ±%in. [±10 mm]

a1 = Length of balcony extension ..................................... ±'I• in. [±6 mm]

b = Width (overall):
Single unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ± 'I• in. [±6 mm]
Multiple unit .................................................. ± 1/2 in. [±13 mm]

b1 = Wall thickness ................................... + 'I• in., -0 in. [ +6 mm, -0 mm]

b2 = Width of closure panel between units ............................... +0 in., - '12 in.

[+0 mm, -13 mm]

c = Depth (overall) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±V. in. [±6 mm]

c1 = Slab thickness ................................................. ±V. in. [±6 mm]

d = Variation from specified plan end squareness or skew . . . . . . . . . . . . . . ±V. in. [±6 mm]

e = Variation from specified elevation end squareness or skew . . . . . . . . . . ±'AI in. [±3 mm]

h = Local smoothness of any surface ....................... 'I• in. in 10ft. [6 mm in 3m]

11 = Location of embedment ....................................... ± 1/2 in. [±13 mm]

12 Tipping and flushness of embedment . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±'Ia in. [±3 mm]

13 Angular rotation of visible embedment or blockout . . . . . . . . . . . . . . . . . . . . . . . 2 degrees

. . . . . . . . . . . V. in. [6 mm] maximum measured at perimeter of embedment or blockout

14 Depth of recess to embedment .................... + v. in., -'IB in. [ +6 mm, -3mm]

n = Size of blockout for door or window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±'Ia in. [±3 mm]

v = Cover over reinforcement ....................................... ±V. in. [±6 mm]

z = Location of electrical boxes ..................................... ±1 in. [±25 mm]

Note: Tolerances for project specific items, such as security hardware, mechanical/electrical/
plumbing embedments, doors, and windows, should be included in the contract documents.

73
Fig. 10.21.1 Prestressed Concrete Panels for Storage Tanks

Plan

b e

11
c

e
Li'
r---------------
·1r
\
I
,,
,, ~
0
I I
0 I \
I I
0 I I

~~
I I
I I
0 I I
0 I I
I
.__0
I a
I
,--
I
0 0
I
I
I
I n, ,,
r
I I

k,
0
I
I
I
I
I
I
I
I I
0 I I n,
n,
I
I
I
I
hL k,

e
I -
L----- -- 1~.c--

Elevation Elevation

74
10.21 Prestressed Concrete Panels for Storage Tanks

a = Length ........................................................ ±'I• in. [±6 mm]

b = Width (overall) ................................................. ±V. in. [±6 mm]

c = Depth (overall) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . + y, in., -'Ia in. [ +6 mm, -0 mm)

e = Variation from specified elevation end squareness or skew

........................................ ±'Ia in. per 72 in. length, ±'I• in. maximum
[±3 mm per 1800 mm, 6 mm maximum)

f = Sweep ....................................................... ±'Ia in. [±10 mm]

h = Local smoothness:
Horizontal surface ..................................... 'Ia in. in 10ft. [3 mm in 3 m)
Vertical surface ....................................... y, in. in 10ft. [6 mm in 3m)

= Bow ........................................ Length/360, 31• in. [19 mm] maximum

i1 = Differential bow between adjacent panels of the same design .......... 'Ia in. [10 mm)

k = Location of strand .............................................. ±'I• in. [±6 mm]

k1 = Location of post-tensioning duct ................................. ±'Ia in. [±3 mm]

k2 = Location of post-tensioning anchor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±V. in. [±6 mm]

k3 Angular rotation of post-tensioning anchor from specified alignment ...... ±5 degrees

11 = Location of embedment ....................................... ±%in. [±19 mm]

12 Size of embedment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±'Ia in. [±3 mm]

n1 = Location of blackout ........................................... ±%in. [±19 mm]

n2 = Size of blackouts .............................................. ±'I• in. [±6 mm]

s = Projection of post-tensioning duct ............................... ±'12 in. [±13 mm)

75
Fig 10 22 1 Bridge Deck Units

(\ (\
_J (\ _j
k, L --1 I ~ c

I Elevation
I

I.
------
______ _j________
------
~
----; i -
I
-----1 - - - -
I
I

LJ
k2
I
!
s, -
-

b
r---t
-I-
- -
I
-
I
r--
-

-+ I
r--

----t-I f--

i - - - r--
I
f--
T
~s3L
I

_J L
Plan

76
10.22 Bridge Deck Units

a Length ........................................................ ±'I• in. [±6 mm]

b ~ Width ......................................................... ±'I• in. [±6 mm]

c ~ Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . + 'I• in., -'Is in. [ +6 mm, -3 mm]

d ~ Variation from specified plan end squareness or skew .............. ±V. in. [±6 mm]

~ Sweep ........................................................ ±'Is in. [±3 mm]

k1 ~ Location of strand perpendicular to plane of panel ................. ±'Is in. [±3 mm]

k2 Location of strand parallel to plane of panel ....................... ±'I• in. [±6 mm]

51 ~
Longitudinal spacing of stirrups .................................. ±1 in. [±25 mm]

52 Stirrup projection from surface .................................. ±'12 in. [±13 mm]

53 ~
Strand projection from end ..................................... ±'12 in. [±13 mm]

77
Fig. 10.23.1 Segmental Box Girder

e
f
Elevation

78
10.23 Segmental Box Girder

a ; Length ......................................... ±Vs in/ft. length, ±1 in. maximum

[±10 mm/m length, 25 mm maximum]

b ; Width (overall) .................................. ±'As in/ft. width, ±%in. maximum

[±5 mm/m length, ±19 mm maximum]

b1 ; Web width .................................................... ±3fs in [±10 mm]

b2 ; Bottom flange width ............................... '11s in/ft. width, ± v, in. maximum

[±5 mm/m length, ±13 mm maximum]

b3 ; Diaphragm thickness .......................................... ±'12 in. [±13 mm]

c Depth (overall) ................................................. ±V• in. [±6 mm]

c1 ; Depth oftop and bottom slab .................................. ±3fs in. [±10 mm]

e ; Grade of form edge and soffit (vertical curve

and super-elevation) .............................. ± 1h in. in 10ft. [±3 mm in 3m]

k ; Location of post-tensioning duct ................................. ±'A! in. [±3 mm]

z ; Location of shear key........................................... ±'I• in. [±6 mm]

Note: The above tolerances should be compared to the specific requirements of the project toler·
ance control plan and adjusted as necessary.

79
Fig. 10.24.1 Pier Deck Units

• Cross section at midspan

c:_
----------------~l __________________
~--- -
t
~
I

I
I
I
v I
I
I
I /
I
I
I
J I
I
n2 I
I
I
I b
I I
I
I
I

/
l I
I
I
I L/
I
I
! q2

I a t I

Plan

r n lsi n
q,
1---

I
I
I
II 0 c

L:..
I

Elevation

80
10.24 Pier Deck Units

a = Length ....................................................... ±'12 in. [±13 mm]

b Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±'14 in. [±6 mm]

b1 Shear key width ................................................ ± 1/4 in [±6 mm]

c Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±V. in. [±6 mm]

c1 = Shear key depth ............................................... ±V.in. [±6mm]

d Variation from specified plan end squareness or skew ............. ±'12 in. [±13 mm]

e = Variation from specified elevation end squareness or skew ......... ±'12 in. [±13 mm]

= Sweep ........................................ ±Vs in. per 10ft. [±3 mm per 3m]

g Differential camber between adjacent

units of the same design ............................ '!4 in. per 10ft. [6 mm per 3 m]

k1 = Location of strand perpendicular to plane of panel . . . . . . . . . . . . . . . . . ±'14 in. [±6 mm]

k2 = Location of strand parallel to plane of panel ....................... ±1 in. [±25 mm]

n1 = Location of blockout. ........................................... ±1 in. [±25 mm]

n2 = Size of blockouts .............................................. ±1 in. [±25 mm]

p = Location of inserts ............................................. ±1 in. [±25 mm]

q1 = Location of handling device parallel to length of member .......... ±6 in. [±150 mm]

q2 = Location of handling device transverse to length of member ......... ±1 in. [±25 mm]

s Longitudinal spacing of stirrups .................................. ±1 in. [±25 mm]

81
Fig. 10.25.1 Box Culvert

c,
l

- ±i
c,
c ~
b

c,

Cross section

~----------------------------------------

Longitudinal Section

82
10.25 Box Culvert

a Length ................................................ -V2,+1 in. [-13,+25 mm]

b Span:
Less than 48 in. [1.2 m] ........................................ ± 711s in. [±10 mm]
48 in. [1.2 m] to 96 in. [2.4 m] .................................. ±3f• in. [±19 mm]
Greater than 96 in. [2.4 m] ...................................... ±1 in. [±25 mm]

b1 = Thickness* of walls ........................... - 311s in., +1 in. [ -4.5 mm, +25 mm]
c = Rise
Less than 48 in. [1.2 m] ........................................ ± 711s in. [±10 mm]
48 in. [1.2 m] to 96 in. [2.4 m] .................................. ±%in. [±19 mm]
Greater than 96 in. [2.4 m] ...................................... ±1 in. [±25 mm]

c1 = Slab thickness ...................................... - 311s, +1 in. [-4.5, + 25 mm]

c2 Haunch dimension .............................................. ±V• in [±6 mm]

e Variation in length of opposite surfaces:

Per 12 in [0.3 m] of internal span ................................ ±Vain. [±3 mrn]
Maximum to 84 in. [2.1 m] span ................................ ±'Ia in. [±15 mm]
Maxirnum over 84 in. [2.1 m] span .............................. ±%in. [±19 mm]

*Refer to ASTM C 850 and ASTM C 789 for reinforcement placement tolerances.

83
Fig. 10.26.1 Prestressed Concrete Railroad Ties

b,
Y•

[pJ ""
""
" "'
""
""
/
")\/
'-
• • • •
• • • •
b,
.I
Section Detail

Y3

- I
r-....,
y,_,
,..~
I ~
' ' ''\..-J'''
'' ' I I
L_j ' ' ''\... ..---''''
...''_j'
I I
I I

I I
I

IV
Elevation

1
Centerline of
rail seat

\II! :
--- ----a+a---------------a+a---- ~---
i i
a

Plan

84
10.26 Prestressed Concrete Railroad Ties*

a = Length ............................................... ±'Ia in. up to 108 in. length

[±3 mm up to 2700 mm length]

b1 = Width at bottom ±'A! in. [±3 mm]

b2 = Width at top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±'Ia in. [±3 mm]

c = Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ± 3As in. up to 10 in. depth

[±5 mm up to 250 mm depth]

h = Local smoothness ............................. v,, in. over 6 sq. in. area of rail seat
[1 mm over 3870 mm 2 area of rail seat]

k = Location of strand or wire .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . ±'A! in. [±3 mm]

y1 = Rail seat slope ...................................................... ±5 degrees

y2 = Spacing between adjacent inserts for rail attachment

............................................... + 'A• in., -0 in. up to 7 in. spacing
[ +2 mm, -0 mm up to 180 mm spacing]

y3 = Spacing between inserts for setting track gage

................................................... ±0.08 in. up to 70 in. spacing
[±2 mm up to 1800 mm spacing]

y4 = Shoulder tilt, vertical or horizontal ..................................... ±2 degrees

* Current tolerances as published by AREMA Committee No. 30 should be reviewed prior to produc-
tion.

85
Fig. 10.27.1 Sills, Lintels, Copings, Cornices, Quoins and Medallions

..--
1-T-l
I I
--
I
--
c,
c

L-..1 : : :
- - - - -~----- ----------

~
'
I
rj
b, :
b

----------~==~~------------------~
---
- -- -
t
~
- - -- --
~
' ' ~ h

a t

86
10.27 Sills, Lintels, Copings, Cornices, Quoins and Medallions

a = Length ........................................................ ±'Ia in. [±3 mm]

Where one face will be installed in dead wall space of mortar joint ... ±'!.in. [±6 mm]

b Overall width of units* .......................................... ±'Ia in. [±3 mm]

b1 = Location of inserts and appurtenances:

On formed surfaces ............................................ ± 1/a in. [±3 mm]
On unformed surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±%in. [±9 mm]

c Overall height of units* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±'Ia in. [±3 mm]

c1 = Total thickness ................................................. ±'Ia in. [±3 mm]

Flange thickness ............................................... ±'Ia in. [±3 mm]
Where one face will be installed in dead wall space of mortar joint ... ±'!.in. [±6 mm]

t Size and location of rustications and architectural features ........ ± 1Aa in. [±1.5 mm]

h = Local smoothness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ± 1/a in. per 5 ft.[±3 mm per 1.6 m]

= Bowing ........................................... span/360, max, ±%in. [6 mm)

= Warpingt .................................... ± 1As in. per ft. [±1.5 mm per 0.3 m]

* Measured at face exposed to view

t Measured per foot of distance from nearest adjacent corner.

87
Fig. 10.28.1 Bollards, Benches and Planters

I I

I. b
.I

88
10.28 Bollards, Benches and Planters

a = Height or length ............................................... ±V. in. [±6 mm]

b Width or diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±V. in. [±6 mm]

o Location of inserts and appurtenances:

Formed surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±'!• in. [±6 mm]
Unformed surfaces ............................................. ±'I• in. [±6 mm]

t = Size/location of rustication/features .............................. ±V. in. [±6 mm]

89
Fig 10 29 1 Pavers

I -
I
---- --- --
3 j

90
10.29 Pavers

a ; Length or width .............................................. ±'116 in. [±1.5 mm]

c ; Thickness ................................................... ± 111s in. [±1.5 mm]

; Warping* .................................................. ±%2 in. [±0.75 mm]

*Measured per foot [0.3 m] of distance from nearest adjacent corner.

91
11.0 Erection Tolerances ance system as a first priority before any precast
members are cast. It is in the interest of all concerned
The text below discusses the tolerance principles that the architect/engineer and the party or parties re-
and considerations related to the erection and ac- sponsible for the tolerances of the interfacing struc-
ceptable matching of precast and prestressed con- ture agree in writing to the overall project tolerance
crete members when they are used for the entire system.
structure or in combination with other structural sys- In general, the more restrictive the erection toler-
tems. It is important to understand the relationships ances, the higher the cost of erection will be. For ex-
of product, interfacing and erection tolerances, as all ample, combining liberal product tolerances with re-
must be taken into account on each project to assure strictive erection tolerances may place a significant
satisfactory panel and member installation. Erection cost burden on the erection phase of the project. This
tolerances are used in the planning of the erection ac- can negate any cost or time saving the designer ex-
tivity to assure that the elements can be assembled pected to achieve by specifying less stringent prod-
to fit together as an integrated building structure. uct tolerances.
It should be noted that in some instances project
erection may be done by a company which may have
no direct contractual relationship with the precast 11.1 Recommended Erection Tolerances
concrete member manufacturer. If this is the case,
The recommended erection tolerance values are
the party with contractual authority over the erector is those to which the member primary control surfaces
responsible for assuring that the project erection tol- are to be set. It is the position dimensions of the pri-
erances are met by the erector. mary erection control surfaces which should be con-
Erection tolerances are determined by consider-
trolled during erection. The remaining position di-
ation of the characteristics of the building structure,
mensions of the member features and secondary
and site erection conditions. They should be devel- control surfaces of the member will be the result of the
oped to achieve uniform joint widths and planar wall combination of the erection tolerances given here
panel conditions. Important features include: individ-
and the appropriate product tolerances given in Ar-
ual member design, shape, thickness, composition ticle 10.0. Also see Article 14.0 for a discussion of
of materials, and overall scale of the member being
clearances.
erected. The specified erection tolerances may affect
Erection tolerances shall control the individual pre-
the work of several different building trades and must cast members as they are located and placed in the
be consistent with the tolerances as specified for
assembled structure. The primary control surfaces or
those trades.
features on the precast members shall be erected to
To understand the importance of erection toler- be in conformance with the established erection and
ances specified, the function of the precast concrete interfacing tolerances. Clearances are generally al-
components should be considered when specifying
lowed to vary so that the primary control surface can
erection tolerances. For example, members which be set within tolerance. Product tolerances shall not
are covered by finish materials may not need the be additive to the primary surface erection tolerances.
close tolerances required for those that are exposed Secondary control surfaces which are positioned
to view. Members used for an industrial building may
from the primary control surfaces by the producttoler-
not require tolerances as restrictive as those used for
ances are usually not directly positioned during the
a visually sensitive commercial or residential applica-
erection process but are controlled by the product tol-
tion. erances. Thus, if the primary control surfaces are
One way to foster collaboration wtth regard to di- within erection and interfacing tolerances, and the
mensional control is for those responsible for erection
secondary surfaces are within product tolerances,
to participate with plant quality control personnel in the member should be erected within tolerance. The
the development of the member dimensional inspec- result is that the tolerance limit for secondary surface
tion plan. By doing this, the plant quality control per-
may be the sum of the product and erection toleran-
sonnel will understand the product tolerances which ces. To ensure trouble-free installation, the product
are critical to the successful erection of the project. tolerances, generally, must not exceed the erection
It is recommended that the producer review pro-
tolerances. An example is the elevation of a second
posed tolerances with the architect/engineer and story corbel on a multi-story column whose first story
erectors prior to agreeing to the final project toler- corbel is selected as the primary elevation control sur-
ances. If a producer encounters project specifica-
face.
tions in which no mention is made of the tolerance to Because erection and product tolerances for
be controlled in a structure to which the precast con- some features of a precast concrete member may be
crete components are being connected, steps additive, the erection drawings should clearly define
should be taken to develop an overall project toler-

