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Datasheet > sept

2005

tolerances for Concrete Surfaces

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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Some Australian standards specify tolerances


for concrete surfaces and it is important to
understand their relevance or limitation for
particular applications. This Data Sheet reviews
the tolerance requirements in various codes and Tolerances can be defined
standards, provides guidance on appropriate
tolerances (particularly for unformed surfaces) as the allowable variations
and discusses the issues involved in achieving the
specified tolerances. from the specified values or
performance levels.
3-m straightedge

Maximum deviation measured

MEASURING TOLERANCES Figure 1: Testing of surface for compliance using a


As the specification of tolerances is dependent straightedge.
on the method of measurement, this is usually
determined first. While the two common methods
3-m straightedge
used in Australia are the optical and straightedge,
methods include:

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).

Straightedge Tolerances can be determined by


placing a straightedge anywhere on a concrete F-Meter Developed by the Face Company in the
surface in any direction and measuring the United States, this instrument is used to assess the
maximum deviation of the surface from the flatness and levelness of floors by measuring the
straightedge Figure 1. The use of a 3-m straightedge Face floor-profile numbers, called F-numbers.
has been found to be a simple and generally The Flatness F-number (FF) is related to the
satisfactory method of measurement in Australia; it maximum allowable floor curvature over 600 mm
is one of the methods prescribed in AS 36101 for computed on the basis of successive 300-mm
measuring surface tolerances. The variation from elevation differentials2.
the straightedge is typically expressed as a The Levelness F-number (FL) is related to the
maximum deviation value. relative conformity of the surface to a horizontal
While the 3-m straightedge technique is plane as measured over a 10-foot (3-m) length.
simple, inexpensive and widely used, some of the Generally, the two F-numbers are expressed as FF /
deficiencies of the method include the difficulty FL. Further information on this measuring system
in testing large pavement areas, an inability to can be found in ACI 3023.
reproduce test results, and failure of the method Large areas can be assessed easily for
to assess the acceptability of irregularities such as compliance using this method, as the instrument
steps and surface undulations (often referred to as can be quickly moved across the surface Figure 3.
waviness) Figure 2. It is important that measurements are taken as
If surface undulations for unformed surfaces soon as possible, since subsequent procedures such
are important, shorter (300- and 1500-mm) as saw cutting of joints, will affect the results.
straightedges as specified in AS 3610 for formed A number of these instruments are now
surfaces can be used. available in Australia; however, the system is still
relatively new and unfamiliar. To allow a contractor
Stringline Stringlines are suitable for assessing to assess the work (and cost) involved in delivering
large elements, but should be used only in still the required finish, a correlation between the
air conditions. They are more suited to vertical F-numbers and an existing familiar method such
surfaces, as the deflection or ‘sag’ over long as the straightedge may initially be required. While
distances could introduce errors for horizontal there is no direct equivalence between F-numbers
surfaces. They are typically held away from the and 3-m straightedge tolerances, Table 1 gives an
surface on suitable spacers to ensure the stringline approximate correlation between the two systems.
is straight and that the deviation of the surface from
the stringline can be measured.

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STANDARDS and SPECIFICATIONS
When specifying tolerances for concrete work,
reference is often made to the Australian Standards
AS 3610 and AS 36005 and to NATSPEC6. The
relevant contents of these are outlined below.

AS 3610 This Standard deals mainly with the visual


quality (appearance) of formed concrete surfaces,
whether they are insitu or precast concrete
elements. The surface finish quality is specified as
one of five classes.
Classes 1, 2 and 3 are for typical architectural
applications where the concrete surface is visible.
Tolerances for each class are specified for various
aspects of the surface finish Table 2. If concrete
elements have non-critical faces and/or some of the
surface finish tolerances are less important, these
can be relaxed and are designated by the suffix ‘X’
after the class of finish, eg Class 2X. The limits of
Figure 3: F-Meter any less stringent tolerances should be included in
the project documentation, but should not be less
stringent than the tolerances given in AS 3600 for
Profilograph This instrument is a variation of structural adequacy.
the F‑Meter. Developed by the Australian Road Classes 4 and 5 are for typical structural
Research Board Transport Research Section applications where the concrete surface is either
(ARRB TR). It is a height-measuring device for not visible, or the surface finish quality is not critical
checking the longitudinal profile of both new and (eg footings, concrete frames covered by other
existing road pavements. finishes). While some requirements for Class 4
finishes are included in AS 3610, the tolerances for
Table 1 Approximate correlation between Class 4 and 5 finishes are generally governed by the
F‑numbers and straightedge tolerances (after requirements of AS 3600, ie structural design rather
ACI 1174). than appearance of the surface.

