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DS2005Tolerances PDF
DS2005Tolerances PDF
2005
INTRODUCTION DEFINITIONS
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Tolerances can be defined as the allowable n Formed surface. A surface requiring formwork
variations from the specified values or performance to provide shape and texture/finish to the
levels. They are provided to ensure that the finished concrete.
concrete surface is acceptable for the application n Unformed surface. A surface that does not
and/or the intended function while acknowledging require formwork to provide either shape or
that some degree of variation is inherent in all finish to the surface, eg the top surface of slabs
building work. or pavements. These surfaces generally have
The position of the concrete element, its function, to meet two independent tolerance criteria: the
appearance and the influence of these on the total ‘flatness’ of the surface and variation from the
project would, in many cases, define the appropriate designed elevation (levelness).
tolerances. On the other hand, tolerances must also n Flatness. The deviation of the surface from a
be reasonable, ie both achievable and able to be straight line joining two points on the surface.
checked in the field using the available techniques n Levelness (elevation tolerance). The permitted
and at acceptable cost. The importance of specifying vertical variation of the surface from a fixed
appropriate tolerances becomes apparent when the external reference point or datum.
outcome fails to meet the original expectations.
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Maximum
Optical Optical survey instruments can be used to
deviation
measure the levelness, flatness, position or plumb
of an element. For pavement or slab levelness and
flatness, spot checks on a grid pattern are often
made. If relying entirely on spot measurements, the
grid size may be quite small, say 0.5 m. Combined
with a straightedge, readings may be taken on, say,
a 3-m grid, with a straightedge used to check the
variation between measured points. Instruments
can have an accuracy of 0.1 mm, and computer
topographical maps drawn indicating slab contours
to assist with the evaluation. Since small grid sizes
may be required, the cost of this method should be Figure 2: 3-m straightedge tolerances fail to assess
evaluated, particularly when used over large areas. surface undulations (waviness).
% of readings
3 Face step
within the element 1 2 2 3 3 5 5 8
at insitu construction joint 2 3 2 3 3 5 5 8 * *
4 Surface undulations**
l = 300 (a – b) ≤ 1 2 2 4 3 4 5 7 * *
l = 1500 (a – b) ≤ 2 4 3 6 5 7 8 10
5 Flatness
1.25 m grid 4 5 6 7 7 10 * * * *
at 5 m over 10 m 5 7 7 10 10 15 * * * *
(not applicable to precast concrete)
6 Out of plumb
height < 3 m 3 5 4 6 5 7 * * * *
3 < height < 8 m 6 8 8 10 10 12 * * * *
(not applicable to precast concrete)
Notes
* Limited by AS 3600
** a and b are respectively the maximum and minimum distances from the straightedge.
Tolerance on:
Footings Concealed Maximum deviation from any specified Maximum deviation of any point on the
height, plan or cross-sectional dimension surface from a straight line joining any two
to be the greater of 1/200 times specified points on the surface to be the greater of
dimension or 5 mm(1). 1/250 times length of the line or 10 mm(1).
Slabs Maximum deviation from any specified Exposed edges to be Class 3(3) or 2
height, plan or cross-sectional dimension (maximum) .
to be the greater of 1/200 times specified
dimension or 5 mm(1). Flatness – Maximum deviation from a
3-m straightedge placed anywhere on the
Surface level – To be within ±10 mm of surface: 12 mm(4).
specified level.
Columns and Walls Position – ±15 mm of specified position. Concealed elements – Class 4(3).
Industrial Pavements Surface level – To be within ±10 mm of Flatness and levelness – To have the
specified level. following F-numbers(5):
drain is above the specified elevation, there will parties involved in the project is critical. The
be less grade on the pavement, if below, there contractor must have a clear understanding of
is more. The tolerance for the pavement should the tolerances required and the importance of
therefore be compatible with that of the drain. achieving them so that appropriate construction
n Minimum grades. Care in nominating a techniques can be used. As the actual finishing
minimum grade is required as the levelness of the surface probably accounts for at least
tolerance of ±10 mm may cause the pavement 50% of the success of a project, it is imperative
to fall in the opposite direction for small vertical that the concretor also be involved in related
differences, especially over short distances. discussions, and development of procedures for
In these situations either more stringent placing and finishing the surface.
tolerances on the control points are needed, or n Compliance assessment. Compliance should
to specialised turret trucks in narrow aisles for generally increases as tolerances become more
high-bay storage. Generally, the more restricted the stringent. Specifying tolerances appropriate for
operating space, the flatter the floor surface needs the application will control costs for the owner
to be to prevent swaying during movement and and possibly avoid unnecessary disputes over
non-compliance.
Page of 9 > tolerances for Concrete Surfaces
n Limitations of construction techniques. An RECTIFICATION
understanding of the tolerance limits possible Depending on the function and appearance of the
using various construction techniques will assist concrete element rectification of surfaces outside
in selecting an appropriate method to achieve the specified tolerances may be possible. Parties
the specified tolerances. For example, tight involved should discuss and agree the procedure
tolerances in large floor areas are generally to ensure that acceptable results can be achieved.
achieved by placing the concrete in narrow Techniques used in rectification work of unformed
strips. If a joint-free surface is required for large surfaces include:
open areas, the use of specialised equipment n Sanding. Belt sanding with an appropriate
such as laser-guided screeding machines abrasive paper can be used for areas requiring
may be required. Construction techniques that minor corrections less than say 0.5 mm.
reduce the waviness of the surface finish will n Grinding or honing. Grinding the surface is an
also improve the flatness. An alternative solution effective way of correcting localised high spots
for tight tolerances may be to use normal in the finished surface, and is the typical method
placement and finishing techniques combined used. Depending on the extent of grinding,
with a self-levelling topping (see below). the appearance will be affected, and possibly
n Construction details. Construction details can surface characteristics such as abrasion
have a significant effect on the final surface resistance.
level and flatness. Examples include adequate n Filling of low areas. Localised filling is not
preparation of the subgrade to reduce the recommended as a long-term solution for the
potential for ground movement, providing long correction of tolerances on exposed concrete
tapers at edge thickenings to reduce the risk slabs. It may be used for minor surface defects
of level changes due to concrete shrinkage, and as a levelling solution under other floor
ensuring proper functioning of joints, and slab finishes.
details and concrete mix to reduce the risk of n Toppings. A proprietary self-levelling topping
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