92
the primary erection control surfaces. If both primary Windows between open shape members where
and secondary control surfaces are critical, provi- they will intersect a joint between members is an ex-
sions for adjustment should be included. The accu- ample which requires interface erection tolerances. A
mulated tolerance limits may be required to be ac- similar condition often occurs where panels are inter-
commodated in the interface clearance. Surface and spersed with glass or metal curtain wall elements.
feature control requirements should be clearly out- Close tolerances are often required between the mul-
lines in the plans and specifications. lion and the glass or curtain wall. This condition de-
Final erection tolerances should be verified and mands additional tolerance flexibility that may be pro-
agreed upon before erection commences and, if dif- vided by special consideration of the tolerance
ferent from those given in this document, stated in adjustment aspects of corner details.
writing and noted on the project erection drawings. Many of the erection tolerances address the toler-
As-built precast erection tolerances are often largely ance on bearing length. Since the bearing length tol-
determined by the actual alignment and dimensional erance may have an effect on erection safety and
accuracy of the building foundation and frame (in structural integrity of the completed structure, it de-
those circumstances where the building frame is serves special attention both in member fabrication
constructed from some material other than precast and in erection. Problems in meeting bearing area re-
concrete}. The general contractor is usually the party lated tolerances should be brought to the attention of
responsible for the plumbness, level, and alignment the architect/engineer.
tolerances of the foundation and the structural frame, The bearing length and the length of the end of the
including the location of all bearing surfaces and an- member over the support are often not the same, as
chorage points for the precast concrete members. shown in Fig. 11.2.1. Bearing length should be mea-
Project specifications should be checked by the sured in the direction of the member span. Bearing
producer to assure that tolerances have been speci- width should be measured at 90 degrees to the direc-
fied for the site construction work which are compat- tion of the member span. For precastto precast erec-
ible with the requirement to erect precast on the build- tion acceptable bearing tolerance conditions which
ing frame. If discrepancies are discovered, they are required for safe erection should be shown on the
should be brought to the attention of the architect/en- erection drawings. For precast to other materials
gineer and resolved as early in the project as possible erection acceptable bearing conditions must be
and in every instance prior to the start of precast pro- shown in the contract documents.
duction. The producer may collaborate with the archi- If for any reason a member cannot be erected as
tect/engineer to provide special details to accommo- shown on the connection details, within the toler-
date the more liberal tolerances that may be ances outlined in this document, the erector should
associated with these site construction features. To notify the responsible party to check the structural
protect the project cost and schedule by minimizing adequacy of the resulting configuration.
erection problems, the dimensions and locations of For insulated wall panels where beams bear on the
in-place structures should be checked prior to start- interior wythe of the panel, it may be practical to speci-
ing precast erection. fy the beam length so that the tolerance can be taken
up in the insulation. This is one method of avoiding
bearing area deficiencies in this type of element.
11.2 Erection Tolerance Groups
11.3 Field Control of Erection Tolerances
The erection tolerances are given in three groups:
Appropriate field procedures should be followed
1 . Precast member to precast member
to ensure the erection of precast members within the
2. Precast member to cast-in-place concrete or
limits of the project erection tolerances. The general
masonry
contractor should establish (and maintain at conve-
3. Precast member to steel construction
nient locations), control points, bench marks and
Because erection is both equipment and site de- lines in an undisturbed condition until final completion
pendent, there may be good reason for the producer and acceptance of the project. Typically, panels are
and erector to work with the architect/engineer to located in the center of their nominal (basic dimen-
considerably vary some of the recommended toler- sional) location on the building. Panels may also need
ances to account for unique project conditions. This to be adjusted to accommodate erection and product
variation could involve modification of both specified tolerances and the locations of other adjacent materi-
product tolerances and specified erection tolerances. als while providing acceptable joint width.

93
F"'lg. 1121 Beanng Length
- - - - - Precast concrete member

Setback distance

lT
V//~
J Bearing length
I
Length over support

Support

Upon completion of panel alignment and before er erection of the structure to the final grade shown on
other trades interface any materials with the precast the design plans.
members the erector, in conjunction with the general Contractors on segmental bridge projects are usu-
contractor, should verify that the panels are erected ally required to submit deflection and/or camber data
within the specified tolerances. for each stage of construction as required to
No erected member should be left in an unsafe construct the structure to its final grade. The proce-
support condition. Any adjustments affecting struc- dure takes into account the effect of time dependent
tural performance, other than adjustments within the prestress losses and creep which will occur during
prescribed tolerances, should only be made after ap- the construction phase.
proval by the engineer of record. A geometric control plan should provide for regu-
lar monitoring of the superstructure deflections be-
11.4 Erection Tolerance Considerations for ginning with the addition of the first segment erected
Segmental Precast Projects and concluding with the last segment erected.
The control plan should also include the adjusting
An overall geometric control plan for the segmen- procedure to be used should the structure, as
tal project should be prepared. The plan should indi- erected, deviate from the predicted alignment by
cate in detail how the geometry control survey will be more than a specified amount.
performed and the actions proposed to assure prop-

94
12.0 Erection Tolerance Listings These tolerances should be considered guide-
lines for the development of project specific toler-
Erection tolerances for precast members are ances for erection
shown on the following pages.

95
Fig. 12.1.1 Beam Erection Tolerances

_ _ _ _ _ _ Bldg. grid
datum

--J a . c c
-·:tl~~~·~~ ----'d

Vertical primary
control ,,,,,,,;,----+--!
n
Ledge L ~=z:b="' Precast concrete
(N/A at inverted both sides '-----
beam
tee beam) at inverted
tee beam Support element

Centerline of
steel support

Plan view Elevation

Precast element to: precast element, cast-in-place concrete, masonry, or structural steel

96
12.1 Beam Erection Tolerances

The primary control surfaces are usually as shown, a~hough this needs to be confirmed on a
job-by-job basis.

a Plan location from building grid datum ............................ ±1 in. [±25 mm]

a1 ~ Plan location from centerline of steel* ............................. ±1 in. [±25 mm]

b Bearing elevation t from nominal elevation at support:

Maximum low .................................................... '12 in. [13 mm]
Maximum high ..................................................... 'I• in. [6 mm]

c ~ Maximum plumb variation over height of element:

Per 12 in. [300 mm] height .......................................... 'h in. [3 mm]
Maximum at rectangular or L-beam ................................. '12 in. [13 mm]
Maximum at inverted tee beam ..................................... %in. [19 mm]

d Maximum jog in alignment of matching edges:

Architectural exposed edges ....................................... v. in. [6 mm]
Visually non-critical edges ......................................... '12 in. [13 mm]

e ~ Joint width:
Architectural exposed joints ..................................... ±V• in. [±6 mm]
Hidden joints ................................................. ±%in. [±19 mm]
Exposed structural joint not visually critical ......................... ± V2 in. [13 mm]

f ~ Bearing lengtht (span direction) ................................ ±%in. [±19 mm]

g Bearing widtht ................................................ ±'12 in. [±13 mm]

Note: When bearing pads are used at unarmored edges they should be set back a minimum of '12
in. [13 mm] from the face of the support or at least the chamfered dimension at chamfered edges.
*For precast elements on a steel frame, this tolerance takes precedence over tolerance on dimen-
sion "a".
t Or member top elevation where member is part of a frame without bearing ledges.

t This is a setting tolerance and should not be confused with structural performance requirements
set by the architect/engineer. The nominal bearing dimensions and the allowable variations in the
bearing length and width should be specified by the engineer and shown on the erection drawings.

97
Fig. 12.2.1 Floor and Roof Member Erection Tolerances

c
Hollowcore plan Double tee plan

~ of steel support -----1

, . , f.-

Double tee U_ '

--1
Support
member
Prim ary control surface

b
To allow for
- 3/4" tolerance
antral surface
d deck w/ b To allow tor
-3f4" tolerance
! to' pretopped tee
underside _A
[-19mm] [-19mm] -f' Bearing pad by design
~ %":__ji.Q~=-
ad by design L____ 3/4"
[19mm} as req'd [19m~r- ~~Hoi dback as req'd
Bldg. elevation datum r-L-- - - - - - - - - - - - - -
Hollowcore elevation Double tee elevation

Precast element to: precast, cast-in-place concrete, masonry or structural steel support

98
12.2 Floor and Roof Member Erection Tolerances

The primary control surfaces are usually as shown. A majority of the time there is no designated
vertical primary control surface, and in some scenarios there are no primary control surfaces at all.
This needs to be determined on a job·by·job basis.

a = Plan location from building grid datum ............................ ±1 in. [±25 mm]
a1 = Plan location from centerline of steel support* ..................... ±1 in. [±25 mm]
b = Top elevation from building elevation datum at member ends:
Covered with topping ............................................ ±.%. [±19 mm]
Pretopped tee/carpet direct hollow-core .......................... ±'I• in. [±6 mm]
Untapped roof ................................................ ±%in. [±19 mm]

c = Maximum jog in alignment of matching edges

(both topped and untapped construction) ............................ 1 in. [25 mm]

d = Joint width:
Oto40ft.member ............................................ ±1f,in.[±13mm]
41 to 60ft. member ........................................... ± 3/, in. [±19 mm]
61ft. plus member ............................................ ±1 in. [±25 mm]

e Differential top elevation as erected (for units of same design and length):
Field topped ..................................................... %in. [19 mm]
Pretopped tees at driving lanes/carpet direct hollow-core ............... 'I• in. [6 mm]
Untapped rooft ................................................... %in. [19 mm]

= Bearing lengtht (span direction) ................................ ±Y• in. [±19 mm]

g Bearing widtht (n/a for hollow-core) ±'12 in. [±13 mm]

h Differential bottom elevation of

exposed hollow-core slabs§ ......................................... 'f, in. [6 mm]

Note: When bearing pads are used at unarmored edges they should be set back a minimum of v,
in. [ 13 mm] from the face of the support or at least the chamfered dimension at chamfered edges.
*For precast concrete erected on a steel frame building, this tolerance takes precedence over toler-
ance on dimension "a".
t It may be necessary to feather the edges to ±'I• in. [±6 mm] to properly apply some roof mem-
branes.
t This is a setting tolerance and should not be confused with structural performance requirements
set by the architect/ engineer. The nominal bearing dimensions and the allowable variations in the
bearing length and width should be specified by the engineer and shown on the erection drawings.
§ Untapped installations will require a larger tolerance.

99
Fig. 12.3.1 Column Erection Tolerances

d d

: r+-
II I 'I
I I.
I
I
I I
II
Plan view
I
I II Splice
I I . _j
:~ ~
Vertical primary
~control surface

~ I
'\r- E
I
Horizontal primary
control surface
(at first corbel)
~
0
!2
I Ill
e II e
0 II
I
0 II II
~ ~
\2
II
b
/
0
I
I
Bldg. elevation ]
I
c _..;,...
-'I
datum
• a
-1
Bldg. grid
_.__ _ _c..__Jc___L_--11 Bldg. elevation I datum -----()
1 datum
Elevation Elevation

100
12.3 Column Erection Tolerances

The primary control surfaces are usually as shown, although this needs to be confirmed on a
job-by-job basis.

a = Plan location from building grid datum:

Structural applications .......................................... ±V2 in. [±13mm]
Architectural applications ........................................ ±'Ia in. [±9mm]

b = Top elevation from nominal top elevation:

Maximum low .................................................... V2 in. [13 mm]
Maximum high ..................................................... v.
in. [6 mm]

c Bearing haunch elevation from nominal elevation:

Maximum low .................................................... V2 in. [13 mm]
Maximum high ..................................................... V• in. [6 mm]

d = Maximum plumb variation over height of element (element

in structure of maximum height of 100ft. [30m]) .................... 1 in. [25 mm]

e = Plumb in any 10ft. [3m] of element height ............................ 'I• in. [6 mm]

I = Maximum jog in alignment of matching edges:

Architectural exposed edges ........................................ v.in. [6 mm]
Visually non-critical edges ......................................... V. in. [13 mm]