3-m straightedge AS 3600 The tolerances specified in AS 3600 relate


tolerance to the size and position of concrete elements to
Maximum deviation ensure that the safety factors for the structural
Floor profile quality FF FL (mm) design of the elements are maintained. The
standard notes that ‘more stringent tolerances
Conventional surface may be required for reasons of serviceability, fit of
Bullfloated 15 13 12 components, or aesthetics of the structure’.
Straightedged* 20 15 8 Specifying tolerances in accordance with
AS 3600 may not be adequate to satisfy other
Flat 25 20 6 requirements, eg where precast components are
Very flat 50 30 3 installed into a building frame Figure 4. Note that
Super flat 100 50–100 AS 3610 is of little use in this regard as it deals with
Typical warehouse 25–35 the surface finish rather than the actual position of
the element.
*Refers to a finishing process in which a long As an example,consider a mezzanine floor in a
straightedge (3 to 4 m) is drawn across the surface factory supported by 3-m-high columns. AS 3600
transverse to the direction of screeding to remove states that for a point on the top surface of a floor
undulations in the transverse direction. or the soffit of a beam or slab adjacent to a column
or wall, the deviation from the specified elevation
shall not exceed 40 mm vertically ie ±40 mm from
the designed level. The actual variation may be
smaller as the deviation from any specified height
must not exceed 1/200 times the specified height or

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5 mm, whichever is the greater. For the mezzanine
floor, the variation in the column height could thus
be ±15 mm (height/200). While this is within the
±40 mm allowed, in the worst case there could be a
30 mm fall across the slab, and the floor levels still
comply with the tolerances given in AS 3600. This
could make the fit of components or construction of
walls difficult.
Thus, if the location (position or elevation) of
a concrete member is critical to the project, then
specifying appropriate tolerances in the project
Figure 4: Concrete frame may require tolerances documentation that are more stringent than those
appropriate for the fitting of components such as allowed under AS 3600 is recommended.
precast units.

Table 2 Acceptable quality of formed surfaces (after AS 3610)

Quality of surface finish Class 1 Class 2 Class 3 Class 4 Class 5

1 Blowholes Refer photographs in AS 3610 for examples N/A N/A

2 Form face deflection Lesser of Lesser of Greater of Greater of


2 mm or 3 mm or 3 mm or 3 mm or
span/360 span/270 span/270 span/270 N/A

Tolerance for straight elements with smooth surface, in millimetres

% of readings

95 100 90 100 80 100 70 100 70 100

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.

