TOLERANCE MANUAL for Precast and Prestressed Concrete ConstructionTable of ContentsForwardPreface To Tolerance Committee Report 1.0General 1.1Need for Collaboration 1.2Responsibility for the Overall Project Tolerance System 1.3Specifying Responsilbilty for Project Tolerances 1.4Custom Nature of Building Construction 1.5Introduction 2.0Groups of Tolerance Issues 2.1Tolerance Categories 2.2Responsibility for Project Dimensional Control 3.0Handling a Pre-pour Tolerance Discrepancy 3.1Handling a Post-Casting/Pre-Shipment Tolerance Discrepancy 3.2Handling a Tolerance Discrepancy Discovered During Erection 3.3Tolerance Acceptability Range 4.0Definitions of Tolerance Related Terms 5.0Relationships Among the Different Tolerance Groups 6.0Relationship of Product Tolerances 6.1Relationship of Erection Tolerances 6.2Relationship of Interfacing Tolerances 6.3Project Economic Considerations 6.4Relationship of Form Tolerances to Product Tolerances 6.5Product Tolerances 7.0Specification of Product Tolerances 7.1Overall Plan Dimension Tolerance Considerations 8.0Effect of Forms on Dimensions 8.1Effects of Prestressing on Dimensions 8.2Effects of Time, Temperature, and Shrinkage on Dimensions 8.3Relation of Measuring Techniques to Tolerances 8.4Tolerances for Blockouts and Openings 8.5Tolerances for Sweep or Horizontal Alignment 8.6Tolerances for Position of Tendons 8.7Tolereances for Handling Device Locations 8.8Tolerances Considerations for Camber and Differential Camber 8.9Tolerances for Squareness of Ends or Variation From Specified End Skew 8.10Tolerances for Position of Weld Plates 8.11Tolerance on Tipping and Flushness of Weld Plates 8.12Tolereances on Haunches of Columns and Wall Panels 8.13Tolerances on Location of Sleeves Cast in Prestressed Products 8.14Tolerance on Reinforcing Steel Bending and Placement 8.15Tolerance on Position of Strand Deflection Points 8.16Tolerance Effects of Warping, Bowing and Local Smoothness of Panels 8.17Special Tolerance Considerations 9.0Considerations for Tolerances of Architectural Members 9.1Tolerance Considerations for Visible Structural Members 9.2Tolerances for Structural Members 9.3Statistical Tolerance Concepts 9.4Tolerance Considerations for Segmental Precast 9.5Product Tolerance Listings 10.0Architectural Wall Panels 10.1Solid or Insulated Flat Structural Wall Panels 10.2Ribbed Structural Wall Panels 10.3Hollow-core Wall Panels 10.4Brick Faced Architectural Elements 10.5Double Tees (Untopped & Pretopped) 10.6Single Tees (Untopped & Pretopped) 10.7Columns 10.8Building Beams and Spandrel Beams 10.9I Beams (Girders) or Bulb Tee Girders 10.10Box Beams 10.11Poles 10.12Hollow-core Slabs 10.13Piling (Hollow and Solid) 10.14Tee Joists/Keystone Joists 10.15Step Units 10.16Sheet Piling 10.17Stadium Riser 10.18Multi-Stemmed Bridge Units 10.19Modular Room Unit 10.20Prestressed Concrete Panels for Storage Tanks 10.21Bridge Deck Units 10.22Segmental Box Girder 10.23Pier Deck Units 10.24Box Culvert 10.25Prestressed Concrete Railroad Ties 10.26Sills, Lintels, Copings, Cornices, Quoins and Medallions 10.27Bollards, Benches and Planters 10.28Pavers 10.29Erection Tolerances 11.0Recommended Erection Tolerances 11.1Erection Tolerance Groups 11.2Field Control of Erection Tolerances 11.3Erection Tolerance Considerations for Segmental Precast Projects 11.4Erection Tolerance Listings 12.0Beam Erection Tolerances 12.1Floor and Roof Member Erection Tolerances 12.2Column Erection Tolerances 12.3Structural Wall Panel Erection Tolerances 12.4Architectural Walls/Spandrel Erection Tolerances 12.5Stadium/Riser Erection Tolerances 12.6Room Module Erection Tolerance 12.7Stair Unit Erection Tolerance 12.8Segmental Bridge Element Erection Tolerance 12.9Circular Storage Tank Erection Tolerances 12.10Pier Deck Erection Tolerances 12.11Erection Tolerances for Bridge Deck Units 12.12Erection Tolerances for Mixed Building systems 13.0Connection Tolerances for Mixed Building Systems 13.1Clearance Considerations in Product Manufacture 14.0Effects of Product Tolerances on Clearance Considerations 14.1Effects of Member Type on Clearance Considerations 14.2Effects of Member Size on Clearance Considerations 14.3Effects of Member Location on Clearance Considerations 14.4Effects of Member Movement on Clearance Considerations 14.5Effects of Member Function on Clearance Considerations 14.6Effects of Erection Tolerances on Clearance Considerations 14.7Procedure For Determination of Clearance 14.8Clearance Examples 14.9Roof Member Clearance Example 14.10Bearing Wall Panel Joint Clearance Example 14.11Cladding for High Rise Steel Frame Building Clearance Example 14.12Interfacing Tolerances 15.0Structural Requirements 15.1Volume Change 15.2Exposure and Corrosion 15.3Waterproofing Requirements 15.4Drainage Requirements 15.5Architectural Requirements 15.6Dimensional Considerations 15.7Vibration Considerations 15.8Fire-Rating Considerations 15.9Acoustical Considerations 15.10Economics 15.11Manufacturing/Erection Considerations 15.12Design Approach for Two Interfacing Tolerance Systems 16.0Defining the Characteristics of a Tolerance Interface 17.0Windows and Doors 17.1Mechanical Equipment 17.2Electrical Equipment 17.3Elevators and Escalators 17.4Architectural Cladding 17.5Structural Steel and Miscellaneous Steel 17.6Masonry 17.7Roofing 17.8Waterproofing 17.9Interior Finishes - Floors, Walls, and Ceilings 17.10Interior Walls and Partitions 17.11Typical Tolerance Related Details 18.0Examples of Tolerance Detailing Related Calculations 19.0Clip Angle for Lateral Restraint 19.1Clip Angle Supporting a Precast Concrete Panel 19.2Precast Corbel with Steel to Steel Bearing 19.3Effects of Beam Camber 19.4Effects of Camber Variation on Top Flange Connections 19.5Deflection of Supporting Elements 19.6Panel Supported by a Cantilever 19.7References 20.0Appendix A - Sample Specification LanguageAppendix B - Sample Contract Language