101
Fig. 12.4.1 Structural Wall Panel Erection Tolerances

Horizontal
pnmary
g~r-- fi_ ~~--h

Vertical primary
control surface
control
surface t
-.--- -h1o
b E
c "-
Cast-in-place
01 0
I
foundation or
0
precast
concrete
Cast-in-place or
precast concrete suppo~--_:~=~"-~'
- ~~J~'I=IIE
~~~(= 1 __J k- Nominal joint width
ITillm=m=mlliffi~
Plan Section Elevation

Precast element to precast or cast..jn-place concrete or masonry

Bldg. grid [
datum Horizontal
primary
control
l_,,r_+--r*==1r-
r--g
1
h

surface

-1 ~ ~ E c E
"-
~ t- ~ "- 0
0 I
I I
0
sLel
structure
-+
--1 a, £r--
of steel structure Nominal joint width
Section
Plan Elevation

Precast element to structural steel

102
12.4 Structural Wall Panel Erection Tolerances

The primary control surfaces are usually as shown, although this needs to be confirmed on a
job-by-job basis.

a = Plan location from building grid datum ........................... ±'!'in. [±13 mm]

a1 = Plan location from centerline of steel support ..................... ±'12 in. [±13 mm]

b = Top elevation from nominal top elevation:

Exposed individual panel ...................................... ±V2 in. [±13 mm]
Non-exposed individual panel .................................. ±%in. [±19 mm]
Exposed relative to adjacent panel .............................. ±'/'in. [±19 mm]
Non-exposed relative to adjacent panel .......................... ±%in. [±19 mm]

c = Support elevation from nominal elevation:

Maximum low .................................................... y, in. [13 mm]
Maximum high ..................................................... v. in. [6 mm]

d = Maximum plumb variation over height of

structure or over 100ft. which ever is less* .......................... 1 in. [25 mm]

e = Plumb in any 10ft. of element height ................................. v. in. [6 mm]

I = Maximum jog in alignment of matching edges ........................ 'h in. [13 mm]

g = Joint width (governs over joint taper) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±'Ia in. [±9 mm]

h = Joint taper over length of panel ..................................... y, in. [13 mm]

h10 = Joint taper over 10ft. length ......................................... 'Ia in. [9 mm]

= Maximum jog in alignment of matching faces:

Exposed to view ................................................... 'Ia in. [9 mm]
Non exposed to view .............................................. 314 in. [19 mm]

= Differential bowing or camber as erected

between adjacent members of the same design ..................... '/,in. [13 mm]t

*For precast buildings in excess of 100ft. tall, tolerances "a" and "d" can increase at the rate of 1/s
in. [3 mm] per story to a maximum of 2 in. [50 mm].
t Refer to Article 8 for description of bowing tolerance.

103
Fig. 12.5.1 Architectural Walls/Spandrel Erection Tolerances

d d Horizontal primary
control surface .A
- r- h

v-
-rtr I IL

''
Vertical primary \ rf-1---L-,
control surface . -------.;. J

e II e h10

':"']" -
"E "E
""0
I
""0
I
-g
b b
<t of steel
~

support ~- r- -~ -~

~ II II
Support
L
member '\ "V=l-
Plan view Side view Elevation view
Walls Walls Walls

Horizontal primary
dd control surface
-rrr
'l~
Vertical primary I
control surface

"E

·'~ L
k
""0 __'j

t
I

gdFd
b
<tof steel

~
support Support
member "v

Plan view Side view Elevation view

Spandrels Spandrels Spandrels

104
12.5 Architectural Walls/Spandrel Erection Tolerances

The primary control surfaces are usually as shown, although this needs to be confirmed on a
job-by-job basis.

a = Plan location from building grid datum* .......................... ±'I' in. [±13 mm]

a1 = Plan location from centerline of steel supportt ±V2 in. [±13 mm]

b = Top elevation from nominal top elevation:

Exposed individual panel ....................................... ±V. in. [±6 mm]
Non-€xposed individual panel .................................. ±V2 in. [±13 mm]

c = Support elevation from nominal elevation:

Maximum low .................................................... Y, in. [13 mm]
Maximum high ..................................................... v. in. [6 mm]

d Maximum plumb variation over height of structure

or 100ft. [30m] whichever is less* ................................. 1 in. [25 mm]

e = Plumb in any 10ft. [3m] of element height ............................ V. in. [6mm]

f = Maximum jog in alignment of matching edges:

Exposed relative to adjacent panel ................................... in. [6 mm] v.
Non-exposed relative to adjacent panel .............................. '12 in. [13 mm]

g Joint width (governs over joint taper) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±V• in. [±6 mm]

h = Joint taper maximum ............................................... 'Ia in. [9 mm]

h10 = Joint taper over 10ft. [3 m]length ................................... 'I• in. [6 mm]

;;:: Maximum jog in alignment of matching faces .......................... % in. [6 mm]

Differential bowing or camber as erected between

adjacent members of the same design ............................... 'I• in. [6 mm]

k Opening height between spandrels .............................. ±'I• in. [±6 mm]

* For precast buildings in excess of 100ft. tall, tolerances "a" and "d" can increase at the rate of Va
in. [3 mm] per story to a maximum of 2 in. [50 mm].

t For precast elements erected on a steel frame, this tolerance takes precedence over tolerance on
dimension "a".

105
Fig. 12.6.1 Single and Double Stadium Riser Erection Tolerances

Riser unit
~ Theoretical
b 1--- Cf of support

,I

Vertical primary
control surface
To allow for
-1"(-25mm) Plan view
tolerance
~1"
(25 mm) -~~1!1-o~ Holdback as required
Shims per design

c
h
p IJ_t:::===con===trolsurtace======~o~
Horlwntal primary ~ n
Elevation view

·n-a
Horizontal primary,_ _ __
control surtace n 1 ~'------ Vertical primary
j \=.. ! g or j control surtace

Riser cross section

106
12.6 Stadium Riser Erection Tolerances

The primary control surfaces are usually as shown, although this is something that needs to
be confirmed with the contractor on job-by-job basis.

a ~ Plan location from building grid line datum ±1 in. [±25 mm]

b ~ Plan location from theoretical centerline of

support structure .............................................. ±1 in. [±25 mm]

c ~ Top elevation from building elevation datum at

members end. (This datum may be adjusted to
accommodate existing field conditions.) ......................... ±'12 in. [±13 mm]

d ~ Maximum jog in alignment of matching edges

at the horizontal primary control surface .............................. 'I• in. [6 mm]

e ~ Maximum jog in alignment of matching edges

at the vertical primary control surface ................................ '12 in. [13 mm]

f ~ Bearing in span direction ....................................... -1 in. [ -25 mm]

g ~
Joint width {horizontal) at end of piece (Joint
width needs to be V. in. [6mm] minimum) ........................ ±'12 in. [±13 mm]

h ~ Joint width (Joint width needs to be 'I• in. [6 mm] minimum in either case)
90° angle .................................................... ±'/2 in. [±13 mm]
Joint width at skewed ends .................................... ±%in. [±16 mm]

~ Differential camber (at mid-span as erected) between adjacent members of the same de-
sign ......................... ± 3/ " in. [±5 mm] per 10ft. [3m] of member length.

k Differential sweep (at mid-span as erected) between adjacent members of the same de-
sign .......................... His in. [±5 mm] per 10ft. [3m] of member length.

Note: Local building codes may require more restrictive riser height tolerances which could also
affect product tolerance.

107
Fig. 12.7.1 Room Module Erection Tolerance

Vertical primary control ~

surface (front)
d d

Building grid or
I
datum (typ) ~---
I
I
I
lar- 1r ·~
I
I
I

l n-··
I
I
"1~J
I
I
~-

I
t I
I
I

I I '
I(
I I cl
I I I I
I
I
II
I'
II
II
I
I
I f [ I
-L
e
-
I I
I II II I I
I I II I I
I b I
I I' II I
:::t ~- - =::::1
--- - - ------=.J
L-- -
li= r- L.
J
c
Horizontal primary control
surface (door head)

Plan view Elevation

108
12.7 Room Module Erection Tolerance

The tolerances listed below are used at the primary control surfaces only, and only those toler-
ances that are applicable to that surface. Normally the primary control surfaces are the front face
of the cell unit as the vertical primary control surface, and either the head of the door (as shown
in Fig. 12.7.1), top of cell, or the bottom of balcony as the horizontal primary control surface. Note:
on jobs where pre-topped balconies are cast as part of the cell unit, the horizontal primary control-
surface may be the top surface of the balcony.

a = Plan location from building grid line datum ...................... ± 112 in. [±13 mm]

b = Vertical control (at primary control surface)

from a horizontal datum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±'Ia in. [±9 mm]

c = Actual grout joint ......................................... 1/2 in. minimum [13 mm]

d = Plumb at element height ............................................ v, in. [6 mm]

e = Maximum jog in alignment of matching edges ......................... 'I• in. [6 mm]

I = Vertical joint width .............................................. ±'Ia in. [ ±9 mm]

g = Joint taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not applicable

109
Fig. 12.8.1 Stair Unit Erection Tolerance

_______ L _________ -o

Plan view

Primary control surface

Intermediate landing

Line of topping
0
pan (if applicable)
b

Elevation view

110
12.8 Stair Unit Erection Tolerance

The primary control surface for stair units is the top of landing at floor levels. Tolerances listed
below are the same whether landings are monolithic or separate pieces.

a = Plan location from building grid line datum ........................ ±'12 in. [±13mm]

b = Differential elevation as erected* .................................. ±'Is in. [±9mm]

c = Joint width ................................................... ±%in. [±19 mm]

d = Maximum jog in alignment of matching edges . . . . . . . . . . . . . . . . . . . . . . . 1 in. [25 mm]

e = Maximum jog in alignment of stair tread nosings

(This tolerance overrides "d" if needed) .............................. '12 in. [13 mm]

f = Maximum jog in alignment of matching edges

at the primary control surface* ...................................... 'Is in. [9 mm]

g = Bearing (in span direction) ..................................... ±%in. [±19 mm]

Note: Local building codes may require more restrictive riser height tolerance which could also af-
fect product tolerance.
*At stair units that have pre-topped precast landings, the maximum jog between stair units as well
as from stair unit to finish floor can not exceed V. in. However, units which have landings that are
topped have more leeway. This needs to be discussed and agreed upon with the general contrac-
tor.

111
 ..
Fig 12 9 1 Segmental Bridge Element Erection Tolerance

r Precast segment

\ Match cast joint

~
v)
---,.+
Plan

,..A

t_ __[_
I
'
\ 7·
~~·
Elevation

I
o·
~=7
_jb
IT

Section A-A

112
12.9 Segmental Bridge Element Erection Tolerance

a = Maximum differential offset between outside

faces of adjacent segments in the erected position ..................... Vs in. [3 mm]

b = Deviation from the theoretical transverse cross slope of the roadway

................... 0.001 radians measured curb to curb at any point along the span

c = Longitudinal angular deviation from the theoretical slope change between two successive
segments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . not to exceed 0.003 radians

d = Deviation from horizontal centerline alignment

as required by the plans and specifications ....................... ±'Is in. [±3 mm]

e = Deviation from vertical centerline alignment

as required by the plans and specifications ....................... ±'Is in. [±3 mm]

113
Fig 12.10.1 Circular Storage Tank Erection Tolerances

Precast panel

Cast-in-place pilaster

Plan

Tendon ducts

e
0

o I
0

Section A·A

114
12.10 Circular Storage Tank Erection Tolerances

a = Variation from the nominal tank radius ... ±'12 in. per 50 ft. of radius [±13 mm I 15.2 m]
(Not to exceed ±1 in. [±25 mm])

b = Maximum variation of nominal tank radius

along any 10ft. [3 m] of circumference . . . . . . . . . . . . . . . . . . . . . . . . . . ±% in. [± 10 mm]

c1 = Radial dimension to panel edge adjacent to location c2

c2 = Radial dimension to panel edge adjacent to location c 1

c 1 -c2 =Radial misalignment between adjoining

precast concrete panels .............................. not to exceed % in. [1 0 mm]

d = Plumbofwalls ..................... V.in.per10ft. [6mmper3m]ofverticalheight

(%in. [19 mm] maximum])

e = Height to top of wall panel ±'12 in. [±13 mm]

f = Height to centerline of post-tensioning ducts

or embedded reinforcement to be welded . . . . . . . . . . . . . . . . . . . . . . . . ±'I• in. [±6 mm]

g = Step in face-interior surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±'I• in. [±6 mm]*

• In applications which involve an internal surface wiper on the sides of the tank it may be required
that this tolerance be made more stringent.

115
Fig 12.11.1 Pier Deck Erection Tolerances

_ r - - - Welded connection or reinforcement

Cast-in-place topping
Cast-in-place joint

Precast deck panel

Bearing strip

Cast-in-place pile cap

Elevation

b Precast deck panel

Precast deck panel

~ e f ~r /
1' :
': I

v
I ::L
I Welded connections
_l
I .
I 1/
I
I I
CL_ T
,----- I Adjacent deck panel
I I :
:I
Plan

116
12.11 Pier Deck Erection Tolerances

a = Variation in placement of end of panel

relative to centerline of pile cap ................................. ±'12 in. [±13 mm]

b = Variation of panel end from a line

parallel to centerline of pier cap .................................. ±'I• in. [±6 mm]

c = Variation in width of panel to panel grout joint . . . . . . . . . . . . . . . . . . . . . ± 1/a in. [±3 mm]

d = Variation in width of joint between panels ......................... ±1 in. [±25 mm]

e = Variation in alignment of adjacent panel edges .................... ± 1!8 in. [±3 mm]

117
Fig 12.12.1 Erection Tolerances for Bridge Deck Units

Bridge y grid datum

Lridge x grid datum

Plan

Bridge elevation datum line

- - - - - - _ ___1__1_

Elevation

118
12.12 Erection Tolerances for Bridge Deck Units

a = Plan location from building datum ................................ ±1 in. [±25 mm]

b = Top surface elevation from nominal top surface elevation .......... ±%in. [±19 mm]

c = Maximum jog in alignment of matching edges ........................ 1 in. [25 mm]

d = Joint width ................................................... ±V,in. [±13mm]

e = Joint taper .................................................... ±'14 in. [ ±6 mm]

= Bearing length in the span direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ± 1/z in. [ ± 13 mm]

g = Differential elevation between adjacent panels ........................ % in. [19 mm]

Note: These tolerances should be compared against those specified by the controlling bridge au-
thority. If the specified project tolerances are more stringent than these, the specified tolerances
shall govern the erection of the project.

119
13.0 Erection Tolerances for Mixed Building precast to other materials, erection acceptable bear-
systems ing conditions must be shown in the contract docu-
ments.
A mixed building system is one which uses precast
If for any reason a member cannot be erected as
and prestressed concrete with other materials, usual-
shown on the connection details within the tolerances
ly cast-in-place concrete or structural steel. Mixed
outlined in this document, the erector should notify
building systems subject erection tolerances to even
the architect/engineer to check the structural ade-
more variables than do single system buildings. Each
quacy of the resulting connection configuration and
industry has its own specified erection tolerances
modify the connection if necessary. The connection
which apply when its products are used exclusively.
design should be reviewed by the erector to assure
Because the industry standard tolerances for differ-
that space has been provided so that adequate mate-
ent materials are not necessarily compatible, it is in
rial, tools and equipment can be used to complete the
the interest of the producer and erector to verify the
connections. Verify that tools and equipment can be
compatibility of each industry's erection tolerances
utilized in the intended manner under the most ad-
with the precast tolerances. Compatibility of toler-
verse combination of possible tolerances.
ances is achieved by connection design and/or by
For a cast-in-place concrete frame the maximum
modification of standard tolerances of one or more of
tolerances that should be permitted, unless other-
the involved building systems.
wise stated in the project specifications, are those gi-
Note that any modification of standard tolerances
ven in the current revision of ACI117 Standard Toler-
on the non-precast portion of the work must be
ances for Concrete Construction and Materials. The
brought to the attention of the architect/engineer so
tolerances given in ACI117 are quite optimistic for tall
the modifications can be coordinated throughout the
buildings when compared to the American Institute of
project design and construction to assure that the
Steel Construction tolerances and to as-built mea-
modified tolerances are, in fact, achieved.
surement of tolerances obtained from measurements
of tall buildings.
13.1 Connection Tolerances for Mixed Build-
Variations in height of floors in excess of the ACI
ing Systems
117 tolerances are more prevalent in cast-in-place
Special attention should be given to assuring that construction than in other types of structures when
the responsible project team member has appropri- compared to published tolerances for example in
ately considered the connection tolerance require- steel frame buildings. This will affect location or mat-
ments when mixed building systems are involved. ing of the inserts in the precast panels with the cast -in
The manner in which precast concrete members are connection devices.
connected to each other or to members fabricated of The producer and erector should be aware that tol-
other materials should be reviewed by the producer erances for cast-in-place structures may have to be
and erector in the context of the specified erection tol- increased even further beyond the values given in ACI
erances. The erector should review the design docu- 117 to account for local trade practices, the complex-
ments to assure it is practical to physically construct ity of the structure, and climatic conditions which will
the connections. exist at the time of construction. For these reasons lo-
For precast to precast erection acceptable bearing cal producers should collaborate with the architect/
tolerance conditions which are required for safe erec- engineer early in the project providing their input on
tion should be shown on the erection drawings. For overall project tolerances.

120
14.0 Clearance Considerations in Product When a project involves particular features sensi-
Manufacture tive to the cumulative effect of generally accepted tol-
erances on individual members, the producer's and
The entire building team should collaborate and erector's review should assure that the architect/en-
cooperate throughout the project to allow the project gineer has provided for this effect by setting a cumula-
to be satisfactorily built using practical tolerances and tive allowance or by providing appropriate clearances
clearances. Clearance is the space provided be- where accumulated tolerances can be absorbed.
tween adjacent precast members and is one of the
most important factors to consider in the planning for
the erection. The clearance is jointly "owned" by all of
14.2 Effects of Member Type on Clearance
Considerations
the members of the building team. What this means