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NATSPEC NATSPEC nominates a flatness tolerance Slabs In addition to the unformed top surface,
for each of three classes of unformed surfaces, viz: formed slab edges may also need to be considered –
n Class A Maximum deviation from a 3-m particularly in residential work. For the latter, both
straightedge is 3 mm. are covered by AS 28707.
n Class B Maximum deviation from a 3-m The formed edges/sides of the concrete slab
straightedge is 6 mm. are generally acceptable if in accordance with the
n Class C Maximum deviation from a 600‑mm tolerances of AS 3600, as the edge is either below
straightedge is 6 mm. ground level or concealed by the external skin of
brickwork and therefore surface appearance is
Class A should not automatically be specified not critical. Note that AS 2870 generally requires
for all floor applications. Achieving a maximum concrete work to be in accordance with AS 3600.
deviation of 3-mm under a 3-m straightedge is Where the edge remains exposed after
difficult and may require special construction construction (clad frame construction or as part
techniques at increased cost. Referring to Table 1, of the termite barrier system) a Class 3 finish to
a reasonable tolerance for a conventional finish the formed surface in accordance with AS 3610
would be a maximum deviation of 12 mm under a should be specified. This will provide a satisfactory
3-m straightedge. With careful level control and surface appearance and satisfy the requirement of
re-screeding where required, it may be possible to AS 3660.18 that ‘the exposed face of the perimeter of
achieve a maximum deviation of 8 mm under a 3-m the slab shall be off-the-form and shall not exhibit
straightedge for the majority of a pavement area. areas of rough surface, honeycombing or ripples’.
More-stringent tolerances should be specified only A more stringent flatness tolerance than
if required for the application, eg a television studio the 12 mm shown in Table 3 may be required for
floor or operating theatre, both of which require particular floor finishes such as polished concrete
sensitive equipment to be moved across the floor. In or vinyl where light reflecting from the surface
these cases Class A may be the appropriate flatness tends to highlight any undulations. A maximum
to specify, but consideration needs to be given variation of 6 mm from a 3-m straightedge would be
to achieving the specified tolerance on site. The a reasonable tolerance for small areas, and 8 mm
specification of a less stringent tolerance and use for larger areas. Reducing the waviness would also
of a self-levelling topping (after construction) may assist in achieving a flatter finish.
be an option to achieve more-stringent tolerances, Tolerances should be measured within 72 hours
particularly if suspended and/or post tensioned of placement, and not be used to assess the
floors are involved. Deflections after formwork performance over a period of time, as ground
removal or stressing can easily exceed the ‘flatness’ movement in excess of the tolerances may occur.
tolerance specified. Note that the waviness of the
floor may be more critical than having a Class A Columns and Walls Tolerances for the location and
finish. Fewer ‘waves’ will effectively increase plumb of these members are usually specified in
the flatness and allow smoother movement of accordance with AS 3600. As surface appearance
equipment over the floor surface Figure 2. is generally not critical (ie members concealed
from view by other finishes) a Class 4 surface finish
SPECIFYING TOLERANCES in accordance with AS 3610 should typically be
Specified tolerances should realistically reflect the specified. This will ensure good general alignment
requirements for the appearance and function of of the surface.
the concrete element. The practice of specifying In general, tolerances need to be considered for
more-stringent tolerances than required to cover individual elements and for the total structure. The
unforseen circumstances should be avoided; latter may govern or dictate the level of tolerances
the more stringent the tolerances, the more for individual members.
sophisticated (and therefore costly) are the If the location of these elements is important, and
construction and measurement methods needed they can not be allowed to ‘drift’ out of position by
to achieve and check them. The recommended the 40 mm allowed in AS 3600, then an appropriate
tolerances for various elements are discussed more stringent tolerance needs to be specified. Again
below and summarised in Table 3. the project documentation may limit the deviation
from the specified plan position to say 15 mm. While
Footings If no requirements are specified, footings this allows some tolerance for dimension and
would be deemed to require only Class 5 finish for plumb, it may require each level to be set out to
which no provisions for the surface appearance are ensure the adequate location of columns and walls.
included in the Standards.

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Table 3 Recommended tolerances

Tolerance on:

Member Position/size Surface quality

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).

Exposed As for ‘concealed’ above plus – Maximum Class 4(3), or higher.


deviation from plumb to be the greater of
1/200 times specified dimension or 5 mm(1, 2);

Absolute position to be within ±15 mm


horizontally.

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).

Plumb – ±10 mm of plumb. Elements with applied finishes – Class(3) to


be specified to provide appropriate substrate.

Elements viewed as a whole – Class 3(3).

Elements viewed in detail – Class 2(3).

Architectural Elements As appropriate for type of member. Class 1, 2 or 3(3, 4).

External Pavements Surface level – Flatness – Maximum deviation from a


(driveways, footpaths, n Non-graded pavement: ±10 mm of 3-m straightedge placed anywhere on the
patios and other specified level. pavement: 12 mm.
pedestrian pavements) n Graded pavement: ±10 mm of a
straight line between control points.
n Control points at top and bottom
of graded pavement: ±10 mm of
specified level.

Thickness – Maximum deviation to be the


greater of 1/200 times specified thickness or
5 mm(1).

Industrial Pavements Surface level – To be within ±10 mm of Flatness and levelness – To have the
specified level. following F-numbers(5):

Thickness – Maximum deviation to be the Finishing method/


greater of 1/200 times specified thickness or pavement type FF FL
5 mm(1).
Bullfloated 15 13
Straightedged(6) 20 15
Flat 25 20
Very flat 50 30

Notes 1 In accordance with AS 3600.


2 If a Class 2 or 3 finish in accordance with AS 3610 is specified, the associated plumb tolerances apply.
3 In accordance with AS 3610.
4 A tighter tolerance may be required for some floor finishes, eg tiled, vinyl, polished, see p5 Slabs.
5 As measured by the F-Meter method described on p2; see Table 1 for straightedge-tolerance equivalents.
6 Refers to a finishing process in which a long straightedge (3 to 4 m) is drawn across the surface transverse to the direction
of screeding to remove undulations in the transverse direction.