is that the joint clearance is used to accommodate the The type of member is partially accounted for
product tolerances, the erection tolerances, and to al- when the product tolerances are considered. Those
low adjustment for appearance. members exposed to view should be specifically re-
Exposed joint clearance determination and config- viewed with regard to clearance requirements. An ex-
uration for architectural panels is an especially impor- posed to view member requiring stringent erection
tant consideration which should be reviewed by the tolerances generally requires more clearance for ad-
producer and the erector in advance of production. If justments than does a non exposed member with a
revisions are indicated the architect/engineer should more liberal erection tolerance. Similarly, a corner
be notified. member should have a large enough clearance pro-
Tolerances in overall building width and length are vided, so it can be adjusted to line up with both of the
normally accommodated in panel joints, making the adjacent panels.
overall building size tolerance and its relationship to In practice, members exposed to view are often
building property lines important considerations in specified with less clearance than non-exposed
joint clearance design. In the architectural panel, the members. As previously noted, more stringent spe-
joint width must not only accommodate variations in cial project tolerances may be needed when narrow
the panel dimensions and the erection tolerances for clearance joints are specified.
the panel, must also provide both a good visual line
and sufficient width to allow for effective sealing. Gen-
erally the larger the panel the wider the basic dimen- 14.3 Effects of Member Size on Clearance
sion of the joint should be in order to accommodate Considerations
realistic tolerances in straightness of panel edge, in
The effect of member size on thermal motions of
edge taper and in panel width.
the member should be considered in the review of the
When all factors are combined and considered,
project clearances. Large members are more difficult
the minimum theoretical architectural panel joint
to handle than smaller ones. A large member being
width should not be less then% in. [19 mm]. Joint
erected by a crane requires more clearance than the
widths specified as less than this amount should be
small member that can be hand erected or adjusted.
discussed in detail with the project architect prior to
start of production, as they may require more strin-
gent special project tolerances to achieve the desired 14.4 Effects of Member Location on Clear-
result. ance Considerations
The following items should be reviewed by the pro-
ducer and erector in their project review to determine The requirements for erecting the member in the
that appropriate clearance has been provided in the structure should be considered in the review of the
design. project clearances. With multistory members for ex-
ample, floor members may be erected by lowering
them from the top down between the previously
14.1 Effects of Product Tolerances on Clear- erected vertical members. This process often re-
ance Considerations quires a greater clearance for erection than does a
roof member.
The product tolerance of the member or system (if
it is an interfacing situation) and the possible maxi-
mum and minimum variations in the size of the mem- 14.5 Effects of Member Movement on Clear-
ber should be considered when reviewing the speci- ance Considerations
fied joint clearance for adequacy. If revisions to the
design are indicated the architect/engineer should be The review of clearances should consider member
notified. movements caused by temperature expansion and

121
contraction, creep, shrinkage, structural deflection should be maintained. At least 1.50 in. [38 mm] of
and rotation. The clearance between vertical mem- clearance between the back of the panel and the sur-
bers and the adjacent horizontal members should al- face of the supporting steel beam should be specified
low for some movement in the horizontal member to in tall or irregular structures regardless of the structur-
prevent the vertical member from being pushed or al framing materials.
pulled out of its original alignment. This is especially The minimum clearance between column covers
critical on exposed structures such as parking decks, and columns should be 1.50 in. [38 mm], with 3 in. [76
where temperature ranges and the associated mem- mm] preferred because of the possibility of columns
ber movements are significant. being out of plumb or a larger than nominal column
The effects of support member deflection on panel dimension interfering with the completion of the col-
movement can effect the clearance specified be- umn cover connections.
tween cladding panels that are supported by structur-
al members. 14.8 Procedure For Determination of Clear-
ance
14.6 Effects of Member Function on Clear-
ance Considerations The following is a systematic approach for making
a trial selection of a clearance value and then testing
The function of a member within the building that selection to ensure that it will allow practical erec-
should be considered in the review of the specified tion to occur. This type of systematic evaluation of all
clearance. For example, allowances should be pro- specified clearances will disclose potential problems
vided for end rotation of heavily loaded beams. Like- or areas which will require special care in member
wise a minimum amount of joint width is needed to as- production and/or erection.
sure the joint can be reliably sealed when the member
must provide protection against the elements. Step 1

14.7 Effects of Erection Tolerances on Clear- Determine the maximum size of the members in-
ance Considerations volved (basic or nominal dimension plus additive tol-
erances). This should include not only the precast
Of all the factors discussed above, product toler- and prestressed members, but also other materials.
ances and member movement are the most signifi- This step includes evaluating the installation toler-
cant variations to consider when reviewing project ances of the non-precast building systems and sub-
clearances. If the clearance provided is too small, systems and the consequences of those tolerances
erection may be slow and costly because of fit-up on the precast member interface.
problems and the possible requirements for rework.
Reviews by the architect/engineer and producer
Step 2
should determine that the erection tolerances have
been considered in the development of clearance Add to the maximum member size the minimum
specifications. The clearance necessary for erection space required for member movement resulting from
of the members will depend on their geometric config- deflections, and thermal movements. Tolerances of
uration, the dimensional accuracy of the building systems installed by other trades are generally as de-
frame or other construction to which the members are fined in the standards of practice for those trades.
connected and the limits of adjustment permitted by
the connection details.
A rule of thumb is that at least 0.50 in. [13 mm] Step 3
clearance be specified between panels and precast Check to see if the selected clearance allows the
concrete panel support members with 1 in. [25 mm] member to be erected within the erection and inter-
preferred. A clearance of 1 in. [25 mm] is the mini- facing tolerances, such as plumbness, face align-
mum planned clearance between panels and cast-in-
ment, etc. If the member interfaces with other struc-
place concrete panel support members with 1.50 in. tural systems, such as steel frame or a cast-in-place
[38 mm] preferred. concrete frame, check to see if the clearance pro-
For steel structures, 1 in. [25 mm] is the minimum vides for the erection and member tolerances of the
clearance between the back of the panel and the sur- interfacing system. Adjust the clearance as required
face of the fireproofing on the steel panel support to meet all of the needs. More clearance may be
members with 1.50 in. [ 38 mm] preferred. If there is needed to accommodate interfacing with other sys-
no fireproofing required on the steel panel support tems which may have large tolerance variations.
members then 1 in. [25 mm] minimum clearance

122
Step 4 variations in subsystem interface requirements is
necessary for every project. One should not assume
Check to see if the member can physically be that by simply specifying that "PC I tolerances shall be
erected with the clearance determined above. Con- used" that everything will work out. That "everything
sider the size and location of members in the structure will work out" is something that needs to be verified
and how connections will be made. Adjust the clear- by the development of the project tolerance plan.
ance as required. An understanding of the planned This is particularly true for complex projects or pro-
erection sequence is important in reviewing the ap- jects which are substantially different from those pre-
propriateness of specified clearances. For complex viously handled by the particular building team in-
situations it is beneficial to involve the erector in this volved.
review. The following examples in Articles 14.10 through
14.12 demonstrate the thought process involved in
Step 5 forming a project tolerance plan. A judgment situation
was created to emphasize that engineering judgment
Review the clearance to see if increasing its di- must be included as part of the clearance determina-
mensions will allow easier, more economical erection tion process. Therefore, the solution shown is not the
without adversely affecting aesthetics. Adjust the only correct one for the situation described.
clearance as required. If adjusting the clearance as The project tolerance plan should not only include
required to allow fit up still results in reasonable clear- the specification of the project tolerances and details
ance widths, the design portion of the tolerance con- but should also provide the basis with which the
trol plan for this element of the building is complete. construction team can verify the accomplishment of
the tolerance objectives leading up to the erection ef-
fort.
Step 6

Review structural considerations such as types of 14.10 Roof Member Clearance Example (Refer
connections involved, sizes required, bearing area re- to Figure 14.10.1)
quirements, and other structural issues. Check struc-
tural adequacy. The structural requirements for bear- Given: A double-tee roof member bearing on
ing areas and connection eccentricities should be ribbed wall panels.
available as input to the review of the project toler- Find: The minimum acceptable joint clearance.
ance plan. See Articles 10.3 and 10.6.

Step 7 Length of member = 60ft. [18 m]long

Length tolerance = ±1 in. [25 mm]
Check design to ensure adequacy in the event that Wall member length to haunch = 25ft. [7.6 m]
minimum member size should occur. Adjust clear- Max. plan variance =±'12 in. [±13 mm]
ance as required for minimum bearing and other Plumb variation = v. in. per 10ft. [6 mm per 3 m]
structural considerations. Haunch depth is 6 in. [152 mm] beyond the face
of the panel.
Long term roof deflection is - V. in. [ -6 mm].
Step 8

Select the final clearance which will satisfy all of the

conditions considered. Procedure:

14.9 Clearance Examples Step 1 - Determine maximum member sizes.

A project tolerance plan incorporating all possible Maximum double tee length = +1 in. [ +25 mm]
product tolerance variations, erection tolerance varia- Maximum wall thickness = + 'I• in. [ +6 mm]
tions, setting of joint clearances, selection of toler- Initial clearance chosen= 3/. in [19 mm] each end
ance accommodating connection details, and the

123
Fig. 14.10.1 Roof Member Clearance Determination (Example 14.1 0)

60' 0" (+1")

-

r
I (
Detail
)
L Double tee roof member
(long term shortening, - %")
\; lJ
25'·0 " I--- Plumb tolerance
~ I--- Wall thickness tolerance ( + 114'', - 1; 8 ~) (1/4" p er 10')

Ribbed wall panels

± W' Plan variance --•11-o•~- ±%'' Plan variance

Elevation

---Jr-- %" Clearance

~======1m

1--- Precast concrete ribbed

Precast, prestressed concrete
double tee roof member
J wall panel

Detail

Step 2 - Evaluate effects of member movement ance should be increased by '12 in. [13 mm]. If the
panel is erected out of plumb outward y, in. [13 mm]
Required clearance adjustment as a result of no clearance adjustment is needed.
member movement = none
Clearance chosen = % in. [19 mm] (from Step 1) Clearance adjustment required to account for
The long term shrinkage and creep movement will erection tolerances = none
increase the clearance, so this movement can bene· Clearance chosen = % in. [19 mm] (from Step 1)
glected in the initial clearance determination, al·
though it must be considered structurally.
Step 4 - Erection Considerations

Step 3 - Evaluate effects of erection tolerances If all members are fabricated perfectly, then the
joint clearance is% in. [19 mm] at either end of the
If the wall panel is set inward toward the building double tee (1.5 in. total) [38 mm]. This is ample space
interior '/, in. [13 mm] and erected plumb, the clear·

124
for erection of this member. If all members are at max- Step 8 - Determine final clearance
imum size variance, maximum inward plan variance,
and maximum inward variance from plumb, the total Minimum clearance to be used = % in. [19 mm]
clearance is zero. This situation is undesirable, as it This clearance satisfies all conditions considered.
would likely require some rework during erection.
However, there is opportunity to directly measure the Note: For simplicity in this example, beam end
span length of the roof member and adjust the wall rotation, flange skew, and global skew tolerances
members upon erection. have not been considered. In an actual situation,
these factors should also be taken into account.
Clearance chosen = % in. [19 mm] (from step 1)
14.11 Bearing Wall Panel Joint Clearance Ex-
A judgment should be made as to the likelihood of ample (Refer to Figure 14.11.1)
maximum product tolerances all occurring in one
location. If the likelihood is judged to be low, the % Given: Bearing wall panel, 18 ft. [5.5 m] high
in. [19 mm] clearance needs no adjustment, but, ifthe erected on a cast-in-place concrete footing.
likelihood is high and the opportunity for adjustment Find: The minimum acceptable clearance be-
upon erection is judged to be low, the tolerance sys- tween the base of the wall panel and the top of the
tem designer might increase the clearance to 1 in. [25 footing.
mm]. In this instance the likelihood has been judged
to be low; therefore no adjustment has been made. For simplicity, it is assumed that the plane of the
top elevation of the wall panels will be set at exactly
the basic elevation.
Step 5 Evaluate the economy of this clearance
Minimum space for proper grouting beneath the
In single-story construction, increasing the clear- wall panel is judged in this case to be '12 in. [13 mm].
ance beyond% in. [19 mm] is not likely to speed up
erection as long as product tolerances remain within Procedure:
allowed variances. No adjustment is required for eco-
nomic considerations.
Step 1 Determine maximum member sizes

Step 6 Review structural considerations Maximum panel height= +'12 in. [+13 mm]
Highest footing top elevation = + '12 in. [ + 13 mm]
Allowing a setback from the edge of the corbel, as- Refer to Product Tolerances Article 10.3
suming in this instance to have be set by the engineer Initial clearance chosen = 1.5 in. [37 mm]
at 1.25 in. [32 mm] plus the clearance, the bearing is This results in '12 in. [13 mm] clearance in the maxi-
4 in. [102 mm] and there should be sufficient space mum member size condition.
to allow expected member movement. The tolerance
designer judges this to be acceptable from structural
and architectural viewpoints and no adjustment to the Step 2 Evaluate effects of member movement
clearance is required for structural considerations.
Bottom of member will be fixed once member is
grouted. No adjustment is required for member
Step 7 Check for effects of minimum member sizes movement.

Minimum double tee length = -1 in. [25 mm] ['12

in. [13 mm] each end). Step 3 Evaluate other erection tolerances
Refer to product tolerances Article 10.3 and 10.6
Plumb tolerance has minimal effect on the clear-
Minimum wall thickness = -Vain. [ -3 mm] anceatthis location.ln this example the top of the wall
Bearing haunch = no change
panel is assumed to be set at the nominal elevation.
Clearance chosen= 3/, in. [19 mm] (from step 1)
The minimum bearing, of 4% in. [117 mm], without
setback is satisfactory in this instance. Step 4 Erection considerations
Note: Wall plumbness is assumed to be at nominal
(no variation from nominal) in this example. Ease of erection is not influenced by the size of this
clearance.

125
Fig. 14.11.1 Bearing Wall Clearance Determination (Example 14.11)

V Panel top elevation

E
E 1----- Precast concrete
"' bearing wall member

~
tl

/Clearance

.-cv ~
j Footing elevation ±Vi' (13 mm)

~
Cast-in-place foundation ----:"+--•
~

Step 5 Evaluate economic considerations mm] standard grout bed with a 2'12 in. [64 mm] thick
possible grout bed is expensive. As a general rule, for
Varying the clearance above 1.5 in. [37 mm] will normal contracting conditions, it is desirable to pro·
make the grouting operation more costly, as more vide at least 1'12 in. [38 mm] of clearance for a detail
grout will be required. The cost of the additional vol· such as this .
ume of grout required can be computed. If special attention to detail in setting and finishing
the tops of the footings is agreed upon with the con·
Step 6 Structural considerations tractors involved, one might reduce the nominal
clearance to 1 in. [25 mm].
Clearance chosen = 1.5 in. [37 mm]
Minimum depth of grout bed= '12 in. [13 mm] Step 8 - Determine final clearance
1.5 in. [37 mm] clearance is acceptable.
Minimum clearance used = 1 in. [25 mm]
Step 7 Check effects of minimum member sizes.
The designer judges that with care to assure foot·
Refer to Product Tolerances Article 10.3 ings are set on the low side of their top elevation
Clearance determined (Step 6) = 1.5 in. [37 mm] construction tolerance. This will likely satisfy all of the
Minimum panel length= '12 in. [13 mm] short conditions considered and provide an economical
Minimum footing elevation = '12 in. [13 mm]low connection.
Maximum clearance calculated = 2'12 in. [64 mm] Note: Alert contractor and erection crews to
instances which may require isolated rework in order
A judgment condition now exists. A 1.5 in. [38 to provide minimum required grout space.

126
14.12 Cladding for High Rise Steel Frame Step 6 Structural considerations
Building Clearance Example (Refer to
Figure 14.12.1) Clearance chosen ~ 23!• in. [70 mm] (From Step
3)
Given: A thirty six story steel frame building is de- This results in an expensive cladding connection,
signed with precast concrete cladding. The steel but it is possible to construct. No adjustment re-
structure is erected to tolerances per AISC. Assume quired.
that member movements have been calculated to be
negligible. In this example, precast tolerance for vari- Step 7 Check minimum member sizes at 36th story
ation in plan is specified as ±'I• in. [6 mm].
Refer to product tolerances Article 10.3
Find: Determine whether or not the panels can be Clearance chosen ~ 2% in. [70 mm] (Step 3)
erected plumb and determine the minimum accept- Minimum cladding thickness ~ - 1/a in. [ -3 mm]
able clearance at the 36th story. Minimum steel beam width ~ - 311s in. [ -4.5 mm]
Procedure: Steel support beam sweep~ -'/• in. [ -6 mm] (to-
ward building interior)
Minimum size of steel variation in plan ~ -3 in.
Step 1 - Product tolerance [ -75 mm]
Clearances calculated~ 6511s in. [156 mm]
Refer to product tolerances Article 10.1 2% + Va + 311s + '!. + 3 ~ 6511s in.
When the minimum condition exists, the resulting
Precast cladding thickness ; + v. in. [ +6 mm] clearance of6'11s in. [156 mm] produces a connection
-Vain. [-3 mm] judged by the designer to be too costly for the precast
Steel member width ~ + V. in. [ +6 mm] - 311s in. concrete cladding on this project. In addition it pro-
[-4.5 mm] duces a high torsional force on the supporting struc-
Steel member sweep (varies) ±V. in. [±6 mm] as- tural steel that must be considered in the design of
sumed. any horizontal steel supporting members.

Step 2 - Member movement effects Step 8 - Determine final clearance

For simplicity, assume this can be neglected in this Minimum clearance used ~ 23/• in. [70 mm]
example.
The 6511a in. [156 mm] clearance is judged not
Step 3 - Other erection tolerances practical, although the 2% in. [70 mm] minimum initial
clearance is still needed for erection. Therefore the
Maximum steel variation in plan ~ 2 in. [50 mm] initially specified erection tolerances need to be ad-
Minimum clearance~% in. [19 mm] justed.
This is the minimum clearance needed to com- Either the precast cladding members should be al-
plete the connection in the field. lowed to follow the steel frame tolerances and be
Clearance chosen ~ 2% in. [70 mm] erected out of the standard plumb tolerances for pre-
cast panels or the steel frame erection tolerances
need to be made more stringent. The likely most eco-
Step 4 - Erection considerations nomical and recommended solution will be for the
Adjustment required ~ none precast cladding members to follow the steel frame
as the variation in plumb in a building of this height will
not be noticeable.
Step 5 - Economic considerations Another solution which has proven to be both
practical and economical in some instances is to
Clearance chosen ~ 23/• in. [70 mm] (From Step
specify the more stringent AISC elevator column
3) erection tolerances for steel columns in the building
Increasing clearance will not increase economy. facade which will receive the precast cladding panels.
Nv adjustment needs to be made for economic con-
This type of solution should be agreed to as part of the
siderations.
design and specification process.

127
Fig. 14.12.1 Determinate of cladding connection tolerances-high rise steel frame (Example 14.12)

I
Theoretical centerline of column
Maximum displacement from theoretical ,I
column center line: "toward" building line ----j ~- 2"

"Away from" building line

11_
I 3
..

I' -t- 36 stories

Possible position of
precast facade
J V4"

If
:. j,I '
Actual position of colum
' 1! I
·I
1"-
r- I

·-+-
2"-

\1 I
20 stories

Theoretical plane of precast

I! '

tacade-"building lineH
,fI,
' Steel framing
}, constructed as per AISC
Code of Standard
' Practice
H
Detail
(
~ :.r '
1/
v

2 3/4"-
(Clearance)
~ '',

·.'
'
~

1\
~ \

DETAIL
Precast ''' .
facade ; '.
,-
':::'::::
r-:-
..
Steel
framing

"
,.
)
128
15.0 Interfacing Tolerances dependent of site work, tolerances should closely
match the normal manufacturing tolerances for the
The purpose of this section is to help the designer materials to be joined plus an appropriate allowance
and producer deal with the problem of designing for (clearance) for differential volume changes between
interface tolerances. As with product and erection tol- the materials.
erances, the party to be responsible for assuring that Following is a partial checklist for the review of in-
interfacing tolerances are appropriately accounted terfacing tolerance requirements. If revisions to clear-
for in the project tolerance plan should be agreed to ances or tolerances are indicated, the architect/engi-
in writing at the start of the project. neer should be notified.
A comprehensive discussion of interfacing toler-
ances is presented and a number of typical details
and examples are given as illustrations. With interfac-
15.1 Structural Requirements
ing tolerances, it is important to note that the toler- a. The potential for introducing unintended struc-
ances associated with the system to be interfaced tural loads from the precast into the interfacing
may be very dependent on the specific system (e.g. subsystems should be evaluated. Does the be-
window system) ultimately procured for the proJect. havior of the structure require that the interfac-
The fact that the specific systems to be interfaced with ing system be isolated from primary or secon-
may not be known until late in the project make this dary structure loads?
issue one which is very important to deal with to as- b. Does the interface perform a structural function
sure a successful installation. in the structure (e.g. load transfer)?
Unusual requirements or allowances for interfac- c. In the determination of erection tolerances
ing should be in the contract documents. It is in the attention should be given to expected deflec-
interest of all parties on the project team to identify tions and/or rotations of structural members
and take steps to accommodate unusual interfacing supporting precast concrete panels.
tolerance requirements as soon as they are identified. d. How are building motions, dimensional
Accommodation of interfacing tolerances may in-
changes, and vibrations taken into account
volve contractual changes, if the interface require- structurally, and how do they collectively affect
ments are not initially defined in the contract, or if
interfacing tolerances?
these requirements change as result of procurement e. If the deflection of the structural frame is sensi-
decisions made alter the precast contract has been
tive to the location or eccentricity of the connec-
finalized.
tion, limits on connection eccentricity should be
In practice the interfacing requirements may not given on the erection drawings. This is particu-
be in the contract documents. It should be noted that
larly important for heavy members bearing on
building systems and hardware are often specified light members, such as open web joists, or can-
and procured by a company which may not have a
tilevered structural members.
contractual relationship with the precast member
f. Consideration should be given to both initial
manufacturer. If this is the case, the party with the
deflections and to expected long term deflec-
necessary contractual authority is responsible for as-
tions caused by creep of the supporting struc-
suring that the project interfacing tolerance require-
tural members.
ments are appropriately coordinated and met.
g. Allowances must be made when detailing con-
For example, windows fabricated by Company A
nections of precast concrete panels to steel
may have a quite different interface tolerance require-
structures for effects of sway in tall, slender
ment than windows fabricated by Company B. On
steel structures.
fast track projects the fact that the precast fabrication
takes place early in the project may drive the installa-
tion and tolerance requirements of the interfacing 15.2 Volume Change
systems and may influence subsystem procurement
choices. If material or component substitutions are a. The potential for volume change effects in the
made for any reason alter the initial design is com- precast or in the interfacing subsystem to
plete, the interfacing design should be reviewed by introduce unintended loads into the interfacing
the producer as well as by the architect/engineer for sub systems should be evaluated.
the new system tolerance requirements to assure b. Does the primary structure or the interfacing
compatibility of tolerances. system undergo mutually incompatible volume
Where matching of the different materials is de- changes that need to be considered? (e.g.,
pendent on work executed at the construction site, in- openings for aluminum windows should allow
terface tolerances should also be related to erection clearance for the expected thermal expansion
tolerances. Where the execution of the interface is in- of the sash.

129
 c. In tall buildings global movements of the build- face between precast concrete and other mate-
ing due to solar heating on one side and sea- rials?
sonal thermal expansions and contractions c. What are the consequences of dimensional tol-
should be considered in the design of panel erance to the drainage system?
clearances and connections.
15.6 Architectural Requirements
15.3 Exposure and Corrosion
a. Which portions of the structure exterior and in-
a. lstheinterfaceexposedtoweather? If so, what terior are exposed to view? On projects where
dimensional requirements result from the need precast members have a primarily architectur-
to provide protection from moisture and the ele- al/visual function architectural requirements
ments? may require special interfacing measures.
b. How do the proposed precast concrete details b. What are the architectural treatments proposed
enhance or detract from the ability of the struc- for the various interfaces? How do the treat-
ture to remain serviceable and durable over ments relate to interfacing tolerance require-
time? To assure the long term durability of pre- ments?
cast members, it must be assured that toler- c. Tolerances for the planeness of concrete sur·
ancing of interfacing subsystems do not pro- faces at the interface with glass or curtain wall
vide a path for corrosion of metallic elements or face should be developed in conjunction with
contribute to unacceptable corrosion staining. the curtain wall installation requirements.
d. The requirement to align architectural panels in
three dimensions may result in special interfac-
15.4 Waterproofing Requirements
ing clearance requirements, even on the non-
a. Interfacing tolerances and clearances should visible faces of the member.
be evaluated for the ability to properly support e. It is important that the project design provides
the installation of weatherproofing materials. adequate clearance between the nominal face
b. What are the waterproofing requirements of the of the supporting structure and the back face of
roofing details, exterior penetrations, and the attached concrete panel. Adequate space
drainage schemes. How do they apply to the must be provided here to allow an efficient and
interface between the precast concrete and the economical erection operation.
other materials?
c. A minimum clearance joint width is typically re· 15.7 Dimensional Considerations
qui red to allow proper installation of water-
proofing sealant systems. Manufacturer's rec- a. How closely can the dimensions of the interfac-
ommendations for minimum joint width for the ing materials be controlled? It is important to
waterproofing sealant system to be used note than unless specifically controlled during
should be considered. the construction process, the industry pub-
d. Cast in grooves, reglets, or lugs that are to re· lished tolerances for the installation of materials
ceive glazing gaskets may require a higher lev- by other trades may or may not be met.
el of precision than other aspects of panel b. What are the dimensional considerations in
construction in order to allow proper installation relation to the proper function of the interfacing
and function. Reference should be made to systems? If the precast installation has specific
gasket manufacturers' tolerances on the interface tolerance needs, it is important to
groove width and surface smoothness neces· communicate these to all levels of the project
sary to obtain a proper moisture seal. design team and follow up with the construc-
tion team. This communication should be
through the party having contractual authority
15.5 Drainage Requirements
over the involved trades.
a. Interfacing tolerances which have an effect on c. The following tolerances, in addition to ACI117
the proper draining of the roof or other features requirements, should be specified for the cast-
which could retain or pond water should be re· in-place concrete construction when precast
viewed to assure that positive drainage is pos- concrete members are to be connected to cast-
sible. in-place structures. It should be noted that spe-
b. Where are the areas to be drained and how cial measures and attention to detail are likely
does the drainage requirement affect the inter- to be required to achieve these more stringent

130
 than usual tolerances in the cast-in-place con- 15.8 Vibration Considerations
crete construction. Following up to assure that
the requested tolerances have actually been a. Does the mechanical subsystem have vibration
achieved has proven to be an important activity considerations which must be accounted for in
in assuring that the construction/precast erec- the interface between it and the precast con-
tion activity proceeds smoothly. crete?
b. If vibrations result in deflections of members,
1. Footings, caisson caps, and pile caps contact between members as result of vibration
aa. Variation of bearing surface for precast mem- should be avoided.
bers from specified elevation:
±0.50 in. [±13 mm] 15.9 Fire-Rating Considerations
2. Piers, columns, and walls. a. Does the need for fire resistance of the system
aa. Variation in plan from straight lines parallel to impose any tolerance requirements on the na-
specified linear building lines: 0.025 in. per foot ture of the interface such as maximum allow-
[2 mm per m] for adjacent members less than able gaps? Code requirements relating to fire
20feet [6 m] apart or any wall or bay length less ratings often require that gaps beyond a certain
than 20 feet [6 m]. size be sealed in a fire proof manner.
0.50 in. [13 mm] maximum for adjacent mem-
bers 20 feet [ 6 m] or more apart or any wall or
bay length of 20ft. [6 m] or more. 15.10 Acoustical Considerations
bb. Variation in elevation from lines parallel to spe-
cified grade lines: a. Does the acoustic environment place any spe-
0.025 in. per foot [2 mm per m] for adjacent cial requirements on the interface between pre-
cast concrete and interfacing systems? Clear-
members less than 20ft. [6 m] apart or any wall
or bay length less than 20ft. [6 m]. ance gaps can sometimes provide a route for
0.50 in. [13 mm] maximum for adjacent mem- unwanted transmission of sound from one
bers 20 feet [6 m] or more apart or any wall or room to another.
bay length of 20ft. [6 m] or more.
15.11 Economics
3. Anchor bolts
Special coordination with the cast-in-place a. Does the chosen interface design alternative
concrete contractor and the use of erection bolt place any unusual or costly demands on either
setting templates common to both the precast the precast or the interfacing system?
and cast-in-place construction effort will likely b. Has the most economical interfacing design al-
be required to achieve anchor bolt tolerances ternative been used? In some cases the cost of
which will allow trouble free erection. accommodating a tolerance sensitive interfac-
aa. Variations from specified location in plan: ing system may be a significant percentage of
±0.25 in. [±6 mm] the total costofthe installed interfacing system.
bb. Variation center to center of any two bolts within c. Has the cost trade-off between in-plant work
an anchor bolt group: ±0.125 in [±3 mm] and field work been considered?
cc. Variations from specified elevation: ±0.50 in
[±13 mm]
dd. Anchor bolt projection: - 0.25 in., +0.50 in. 15.12 Manufacturing/Erection Considerations
[-6mm, +13mm] a. Does the interfacing method consider practi-
ee. Plumbness of anchor bolts: ±0.062 in. [±2
calities of manufacturing? The manufacturing
mm]
and erection work necessary to accommodate
4. Tolerances for structural steel framing should an interfacing tolerance should be objectively
be specified to conform with the American Insti- evaluated. Viable methods of attaining the re-
tute of Steel Construction (AISC) "Code of quired interfacing tolerances should be defined
Standard Practice for Steel Buildings and before the producer agrees to provide them.
Bridges". b. Is the time required to manufacture the inter-
Particular attention is directed to the "Commen- face consistent with factory production?
tary" included with the AISC code. The commentary c. Can the interfacing parts of the structure be
provides a detailed explanation of the specified steel erected together safely and economically?
erection tolerances.

131
16.0 Design Approach for Two Interfacing Tol- tems which must be precisely installed to stringent
erance Systems tolerances in the completed structure.
Another example of functional requirements is the
Unless the design and construction team has a building drain line that must have a flow line slope
significant background of successful experience with which allows adequate drainage. This will place func-
a particular building system type, and the handling of tional limits on where the line must penetrate m<:>m-
all of the interfaces, the only way to assure the pro- bers. Consider a tee beam that has harped prestress-
posed approach to handling interfacing tolerances ing strands in the stems, making the end areas of the
will be viable is to systematically and numerically re- beam potentially difficult locations to interface with
view the proposed tolerances and interfacing require- the prestressing strands for the drain line penetra-
ments. tions.
The following approach is one suggested method
of organizing the task of systematically reviewing the
interface specified between two tolerance systems. It Step 3 Review the dimensional tolerances of each
interfacing system.
is in the interest of the producer to confirm that some-
one on the project team is responsible for and has in- For example, determine from the manufacturer's
fact reviewed the project interface tolerances. specifications what the external tolerances on the
The nominal clearance dimensions shown on the specified prefabricated metal door jamb are. Deter-
erection drawings should be equal to the actual clear- mine from the precast/prestressed concrete product
ance required plus the outward tolerance permitted tolerances what the tolerance on a large panel door
for the adjacent construction. The clearances should opening will be. For the door installation, determine
be evaluated on the assumption that the precast pan- what the floor surface tolerance requirement will be in
el will be as far out of the nominal position as is al- the area of the door and its swing path.
lowed, in the direction which creates the requirement
for the largest clearance. Special attention should be
given to complex geometric interfaces. Drawing the Step 4 Review the operational clearance specified.
interface to scale showing the possible local and
The most significant tolerance interface problems
global variations is one way to evaluate an interface
result when the members of the project team don't
situation.
understand or are unaware of special operational re-
quirements of interfacing subsystems. For example,
Step 1 Review the interface between the two sys- determine the magnitude of operational clearances
tems. which are needed to align the specified door to func-
tion properly. Then, review the nominal dimensional
a. Has the architect/engineer graphically defined
choices to assure they include an allowance for nec-
the interface to show its shape, location, and
essary clearances.
any split of contractual responsibility?
b. Has the architect/engineer shown the material
furnished by the different contracting parties? Step 5 Review compatibility of the interface toler-
For example, one might indicate the precast panel ances.
furnished by the precaster, the window furnished and
Interface tolerance incompatibility problems re-
installed by the general contractor, and the sealant
solved in the design phase of the project do not be-
between the window and the precast concrete fur-
come member fabrication problems or erection prob-
nished and installed by the general contractor. On fast
lems.
track projects it may be necessary for the window
Starting with the least precise specified system, re-
suppliers to measure the as-built window openings in
view the minimum and maximum tolerance condi-
the precast members prior to fabricating the win-
tions and compare the precast dimensions against
dows.
the minimum and maximum dimensions of the inter-
facing system. If interferences result, notify the archi-
Step 2 Review the functional requirements of each tect/engineer. For example, it is usually more eco-
interfacing system. nomical to make a larger window opening to provide
more clearance than to specify a prefabricated win-
Functional requirements which require close toler- dow system with either nonstandard sizes or toler-
ances, such as justice facility locking mechanisms, ances more stringent than standard. It is important to
require special attention. Often tolerance friendly in- understand how a close tolerance interface is ad-
terface details which can accommodate significant justed upon installation and how much adjustment
tolerance variations can be used to economically in- capability is required.
terface the precast members with interfacing subsys-

132
Step 6 Review procedures for compatibility. tolerances have been made. If project specifications
are silent on the topic of interface tolerances, it is in
Review assembly and installation procedures for the producer's interestto requestthat additional infor-
the interfacing systems to assure compatibility. Re- mation be provided regarding interfacing tolerance
view the installation procedure to assure that the pre- requirements of specified subsystems.
ferred adjustments to accommodate the tolerances
of the interfacing systems have been indicated. Re-
Step 7 Review final project specifications
view such items as minimum allowable bearing
areas, minimum and maximum joint gaps, and other Review the final project specifications as they re-
features which will vary in dimensions as a result of late to interfacing. Be especially aware of changes
the interface tolerances. which may be required as a result of possible subsys-
Review that appropriate economic trade-{)tf con- tem substitutions made during the final bidding and
siderations such as in-plant work versus field work, procurement activities.
and minor fit-up rework versus specification of tighter

133
17.0 Defining the Characteristics of a Toler- 17.1 Windows and Doors
ance Interface
a. No load transfer through window element
The following list of questions should be consid· b. Compatible with air and moisture sealant sys-
ered in the producer's review olthe nature olthe inter- tem
face between the precast member and an interlacing c. Open/close characteristics (swing or slide).
system: Windows that must open and close may have
1. What specifically is to be interlaced? more stringent interlace requirements than
2. How does the interface function? those which do not.
3. Is there provision for adjustment upon installa· d. Compatibility with door locking mechanisms
lion? Some interfacing subsystems have adjustment
capability within the subsystem. Others may have 17.2 Mechanical Equipment
zero adjustment capability built in.
4. How much adjustment can occur without re- a.Duct clearances for complex prefabricated
work? It is important to understand who will be re- duct work.
sponsible for any tolerance related rework that may b. Large diameter prefabricated pipe clearance
be required. requirements.
5. What are the consequences of an interlace tol- c. Deflection clearance requirements for deflec-
erance mismatch? tion associated with large-diameter piping and
a. rework requirements (labor and material) valves.
b. rejection limits (when a will a remake be re- d. Expansion and contraction allowances for hot
quired?) and cold piping. Large diameter piping with
6. What are the high material cost elements of the significant thermal differentials may be associ·
interlace? It is important to understand who is ated with significant forces if the piping is not
responsible for the cost of materials and labor appropriately isolated from the structure.
required to complete the different interfaces. e. Vibration isolation/transfer considerations.
7. What are the high labor cost elements of the in· 1. Acoustical shielding considerations.
terlace? This is especially important for field g. Hazardous gas/fluids containment require-
installed interlacing subsystems. ments. Hazardous materials applications may
8. What are the normal tolerances associated with result in special gap sealing requirements
the system to be interlaced? Different types of unique to this type of installation.
systems may have substantially different inter-
facing requirements.
9. Are the system interlace tolerances simple pia·
17.3 Electrical Equipment
nar tolerances or are they more complex and a. Coordination of multiple mating conduit runs.
three dimensional? For example, mechanical b. Prefabricated cable trays that must align.
piping for on-site fabrication in primarily straight c. Embedded conduits and outlet boxes. Visible
runs may have different interlacing tolerance outlet boxes or switch boxes embedded in pre·
requirements than do complex prefabricated cast walls may require special angular align-
mechanical piping systems which have bends ment tolerances for visual reasons.
occurring at penetration locations. d. Corrosion considerations related to DC power.
10. Do all of the different products of the type being e. Special insert placement requirements for e\ec·
interlaced with have the same interlace toler- trical isolation and potential for adverse reac·
ance requirements? tion with galvanized materials.
11. Does the designer of the precast system have f. Location requirements for embedded ground·
control over all aspects of the interlaces in·
ing cables.
valved? If not, what actions need to be taken g. Shielding clearance for special "clean" electri·
to accommodate this fact? cal lines.
If the answers to these questions indicate the need
for revision to interfacing tolerances or details, the ar·
chitect/engineer should be notified. 17.4 Elevators and Escalators
Listed below are some common characteristics
a. Elevator guide location requirements. Different
and considerations which are typical of most sys·
manufacturers of elevators and escalators.
tems:

134
 have specific interface tolerance requirements b. Detailing to assure desired contact bearing be-
which may be different. tween masonry and precast members.
b. Electrical conduit location requirements. c. Detailing to assure desired transfer (or isola-
c. Elevator door mechanism clearances. Floor tion) of load between masonry shear wall and
slope tolerances at elevator door locations may precast frame elements.
require special consideration.
d. Special insert and control switch placement re- 17.8 Roofing
quirements.
The tolerance requirements for interfacing with
17.5 Architectural Cladding unique roofing systems should be reviewed as part of
the project tolerance plan.
The three dimensional interface requirements of a. Roof camber, both upon erection and long
architectural cladding systems, especially at corners, term, as it relates to roof drain placement.
locations of unique geometry, and areas of interface b. Fit-up of prefabricated flashing.
from one cladding type to another should be ac- c. Dimensional effects of increased deflections re-
counted for in the project tolerance plan. sulting from added material during re-roofing.
a. Joint tolerances for the specified caulking sys- d. Coordination of structural control joint locations
tem. with roofing system expansion/contraction pro-
b. Flashing and reglet fit-up (Lining up reglets visions.
from panel to panel is very difficult and often e. Location of embedded HVAC unit supports.
costly. Surface-mounted flashing or field cut re- f. Deflections due to live loads and added equip-
g lets should be considered.) ment dead loads.
c. Expansion and contraction provisions for dis-
similar materials. 17.9 Waterproofing
d. Effects of differential thermal gradients.
The party with primary responsibility for interface
17.6 Structural Steel and Miscellaneous Steel coordination of waterproofing details at the shop
drawing stage should be defined in writing for the
The party with primary responsibility for interface project.
coordination of structural steel shop drawings with a. Location and dimensions of flashing reglets.
precast concrete shop drawings should be defined in b. Location and shape of window gasket grooves.
writing for the project. c. Coordination of waterproofing system require-
a. Details to prevent rust staining of concrete. ments with structural system expansion provi-
b. Details to minimize potential for corrosion at sions.
field connections between steel and precast d. Special details around special penetrations.
concrete.
c. Coordination of structural steel expansion/con-
traction provisions with those of the precast
17.1 0 Interior Finishes-Floors, Walls, and
system. Ceilings
d. Special provisions for weld plates or other at-
tachment features for steel structures. Different interior finishes require different levels of
e. Consideration of thermal insulation and fire tolerance on substrata to which they are applied.
proofing requirements. Thus the interface tolerance requirements of the finish
types specified for the project are a consideration to
17.7 Masonry be addressed in the project tolerance plan.
a. Joints between plank members for direct car-
The party with primary responsibility for interface pet overlay.
coordination of masonry shop drawings with precast b. Visual appearance of joints for exposed ceil-
concrete shop drawings for the project should be de- ings.
fined in writing. c. Fit-up details to assure acceptable appearance
a. Coordination of masonry expansion/contrac- of interior corners.
tion provisions with those of the precast sys- d. Appearance of cast-in-place to precast con-
tem. crete interfaces.

135
17.11 Interior Walls and Partitions c. Effects of thermal bowing of wall panels.
The potential for thermal bowing to result in gaps
a. Clearance for prefabricated cabinetry and oth- between floors and walls should be evaluated.
er prefabricated finish elements.
b. Interfacing of mating embedded conduit runs
and switch boxes.

136
18.0 Typical Tolerance Related Details concerned with tolerance related considerations,
therefore structural design and aesthetics, while of
The following pages illustrate assemblies and de- great importance, are not generally emphasized.
tails often used in precast concrete structures. In Note that in all details showing weld plates, an-
some instances, precast to precast details are chors and auxiliary reinforcing are not shown to avoid
shown. However, many of the details are also applica- confusion in the graphics. These elements, should be
ble to interfacing with other materials. properly designed and included in the actual
Detailing suggestions are given with each assem- construction details as appropriate.
bly shown in this section. This section is primarily

137
Fig 18.1.1 Detailing Suggestions for Column to Footing Connection Using Anchor Bolts

1----- Precast concrete column

- - Corner pocket

Alternate form for

Base I[--~ use with flowable
non-shrink grout

Dry pack or
non-shrink ,----- Top of footing
grout

c4------l-- Anchor bolts

1. Provide clearance "t>;' to accommodate tolerances required as result of the

combination of column length and footing elevation tolerances. This dimen-
sion is typically set to accommodate bottom leveling nuts and for proper
tamping of dry pack grout.
2. Provide pocket dimension "B" large enough for easy operation of a manual
or power wrench to tighten anchor bolts to assure contact bearing with the
base plate.
3. Control dimension "C" to acceptable levels of tolerance by using templates
to set anchor bolts embedded in the footing.
4. Control dimension "D" by using a template which matches the footing an-
chor bolt template or by providing tighter tolerance on the location and size
of the receiving holes in the base plate.
5. Check that minimum specified anchor bolt thread engagement has been
achieved. If not, reconsider clearance "t>;' or increase anchor bolt length
above top of footing.

138
Fig 18.2.1 Detailing Suggestions for Column to Footing Connection Using Footing Sleeves

J,v
Precast concrete column

I
c,c

Shims I

~
Dry pack Alternate form for
I use with flowable

4
non~shrink grout
' I' l
A/ i==:I::::
t I Interlocking conduit
sleeve

<
I >
Flowable
non-shrink
grout ~~~-B 'W
' t
"'IV

1. Provide clearance "/'\' large enough to accommodate tolerances required as

result of the combination of column length and footing elevation tolerances.
2. Provide sufficient minimum clearance (dimension "B") to accommodate pro·
per flow of grout.
3. Control dimension "C" by using a template to control the placement of pro-
jecting column reinforcement to be embedded in the footing sleeves.
4. For the sleeves in the footing use oversized conduit or corrugated pipe at
least two times the diameter of the reinforcing bar bundle to accommodate
both the placement tolerances for the footing sleeves and the tolerance of
projecting column reinforcing bars.

139
Fig 18.3.1 Detailing Suggestions for Column to Footing Connection Using Splice Sleeves

j ___
Precast concrete column

cl c
Splice sleeves

~
I
· - Column reinforcement

I
'

'u
~/
Dry pack
I
Top of footing
( ',u
sL/ n .
I (n f
' y
t
A

I f
Footing dowels
:
> <>
~ '
"
r

1. Use matching templates for the location of column reinforcement and splice
sleeve placement within the footing to control critical dimensions "C" and
"C 1 " which should be identical.
2. Provide clearance "/'\' large enough to accommodate tolerances required as
a result of the combination of column length and footing elevation toler-
ances. Also, this clearance must be adequate to allow access for the proper
grouting of the reinforcing bar sleeves.
3. Consult manufacturer of reinforcing bar sleeves for proper dimensions "B"
and "D" and for the tolerance on these dimensions.
4. Before executing splice sleeve assemblies always seek installation recom-
mendations from the manufacturer of the reinforcing bar splice sleeve used.

Note: Some producers have reported good success with splice sleeve connec-
tions where the sleeve portion of the connection is placed within the footing.

140
Fig 18.4.1 Detailing Suggestions for Wall Panel to Footing Connection

[----
---,----' ,v
Centroid

Precast concrete B
wall panel

Dry pack or non-shrink

I Inside of wall

~
grout if required
~

Top of footing
l
\ L l \ t:
-
v

/1
A/ ~

<1 I~

>
f
<1

- c
<1
l >
~I
~
Shims
d
.d ~

)1~
I v

1. Provide clearance "Pi' to accommodate tolerances as result of the combina-

tion of panel length and footing elevation tolerances.
2. Locate erection shims under the the panel centroid (dimension "B") to allow
adjustment of wall plumbness.
3. Provide a weld plate size in both wall panel and footing which gives adequate
projection "C" to accommodate the tolerance required for plate placement
and the combination of panel length and footing elevation tolerances.
4. Depending upon which is the most critical from aesthetic or functional points
of view, use either the inside or the outside surface of the wall as an erection
control surface. Do not use the wall centerline (centroid) as a control, since
tolerances variations of wall depth cause it to be a less useful reference.

141
Fi 18.5.1 Detailing Suggestion for Column to Column Connection

--- ;------

-
n
r-- ,---
Precast concrete column

B
vm -',
~Shims

Non-shrink grout / ~I I
T'i'
II
II _j
I I I I
I I I I
I I I I
I I I I
Column anchor bolts -1 I I I
~ ~
I. c .I
v

1. Provide adequate clearance ''Pi' to accommodate the tolerances required for

column length.
2. Provide pocket dimension "B" large enough for easy operation of manual or
power wrench to tighten bolts.
3. Control dimension "C" by using template for setting anchor bolts in the lower
column.
4. Use a grout thickness adequate to accommodate leveling nuts.

142
Fig 18.6.1 Detailing Suggestion for Composite Beam Supporting Double Tees

Cast-in-place concrete
integration pour

Use smaller size Cut back flange

bars at top

I
I l
I I
I I I
> I I
I I
I
I
Precast concrete I I I
double tee

L 1 r
Shear reinforcement

Precast concrete
support beam

1. In order to avoid conflict between embedded shear reinforcement protrud-

ing from the support beam and tee stems, consider the layout of the double
tee stems when determining the spacing of the beam shear reinforcement.
2. Provide adequate amount of cutback of the tee flange to allow forming of the
composite portion of the beam while avoiding tight form tolerance require-
ments.
3. Use more small bars rather than fewer large bars as top steel, as these bars
must often thread through the limited clearance between the tops of the tee
stems and the horizontal portion of the embedded shear reinforcement ex-
tending from the support beam.

143
Fig 18.7.1 Detailing Suggestion for Beam to Column Connection

D Bottom 0/D of A Top W/D of conduits

conduits to be filled to be filled with grout

I
material
ll
with compressive

~--~--~:~: !~~:·:----r-~
: : !: :
I1n1I I'1n1I I I
1n1 1n1
I' L

1111 ' 1111 < 1111 . 1111

_lllllllllc__ ~---+----~11~11 1~1~111~------~
1111 1111 L___ _ ~llll 1111
:::: ::::
' :::: 'I::::
( b l
~~ L
1
b

~ ~
Top of column -----~_jj f-'1
Threaded inserts
b i
1
b L Precast concrete
beam

c c
Precast concrete --~r--~,--j
column 11
IV

1. Use embedded conduits with oversized diameter to accommodate toler·

ances required for insert placement in the column.
2. Control dimension "B" by using a jig or template to position the inserts in the
column.
3. Provide clearance ''/'!' to accommodate the tolerances required for the com-
bination of beam length and beam end squareness tolerances for both inter-
facing beams.
4. Prevent rotation of the beam due to unbalanced loads during erection.
5. To simplify erection, use top of column as a primary control surface. Vary
grout pad thickness at the bottom of the column as required to accommo-
date tolerances in column length.

144
Fig 18.8.1 Detailing Suggestion for Exterior Spandrel Beam to Double Tee Connection

Add concrete
to gain cover

Concrete topping

L
---.__
'
~ ..Jl
Refer to product
>
tolerances for <
location tolerance
on insert _a
~
Dapped end

L i
~
A

i
tees

Precast concrete
spandrel beam

1. Allow adequate offset "t>:.' in order to accommodate tolerances resulting from

the combination of the beam depth and double tee bearing elevation toler-
ances. This is to ensure that the bottom of the tee stems will not be lower
than the bottom of the spandrel beam. If this occurs. the random bottom line
of the tee stems referenced from the soffit of the spandrel will create an un-
wanted visual effect when viewed from the exterior. A dimension "t>:.' ~ 1 in.
[25 mm] usually provides a satisfactory condition.
2. This same type of offset dimension ''Pi' should be used when interlacing with
a suspended ceiling.
3. Provide adequate clearance "B" to accommodate the combination of the fol-
lowing tolerances: beam length, beam end squareness in elevation and
beam flange squareness in plan.
4. Consider locally thickening concrete topping adjacent to spandrel to ac-
commodate insert placement tolerances and assure adequate concrete
cover over bars threaded into insert in spandrel. This detail can also be bene-
ficial to drainage in this area.

145
Fig 18.9.1 Detailing Suggestions for Load Bearing Wall Panel to Tee Connection

Precast concr ee
t
+
- t double tee
B
r::::: 7
~
l
~ '>

-2 ~ ~ ~ ~
Haunch
elevation

r-

Precast concrete
wall panel

1. To create a visually pleasing line at the top of the panel and ease the erection
of the roof elements, the haunch elevation of precast concrete wall panel
should be set as a primary control surface. Tolerances for wall length and
footing elevation should be absorbed at the panel bottom connection by
varying the grout pad thickness.
2. Provide adequate clearance "/'\' to accommodate the following tolerances:
beam length, beam end squareness in elevation and beam flange square~
ness in plan.
3. Provide weld plate in tee flange and in the wall panel of sufficient size to pro~
vide adequate projection "B" beyond the clip angle to accommodate toler-
ances in beam length, beam depth, and weld plate placement while allowing
space for proper welding.

146
Fig 18.10.1 Wall Panel to Tee Flange Connection

"Finger-tight" bolt Flashing

with positive lock off

Slotted insert Double tee

Precast concrete
wall panel

1. Provide adequate insert slot clearance "!>!' to accommodate anticipated

camber growth of tee, including the effects of camber tolerances.
2. Provide adequate insert slot clearance "B" to accommodate anticipated
deflection of tee under load, long term sag and to accommodate differential
elevations at the top of wall panels.
4. Do not tighten bolts connecting tee flange to wall panel more than "finger
tight" per the AISC recommended practice, since tightening the bolts can
result in overloading the connection when the double tee deflects.
5. Provide a positive lock-off of finger tight bolt from tee angle to slotted insert
so that it will not work loose during the life of the structure. Provide adequate
clearance gap "C"to accommodate combination oftee erection tolerances
and local smoothness tolerance of the tee flange edge.

147
Fig. 18.11.1 Fascia Beam to Tee Connection

Add concrete to
gain cover
Topping
Precast concrete - I
fascia panel

Clearance ---t-----f Strut

gap ··c··
Double tee

l B

Use angle not plate

1 . Consider locally thickening concrete topping adjacent to fascia panel to ac-

commodate insert placement tolerances and assure concrete cover over
bars threaded into insert in fascia panel. This detail can also be beneficial
to drainage in this area.
2. Consider the camber of the the tee when determining the location of the in-
serts in the fascia panels. Consideration should be given to using a slotted
connection here.
3. Provide adequate clearance gap "C" to accommodate combination of tee
erection tolerances and local smoothness tolerance of flange edge.
4. Allow offset "B" in order to accommodate tolerances resulting from the com-
bination of the beam depth and double tee bearing elevation tolerances, and
beam camber. This is to ensure that the bottom of the tee stems will not be
lowerthan the bottom of the soffit of the fascia panel. If this occurs, the ran-
dom bottom line of the tee stems referenced from the soffit of the facial panel
will create an unwanted visual effect when viewed from the the exterior. A
dimension "B" = 3 in. [75 mm] should be considered and checked for ade-
quacy.

148
Fi . 18.12.1 Scu er Blockout in Wall Panels
-

- ,.-
------ t---c Scupper blackout
B
IX t
A

Collection box ' <>

Downspout
1-- ..-c

--
.---
i
Double tee

Precast concrete
wall panel
v

1. Provide clearance ""Pi" to accommodate tolerances resulting from a combina-

tion of tee depth, insulation thickness, and roofing material thickness toler-
ances. When locating scuppers in wall panels oriented parallel to direction
of beam span, consider the effects of beam deflection when determining
scupper elevation.
2. Provide a scupper dimension of "B" 6 in. by 6 in. [150 mm by 150 mm] mini-
mum to minimize the potential for plugging these openings.
3. Place scuppers away from panel joints to keep water from running into these
areas.
4. Top of water collection box should be set at the same elevation or slightly
lower than the bottom of the scupper to assure that tolerances allow positive
drainage of the roof under all conditions.
5. Provide adequate clearance "C" to accommodate the following tolerances:
beam length, beam end squareness in elevation and beam flange square-
ness in plan.

149
Fig. 18.13.1 Wall Panel to Bar Joist Connection

_.-,------ Embedded weld plates

- Ledger angle

Precast Keep concrete

' - - - - concrete -----~--!
under ledger
wall panel angle at or below
plate surtace

Section A-A

1. Provide adequate weld plates of sufficient size as needed to accommodate

the combined effects of erection tolerances for the wall panel and embedded
weld plate location and still provide adequate plate projection ''B'' to allow
proper welding.
2. Provide adequate clearance "1'1.' to accommodate the following tolerances:
bar joist span and the panel plumbness erection tolerance and plan place-
ment tolerance for the wall panel.
3. On the element production drawings, note that the concrete adjacent to the
weld plates for the ledger angle (cross hatched area above) should be held
to a tolerance of +0 in. to - '14 [-6 mm] relative to the surface plane of the
embedded weld plates, to prevent interference problems when the continu-
ous ledger angle is attached in the field. Alternatively, the embedment plate
can be raised above the surface of the concrete.

150
Fig. 18.14.1 Masonry Wall to Tee Connection

A~ Cut back flange

.. ~.
c Precast concrete
double tee
Bearing
Precast concrete
double tee
plate

Masonry wall Masonry wall

1. Provide adequate clearance ''Pi' to accommodate tolerances required for the

vertical alignment of masonry and tee length tolerance. Dimension "Pl.'
should be based on ease of erection, forming, and fire resistance consider·
ations.
2. Set beam length such that there will always be a positive clearance or set
back "B" from the face of the masonry wall when beam length, beam end
skew, and masonry wall construction tolerances are considered.
3. Locate tee support bearing plates to assure that beam soffit does not contact
masonry shell at "C" when the combined effects of all tolerances and beam
deflection and end rotation under load are considered.

151
Fig 18.15.1 Typical Hollow-core Floor Joints

Joint tolerance (floor)

------------,~~~~=:::!________- ' - - Precast concrete

hollow-core slab

>

L\___________ _
Grout
Joint tolerance (ceiling)

1. Use leveling devices to level the bottom edges of hollow core slabs at the
joint location to minimize the effects of any differential camber when the ceil-
ing is to be exposed or planned to receive direct acoustical treatment on the
ceiling.
2. Do not release the leveling devices used to level the joints until the grout has
attained adequate strength to hold the planks in the leveled position relative
to one another.
3. Consider use of joint fairing materials for direct carpet applications.

152
Fig 18 16 1 Tee Flange to Flange Connection

.....
I\__

I I ~ I I

~ ~----~
'< ~ ~------=?
~
' '
--- rt
---

r \ I I ( I
' ( \ '
L__ Weld bar
I Weld plates -
I

I Double tee I
'

I
L:._j ~
I I

1. Provide flange connection weld plates at an angle as shown above to ac-

commodate tolerances required for plate placement and allow the place-
ment of a proper flare weld. Plate tipping tolerances are less critical for flange
connector plates angled as shown compared to the more stringent tipping
tolerances required for proper welding connector weld plates oriented with
their surfaces parallel to the vertical centerline of the flange to flange joint
(see Fig. 18.17.1, Detail B).
2. For the detail shown above use tipping tolerance for flange to flange weld
plates of ± 1/a in. [±3 mm] in both directions.
3. Provide weld bar size that is larger than the nominal double tee joint to assure
it fills the joint under the full range of expected tolerance variations.

153
Fig. 18.17.1 Typical Pretopped Double Tee Joints for Parking Structures

A Note: Hold concrete back

as shown to avoid cracking
Joint sealant problems

l
----1
----~

Double tee --~

Note: This detail requires tighter

plate tipping tolerances than does
Tool joint to the angled plate shown in Detail A
receive sealant

't Joint

Detail A Detail B

1. Tool edges of tee flange at weld plate locations as shown to assure that there
is not a thin section of concrete directly above the weld plate that will be
prone to cracking because of thermal expansion of the plate during welding.
This can result in failure of the sealant system.
2. Tool edges of tees to provide the proper shape to the joint to accept the seal-
ant specified for the project. Consult sealant manufacturer for recommenda-
tions when defining the edge tooling to produce the sealant cross section
of the joint to be sealed.
3. Provide adequate clearance gap "'/>!.' to accommodate tee flange edge
smoothness tolerances and still provide the minimum joint width necessary
for proper sealing. Tolerance for alignment and smoothness of flange edges
in pre-topped systems may require more stringent special project toler-
ances to accommodate some sealant systems. Consult sealant manufactur-
er recommendations for sealant joint geometric requirements and toler-
ances.
4. Do not weld flange connectors until the tees are adjusted in such a manner
that acceptable matching of the tee flange top surfaces has been attained.

154
Fig. 18.18.1 Conduits Embedded in Double Tee Stems

Conduits located out of

- strand drape zone

I
I

-r-- - --o- -- - --!-- -o----- G-r-

< >--._ ----- I Draped strands I ----- --:( >
r-- - .::: -- -i_ ' -- --_::-- -
- --
r- - - -- - -..::::- ..:::::::::-
-~,=-
I -::::::::---
::::::----
- - - - - -

Double tee
Span

1. Locate embedded conduits above the level of the top strands or establish
special project tolerances for lower conduit placement to accommodate the
interface of the conduit with the draped strands.
2. Consider the tolerances associated with the placement of shear reinforce-
ment when locating or setting location tolerances for conduits embedded in
tee stems. If functionally acceptable, conduit tolerances should allow for re-
location of embedded conduits by one conduit diameter plus one shear rein-
forcing bar diameter to avoid relocating shear steel to accommodate conduit
placement.
3. Provide positive support to embedded conduits during casting to assure
that placement tolerances are attained.
4. If conduit centerline alignment tolerances are important for embedded con-
duit in tee stems this should be specified as a special project tolerance.

155
Fig. 18.19.1 Typical Bearing Wall System Joint

tt
I
-

IV
~ Grout

I
Ir Topping

~--~~~~~~~~--~
~> Precast concrete
I hollow-core slab

~Grout
Bearing pads
Leveling device

Precast
concrete
wall panel

1. Require tighter tolerances than standard for the slab length due to the very
small bearing width usually available in the panel framing system for such
structures.
2. Provide leveling devices which allow adjustment for wall plumbness at each
floor to assure that the tolerances required for vertical plumbness are not ex-
ceeded. The main reason for careful attention to wall plumbness tolerances
is the availability of only a small bearing area.

156
Fi . 18.20.1 Staggered Architectural Wall Panels

llllll

\ ~

Shadow lines
1!llllJ
17
""""U'.IJl iJllll"' "-UlUll ~

~
\ aiiijijjji
Staggered architectural panels

1. Check design of panels to assure that excessive thermal bowing will not be
a problem. As shown in the drawing bowing of staggered panels can result
in unwanted shadow lines at certain times of the day.
2. Consider joint configurations and joint tolerances to minimize unwanted
shadow effects.

157
Fig. 18.21.1 Typical Architectural Panel Joints

r
Joint width (clearance)

~:q
I

~ ~J
I L Precast
{
concre~e panel
~ ~ Reveal joint

r JOint tolerance apphes

l
t!------,-------,/
to thos wodth

~1---------'ljr----------11
1

f-1------------') i . ~
~ ~
1

Chamfered joint Butt joint

(to be avoided)

1. Specify either a chamfered or reveal joint, since these types of joints can ac-
commodate the tolerance required for panel thickness and the shadows
formed within these joints will minimize any adverse effects on the aesthetic
appearance of the joint system.
2. As a general rule, the minimum design joint width should not be less than
%in. [19 mm]. When panel production and erection tolerances are applied
to joints which are designed narrower than this, the joints may become too
narrow to allow effective caulking.
3. Avoid the use of butt joints, as the tolerance variations in panel thickness
may result in the formation of unwanted shadow lines directly over the pan-
els rather than within the joint area. This may impair the aesthetic appear-
ance of the panel assembly.

158
Fig. 18.22.1 Precast Column Near a Previously Constructed Wall Corner

Pockets in wall to complete

corner column bolt connection
it column is erected after panel
placement

Column

Precast
concrete
panel

1. Provide pockets in the walls at either of the locations as shown above. Pock-
ets should be sized and oriented to allow execution of bolted connections
marked "X". Alternatively provide adequate clearance "/li' to provide wrench
access necessary to complete the connection at "X".
2. Unless adequate access is provided for bolt tightening, it is likely that the
bolted connection "X" will not be completed.

159
Fig 18.23.1 Fascia Panel Connection to Cast-in-Place Slab

Precast concrete panel -

L Cast·in·place floor

1.------- Cast-in-place wall

_ L_ _ _ __uA~-----L

JL A Min. t • (25 mm)

1. Provide a minimum of 1 in. [25 mm] clearance"/!>!.' to accommodate the toler-

ances from a combination of the panel thickness and the edge location of
the cast-in-place slab and wall. If the minimum 1 in. [25 mm] clearance is
used, care must be taken with dimensioning and detailing to assure that the
cast-in-place and precast tolerances allow proper fit up without the require-
ment for rework.
2. Plan slab reinforcement location so that slab reinforcement is located away
from the blackout location needed to complete the weld. Typically the rein-
forcing should be located adjacent to or below the bearing plate at this loca-
tion.
3. Do not support the precast fascia panel at more than two points. If the panel
is supported at more than two points the relative movement of the floor slab
with respect to the panel may redistribute panel bearing loads in an adverse
manner.

160
Fig. 18.24.1 Typical Fascia Beam to Tee Connection

v-~ -~-

Fascia beam~
f-.-
v Cut back flange

l.o
A f
A- J:
L
I
I
I
I
>

~ Individual pockets for

each stem of double tee .

f-.-
Rectangular beam

'v -~

1. Allow adequate clearance "Pi' at the fascia end of the double tee to assure
that the tee stems can be easily slid into the pockets provided in the fascia
beam.
2. Provide a sufficiently wide cut back of the double tee flange to assure that
the tee flanges have adequate clearance from the inside surface of the fascia
beam. The clearance needs to be set sufficiently large so thatthe tee's flange
does not contact the fascia beam when the tee is slid into the pockets at an
angle as is required for erection. The maximum dimension of the cut back
clearance should consider the requirements for erection, ease offorming for
the cast-in-place floor, and fire resistance considerations.

161
Fig. 18.25.1 Window Openings in Wall Panels

1\
v v v

A A

Window B
B
opening

1\ 1\ 1\
v v v
~

Panel ~

Panel '-- Panel

1. Consider the tolerance variations in window width and the minimum re-
quired caulking width between the window jambs and the wall panel to de-
termine blackout dimension ''Pi' and the tolerance on the "/>\' dimension.
2. Consider the tolerance variations in window height and the minimum re-
quired caulking width between the window heads and the wall panel to de-
termine blackout dimension "B" and the tolerance on the "B"' dimension.
3. Avoid locating window blackouts across a wall panel joint (see above). This
introduces the erection tolerances for panel location and plumbness com-
bined with the tolerance for panel width and joint width into the interfacing
requirements for the window system. This is much more difficult to success-
fully execute than the window blackout which is wholly contained with a
single panel.

162
Fig 1B 26 1 Precast Concrete Wall Beam to Column Connection

,------- Precast concrete wall beam

-+-~\,--~---+
v
____;/\\ ~-----

<

> <
I \r--\-------_ _i_--f--1/ I
I
.I \
\_____ Dry pack over columns
__/ I L 1

Cast- in-place floor

1----- Cast-in-place columns

-Lv-~ -Lrv--

1. Provide adequate clearance "/>!.' to accommodate cast-in-place concrete

floor tolerance and assure that panel loads are transferred at column points
only as shown above. This is necessary to avoid unintended loading of the
floor slab and eccentric loading of the supporting columns.
2. Do not use flowable grout at panel load transfer points over the columns un-
less special provisions are made to assure complete grouting and positive
load transfer.

163
Fig. 18.27.1 Slab on Grade Connection to Precast Wall

Precast wall panel

Wall panel lifting Cast-in-place
device used as concrete floor slab
tie to floor
~ _1------------'-------,----1
A
Hairpin as required

1. When panel lifting device embedments are used as a tie to the floor, use a
placement tolerance of ±'/,in. [ ± 13 mm] rather than the larger standard PCI
tolerance given for embedded lifting devices when they are only used for lift-
ing.

2. Use added concrete in the floor as shown by the crosshatched area to ac-
commodate tolerances required to place lifting devices as well as to provide
adequate concrete cover "Pi'.

164
Fig. 18.28.1 Insulated Slender Wall Panels-Corner Detail

Insulated wall panels

Corner joint

1--- Steel column

1. Consider the potential for opening of the corner joint as result of thermal
bowing of these adjacent panels in different directions. Assure that any cal-
culated joint opening does not exceed the motion capabilities of the speci-
fied joint sealant and joint sealant detail.

2. Provide a corner connection as shown above to resist thermal forces and

prevent opening of the corner joint where the calculated panel joint move-
ment exceeds the motion capability of the specified joint sealant detail.

3. Allow adequate clearance "N between the columns and the inside face of
the panels so that the tolerances required for the placement of the em-
bedded hardware, tolerances for erection of the panels and the completion
of the connection welding can be easily accommodated.

165
19.0 Examples of Tolerance Detailing Related If this tolerance situation exists:
Calculations

A detailed numerical approach to designing de- e = 2.5 in. + 0.25 in. + 0.38 in.
tails for tolerances is illustrated here. Examples illus- = 3.63 in. [92 mm]
trating the consequences of certain tolerance condi-
tions shown. These examples only address tolerance
Therefore, increase the size of the angel to:
related issues and do not represent a complete con-
sideration of all of the elements which must be consid-
ered in a comprehensive design of connections. 6 in. x 4 in. [152 mm x 102 mm]

19.1 Clip Angle for Lateral Restraint

Required angle thickness = 0.44 in. [11 mm].
If all the dimensions of the connection are at their which represents a 45 percent increase in clip angle
basic values as shown in Fig. 19.1.1 (a) then: weight.
In the design of connections, one should not as-
Pu = 2 kips [8.9 kN] sume that all dimensions are the basic dimensions.
e = 2.5 in. [62 mm] Use judgement in establishing design parameters,
Fy = 36 ksi [248 Mpa] balancing the cost impact of designing to accommo-
Angle length= 6 in. [152 mm] date the situation where all standard PCI and other in-
Required angle thickness = % in. [9 mm] terface tolerances accumulate in the most adverse
However, a vertical slot, as shown in Fig. 19.1.1 (b), manner rather than specifying tighter tolerances.
is needed to allow for the following tolerances: Depending on the circumstances, it may be more
realistic to assume that the most probable tolerance
1. Panel erected 0.25 in. [6mm] higher than nomi- condition for the connection design lies between the
nal (see Article 12.0). nominal dimension and the extreme worst case. If
2. Insert is located 0.5 in. [13 mm] higher than this assumption is made, the cost impact to the con-
nominal (see Article 10.0). nection may be less. However, some field adjust-
3. Beam (steel or cast-in-place concrete) is lo- ments should be anticipated and the cost effect of
cated % in. [9 mm] lower than nominal (refer- these considered in the choice of design parameters
ence AISC or ACI publications). for the connection.

Fi .19.1.1
Panel location
+ W' higher
Insert location f--- than nominal
%"higher
than nominal L6 X 4"

Insert L4 x 4"
Insert -
Slot in angle

p"
upport
t "" 4 "
location %'
lower than

"t'
4 nominal
Precast Precast
Concrete Concrete
Panel Cast~in-place con- Panel Cast-In-place con-
crete support crete support

Theoretical tolerances; all dimensions nominal Possible condition with all tolerances combined
(a) (b)

166
19.2 Clip Angle Supporting a Precast Con- To keep the eccentric load ofthe angle at 5 in. [127
crete Panel mm], the shims must be shifted toward the precast
panels as shown. This results in torsion in the support
In this case, the designer has determined that the beam, which may not be accounted for in its original
line of load is desired to be at the center line of the design.
supporting beam to avoid torsion in the beam. If all If Condition No. 2 shown in Fig. 19.2.1 (c) exists, to
dimensions are basic or nominal as shown in Fig. keep from eccentrically loading the support beam,
19.2.1 (a}, no torsion in the supporting beam results the eccentricity of the loading of the angle increases
from the connection and the angle is designed with to 6.25 in. [159 mm]. This results in a requirement to
an eccentricity equal to 5 in. [126 mm]. increase the thickness of the support angle.
Possible Condition No. 1, shown in Fig. 19.2.1 (b) The conclusion is generally the same as example
may exist because the beam sweep tolerance is 1 in. 19.1. It will likely be more economical to use a heavier
[25 mm] away from the panel (AISC Code of Standard angle and load the steel support beam though its cen-
Practice) and the panel is located 0.25 in. [6 mm] troid.
away from its nominal position (see Article 12).

Fi . 19.2.1

6" e= 5" Line of

load
l 8 X 8 X%" Line of
load

Steel
' -1"Beam
support I I sweep

beam =F'-'== '==

I
~~- 11/4"
1 ... CG of
angle
-·~L - L.

Line of
Precast load
concrete
panel

Theoretical tolerances; Possible Condition No. 1 Possible Condition No. 2

all dimensions nominal

(a) (b) (c)

167
19.3 Precast Corbel withSteelto Steel Bearing lion of tolerances.
It should be noted that corbels designed for ulti·
If all of the dimensions are nominal as shown in mate loads will support beams experiencing ultimate
Fig. 19.3.1 (a), or if a favorable tolerance condition ex- deflections. This may result in a condition similar to
ists as shown in 19.3.1 (c), a corbel designed for an that shown in Fig. 19.3.1(d). This will occur even
eccentricity equal to 41/, in. [114 mm] would be ade- when all of the feature dimensions of both the beam
quate. and the column haunch were originally at nominal val·
If the situation shown in Fig. 19.3.1 (b) exists due ues. The use of bearing pads is encouraged to en-
to the slope of the haunch bearing (Reference Article sure better load distribution.
10), or if the situation shown in Fig. 19.3.1 (d) exists The use of properly designed beam end armors as
due to tipping of the bearing plate, the corbel must be shown in Fig. 19.3.1 (e) is another way of addressing
designed for an eccentricityof8.0 in. [200 mm], an in- this situation. The column haunch armor design must
crease of 78 percent. take into account the higher concentrated load asso-
It is very unlikely that the nominal zero tolerance ciated with this detail. The joint must be detailed to
condition shown in Fig. 19.3.1 (a) will occur and it is assure that the unarmored concrete on the beam sof-
quite possible that the condition shown in Fig. fit does not bear on the haunch armor plate. This de-
19.3.1 (b) or (d) will occur. Therefore, the corbel tail can be less tolerance critical than the detail shown
should be designed for the most adverse configura- in Fig. 19.3.1(a) through 19.3.1(d).

168
Fig 19.3.1 Precast Corbel with Bearing

Precast Precast
concrete concrete
beam beam

s"
Precast Precast
concrete concrete
column column

Theoretical tolerances; all dimensions nominal Haunch plate tipped: maximum haunch eccentricity

(a) (b)

Precast
concrete
beam
r!
I

<

<4''~ L
Precast
concrete
column

Beam bearing tipped; Beam bearing tipped;

m1nimum haunch eccentricity maximum haunch eccentricity

(c) (d) (e)

169
19.4 Effects of Beam Camber in the example shown has been finished level, without
regard to the cambered position ofthe beam finished
Prestressed floor and roof members usually exhib- surface.
it camber as a result of eccentric prestress force. The The reduced topping thickness at the mid-span
camber is a function of the design of the product and location may cause problems if not anticipated in de·
since it is subject to product tolerances, may not be sign, or excess topping may be required if the design
"built-in" to the desired levels. mid-span topping thickness is to be maintained and
If the effect of camber is neglected, the situation the top of the topping elevation is raised. This condi-
shown in Fig. 19.4.1 (a) may be the condition that the tion also leads to variations in topping dead load
designer expects. which may differ from design assumptions.
In actual fact, however, the real condition may re· The dimensional effects of design camber, espe-
semble Fig. 19.4.1 (b), where a long-span member cially of long-span members, should be evaluated as
may have several inches of camber. The floor topping part of the design process.

Fig. 19.4.1 Effect of Beam Camber

r- Topping ["""Topping

- I .I

7
'
I
'------- Double tee
L· Double tee

-lrv

Expected condition neglecting camber Possible result of beam camber

(a) (b)

170
19.5 Effects of Camber Variation on Top Since welded diaphragm connections between
Flange Connections members of this type are common, the designer
should consider how the connections will be made
under conditions of adverse combinations of product
Camber variations between adjacent beam mem- and erection tolerances. This condition can also lead
bers can create significant dimensional discontinui- to excessive topping on one member while the adja-
ties which may make the completion of important cent member may receive too little topping.
connections difficult. Specifications for erection should address the
In the section shown in Fig. 19.5.1, a step of 0.75 maximum allowable difference in adjacent member
in. [19 mm] between the flanges is possible, even if top elevations if this is a design consideration for ei-
both of the long span roof or floor members are within ther connection effectiveness or topping thickness.
the differential camber tolerance.

Fi . 19.5.1 e Connections

r
Mismatch that connection
must accommodate
Topping
) I
.
.

1----- Tee beam -----~

Beam Flange Joint Considerations

171
19.6 Deflection of Supporting Elements Loading from other sources may also cause
deflection related problems. For example, if precast
II support member deflection is neglected when a concrete is erected prior to floor slab construction, the
series of small architectural panels are supported on weight of the floor may deflect the support beams and
a long span beam, the designer may expect that the cause a problem similar to that shown in Fig.
condition will be as shown in Fig. 19.6.1 (a). 19.6.1 (b).
In actual fact, if the supporting beam is very flex- This effect can be avoided by either determining
ible, the final condition may be as shown in Fig. the beam intermediate and final deflections, and set-
19.6.1 (b). The support beam will deflect in incre- ting the precast concrete panels such that the final
ments as each panel is erected, resulting in an in- deflected condition of the support beam will bring
plane rotation of the panels previously erected. This them into alignment. Alteratively, adjustments can be
rotation can result in variations in joint widths as illus- made to the panels alter they have all been erected.
trated in Fig. 19.6.1 (b).

Fig. 19.6.1 Deflection of Supporting Elements

Steel support beam

Precast G) 0 G) _§J ./.
concrete
panels
1----- ----- r------
1----- ----- r------ ----

l Equal joint width over height of panel

Uv lv
Assumed condition neglecting support member deflection

(a)

Steel support beam

with greater than
Precast
concrete
+-----
C0 0 G) _§L/ expected deflection
panels
f-----
----- r----- -----
----- r-----
l Joints tapered over height of panel

Lv Ly.._
Possible condition resulting from support member deflection
(b)

172
19.7 Panel Supported by a Cantilever movement of the panel, but also in rotation as shown
in Fig. 19.7.1 (c).
Panels supported by cantilever construction re· Of particular note is the condition when panels
quire extremely careful consideration because of the supported on cantilever supports are adjacent to
tendency of cantilevers to deflect and rotate signifi· panels supported in a different manner. This may re-
cantly. Often, the best way to solve this problem is to sult in unwanted joint tapers and jogs in alignment.
use a support scheme that does not rely on cantilever The possibility of increased deflection and rotation of
action. Such a solution is shown in Fig. 19.7.1 (a). If the panel over time, resulting from creep off the sup-
the detail shown in Fig. 19.7.1 (b) is used, any deflec· porting cantilever, must also be considered.
lion of the cantilever will not only result in vertical

Fig. 19.7 .1 Panel Supported by Cantilever

c~~~~=~:
panel
---llu~~===::;::===? Support member

Auxiliary
strut
support

(a) Auxiliary strut support

Precast ~
Cantilever
support
member
r Deflected cantilever
support member

con~~~~ - ... ULC:====;:::==:::< Precast

concrete
panel

(b) Expected final condition (c) Possible resulting condition

173
20.0 References 15. Spotts, M.F. "Simple Guide to True Position
Dimensions." Machine Design Magazine
1. Precast/Prestressed Concrete Institute. Ar- (January 22, 1976).
chitectural Precast Concrete. Chicago: Pre· 16. Latta, J.K. "Inaccuracies in Construction."
cast/Prestressed Concrete Institute, 1973. Canadian Building Digest 4 (April 1975).
2. Precast/Prestressed Concrete Institute. PC/ 17. Holbek, K., and PAndersen. "European Con-
Design Handbook - Precast and Pre- cepts of Construction Tolerances." ACI Jour-
stressed Concrete. 5th ed. Chicago: Precast/ na/74, no 3 (March 1977): 101-108.
Prestressed Concrete Institute, 1999. 18. American Institute of Steel Construction.
3. Barry, Austin B. "Errors in Practical Measure- Code of Standard Practice for Steel Buildings
ment." In Science, Engineering and Technol- and Bridges. Chicago: American Institute of
ogy New York: John Wiley & Sons, 1978. Steel Construction, 1992.
4. Spots, M.F. "Fast Dimensional Check With 19. Foster, Cowell W. A Treatise on Geometric Di-
Statistics." Machine Design Magazine (Octo- mensioning and To/erancing. Minneapolis:
ber 12, 1978). The Honeywell Company, 1966.
5. Duster, J.A. "Are Your Tolerances Really Nec- 20. Amrhein, J.A. Reinforced Masonry Engineer-
essary?" Precast Concrete Magazine (June ing Handbook, Clay and Concrete Masonry
1971 ). 5th Edition. Los Angeles, California: Masonry
6. Griffiths, T.J. Standardization and Tolerances Institute of America, 1994.
in Precast Concrete Construction. CP 88/68. 21. Laursen, F. Brink. "Tolerances for the Main Di-
Building Research Station. United Kingdom: mensions of Concrete Components." Build
Ministry of Public Works, 1967. International (May-June 1971).
7. American Concrete Institute. "Standard Tol- 22. Federation lnternationale de Ia Precontrainte.
erances for Concrete Construction and Mate- "Tolerances for Concrete Structures." FIP
rials." ACI 117-90. Part 5 of ACI Manual of Joint Committee Report presented at the Fe-
Concrete Practice. Farmington Hills, Michi- deration lnternationale de Ia Precontrainte,
gan: American Concrete Institute, 1998. London, United Kingdom, November 15,
8. Canadian Standards Association. Precast 1977.
Concrete Materials and Construction National 23. American Concrete Institute Committee 315.
Standard of Canada. CAN3-A23.4-M78. Can- Details and Detailing of Concrete Reinforce-
ada: Canadian Standards Association, 1978. ment. ACI 315-92. Farmington Hills, Michi-
9. Speyer, Irwin. "Considerations for the Design gan: American Concrete Institute, 1992.
of Precast Concrete Bearing Wall Buildings to 24. Birkeland, Philip W., and Leonard J. Westhoff.
Withstand Abnormal Loads." PC/ Journa/21, "Dimensional Tolerances in a Tall Concrete
no 2 (March-April 1976). Building." GB-53. ACI Journal 68, no 8 (Au-
10. Norges Bygg Forkin·1ngs Institute. To/eranser gust 1971): 600-607.
i Bygg (Tolerances in the Building Industry). 25. American Concrete Institute. Recommended
Report No. 79. Norway: Norges Bygg Forkin- Practice for Concrete Formwork. ACI
ings Institute, 1973. 347R-94. Farmington Hills, Michigan: Ameri-
11. ''AISC Erection Tolerances for Columns." can Concrete Institute, 1994.
Modern Steel Construction, Third Quarter 26. Walker, H. Carl, and Marvin L. Vender, Wal.
(1975). "Tolerances for Precast Concrete Struc-
12. Fisher Ill, A. Ernest. "Tolerances Involving Re- tures." PC/ Journal 21, no. 4 (July-August
inforcing Bars." ACI Journa/74, no. 2 (Febru- 1986): 44-57.
ary 1977): 61-70. 27. PCI Committee on Tolerances. "Tolerances
13. Connally, J.P. and D. Brown. "Construction for Precast and Prestressed Concrete." PC/
Tolerances in Reinforced Concrete Journa/26, no. 2 (March-April1981): 40-72.
Beam-Joists." ACI Journal 73, no. 11 (No- 28. PCI Committee on Tolerances. Discussion of
vember 1976): 613-617. Tolerances for Precast and Prestressed Con-
14. Stephan, D.E., and A. Murk. "Establishing crete, by PCI Committee on Tolerances. PC/
Tolerances in Concrete Construction." ACI Journal 27, no. 4 (July-August 1982):
Journa/74, no. 5 (May 1977): 208-211. 140-142.

174
29. PCI Committee on Tolerances. "Tolerances 31. Precast/Prestressed Concrete Institute.
for Precast and Prestressed Concrete." PC/ Manual for Quality Control for Plans and Pro-
Journal 30, no. 1 (January-February 1985): duction of Architectural Precast Concrete
26-112. Products. MNL-117 -96. 3rd ed. Chicago: Pre-
30. Concrete Reinforcing Steel Institute. Manual cast/Prestressed Concrete Institute, 1996.
of Standard Practice. 26th Ed. Chicago: Con- 32. Precast/Prestressed Concrete Institute.
crete Reinforcing Steel Institute, 1997. Manual for Quality Control for Plants Produc-
ing Precast/Prestressed Concrete Products.
MNL 116-99. Chicago: Precast/Prestressed
Concrete Institute, 1999.

175
Appendix A-Sample Specification Language

A.1 To Specify Tolerances for Architectural Precast Concrete

Element tolerances for architectural precast concrete members shall be per Tolerances for Precast and Pre-
stressed Concrete Construction, MNL 135-00, by the Precast/Prestressed Concrete Institute, Article 10.1 and as
amended with the special project tolerances listed below.

Specific project tolerance requirements which

are different from those outlined in the above doc-
ument are listed below:

Attach sketches as required.

A.2 To Specify Tolerances for Architectural Trim Units

Element tolerances for architectural concrete trim members shall be per Tolerances for Precast and Prestressed
Concrete Construction, MNL 135-00, by the Precast/Prestressed Concrete Institute, Articles 10.29, 10.30 and
10.31 and as amended with the special project tolerances listed below.

Specific project tolerance requirements which

are different from those outlined in the above doc-
ument are listed below:

Attach sketches as required.

176
A.J To Specify Tolerances for Structural Precast Concrete Elements

Element tolerances for structural concrete members shall be per the applicable element type as described in
Tolerances for Precast and Prestressed Concrete Construction, MNL 135-00, by the Precast/Prestressed Concrete
Institute, Article 10.0 with Articles 10.1, 10.29, 10.30 and 10.31 specifically deleted and as amended with the special
project tolerances listed below.

Specific project tolerance requirements which

are different from those outlined in the above doc-
ument are listed below:

Attach sketches as required.

A.4 To Specify Tolerances for Group CA/BA Structural Elements with Special Surface Finishes

Element tolerances for Group CNBA structural concrete members shall be per the applicable element type as
described in Tolerances for Precast and Prestressed Concrete Construction, MNL 135-00, by the Precast/Pre-
stressed Concrete Institute, Article 10.0 with Articles 10.1, 10.29, 10.30 and 10.31 specifically deleted and as
amended with the special project tolerances listed below.

Group CA/BA elements have specific project tol-

erance requirements on selected features which
are different from those outlined in the above doc-
ument are listed below. (Note that these products
are not governed by the architectural tolerances
listed in Article 10.1).

Attach sketches as required.

177
A.S To Specify Erection Tolerances for Architectural Precast Concrete Elements

Erection tolerances for architectural precast concrete members shall be per Tolerances for Precast and Pre-
stressed Concrete Construction, MNL 135-00, by the Precast/Prestressed Concrete Institute, Article 12.5 and as
amended with the special project tolerances listed below.

Specific project tolerance requirements which

are different from those outlined in the above doc-
ument are listed below:

Attach sketches as required.

A.6 To Specify Erection Tolerances for Structural Precast Concrete Elements

Erection tolerances for structural precast concrete members shall be per Tolerances for Precast and Prestressed
Concrete Construction, MNL 135-00, by the Precast/Prestressed Concrete Institute, Article 12.0with Article 12.5
specifically deleted and as amended with the special project tolerances listed below.

Specific project tolerance requirements which

are different from those outlined in the above doc-
ument are listed below:

Attach sketches as required.

178
A. 7 To Specify Erection Tolerances for Group CA/BA Structural Precast Concrete Elements

Erection tolerances for Group CA/BA structural precast concrete members shall be per Tolerances for Precast
and Prestressed Concrete Construction, MNL 135-00, by the Precast/Prestressed Concrete Institute, Article 12.0
with Article 12.5 specifically deleted and as amended with the special project tolerances listed below.

Group CA/BA elements have specific project tol-

erance requirements on selected features which
are different from those outlined in the above doc-
ument are listed below. (Note that these products
are not governed by the architectural tolerances
listed in Article 12.5).

Attach sketches as required.

179
Appendix B-Sample Contract Language - Responsibility for Project Tolerances

Project Tolerance Responsibilities for P r o j e c t - - - - - - - - - - - - - - - - - -

The responsibility for the development of the project tolerance plan in the project lies with the following party:

Owner
Architect of Record
_ _ Engineer of Record
Precast Producer
General Contract

This plan is to be reviewed and approved by the following party or parties:

Owner
Architect of Record
_ _ Engineer of Record
Precast Producer
General Contract

The responsibility for tolerances on this project are further defined on the attached matrix title "Responsibility
for Tolerances" which has been prepared specifically for this project.

180
 Fig. 8.1 Tolerance Responsibility
Comments
Project Activity Owner Architect/ General Precast Precast Precast Erector Erection
Engineer Contractor Plant Man- Plant Plant Manage- Quality
agement Engineer- Quality ment Control
lng Control

Set Requirements

Determine How to Satisfy Requirements

Define Overall Project Tolerance Plan

-----
Specify Typical Product Tolerances

Specify Typical Interface Tolerances

Specify Typical Erection Tolerances

CD
~
Select Interface Tolerance Details

Identify Special Project Tolerances

Accept Project Tolerances

Confirm Product Tolerances Achieved

Confirm Erection Tolerances Achieved

Confirm Interface Tolerances Achieved

Legend: P = Prime Responsibility A/A= Review and Approval Authority I = Input Required From