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Regarding the plumb, it is recommended that possible impact with racking. While the degree of
the 10 mm variation given in AS 3600 be regarded flatness and levelness is dictated by the requirements
as a maximum, rather than minimum value. This of the suppliers of these turret trucks, more-stringent
makes the requirements for plumb approximately tolerances are often specified due to particularly
consistent with a Class 3 finish in AS 3610. narrow aisle widths, or the need to compensate for
subsequent movements eg subgrade settlement.
Architectural Elements In addition to specifying For high-bay racking, generally a very flat floor
tolerances for the position of concrete elements, will allow the efficient operation of fork lift trucks
where the visual appearance is important, (manufacturers’ specifications need to be checked),
tolerances for the surface finish must also be with specified tolerance values of FF = 50 and FL= 30.
specified. A group of tolerances which define the As noted in Table 1, this is roughly equivalent
surface finish are usually specified as either a to a maximum deviation of 3 mm under a 3-m
Class 1, 2 or 3 finish in accordance with AS 3610. straightedge, and thus consistent with the class A
Class 1 finishes should be specified only for finish nominated in NATSPEC.
selected small elements contained in a single pour, Note: Specifying tolerances using the F-number
and not for entire building facades. This is due to method is more suitable for industrial pavements
their cost and difficulty to achieve over larger areas. where measuring tolerances over large areas may
Class 1 is often specified for residential and public be difficult using other methods.
applications where close scrutiny of the finish is The specification of more-stringent tolerances
possible. ie a ‘superflat’ floor, involving a considerable
Class 2 finishes are appropriate for exposed increase in cost, is generally not warranted.
concrete in areas where people have the opportunity However, each project must be assessed and the
to view the finish in detail. Typically class 2 would appropriate tolerance determined.
be the minimum finish for residential applications
and other building and structural elements where ACHIEVING TOLERANCES
people can be in close proximity. When specifying tolerances consideration should
Class 3 finishes would suffice for most exposed be given to how they will be achieved on site.
concrete applications such as carparks where the Tolerance requirements need to be communicated
structure is viewed as a whole, and people are less to the contractor so that appropriate construction
alert to the actual finish. techniques and procedures can be planned to
deliver the desired result. This is critical where
External Pavements In determining tolerances for tight tolerances have been specified, as additional
external pavements, consideration should be given to: time and cost will be involved in achieving them.
n Drains. Most graded pavements fall to a drain, Consideration should be given to the following:
which itself has an elevation tolerance. If the n Communication. Communication between all

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

an appropriate minimum grade. be assessed within 24 hours, but no later than


72 hours after placement of concrete, and
Industrial Pavements The surface flatness is often prior to any activities such as post-tensioning,
the critical factor for these pavements, and the formwork stripping/backpropping and loading
tolerances need to suit the application. Forklift uses which may affect the levels.
range from general circulation areas and wide aisles n Reasonable tolerances. Construction cost

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.
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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

slab curling. can be applied to the surface not only to correct


n Movement and/or deflection. While the tolerances, but also to provide a uniform
specified tolerances may be satisfactory when appearance to the finished surface.
checked for compliance, subsequent movement
and/or deflection of the concrete member
(eg due to ground movement, stripping of
formwork, loading, stressing) could result in
the final surface not complying. An alternative
to specifying more-stringent (and perhaps
unreasonable and more-costly) tolerances to
allow for this movement is the specification
of less-stringent tolerances combined with an
appropriate self-levelling topping.
n Self-levelling toppings. Surfaces requiring
tight tolerances (eg operating theatres, studios),
or ones subject to subsequent movement/
deflection may benefit from the use of a topping
by which such tolerances are readily achievable.
A further benefit is that, since the topping can be
placed at the end of the construction period, the
need for protection of the floor is minimised.
n Trial slabs. The importance of trial slabs or
test panels that incorporate all the features
of the critical slabs or elements, from
preparation, formwork, jointing, placing,
compacting, finishing and curing, can not be over
emphasised. Trial slabs provide the opportunity
to further refine the techniques required
to achieve the final result, and to a greater
understanding and appreciation of the extent of
work involved.

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sept CCAA OFFICES
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St Leonards NSW Australia 2065
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REFERENCES St Leonards NSW 1590
TELEPHONE: (61 2) 9437 9711
1 AS 3610 Formwork for concrete, Standards
FACSIMILE: (61 2) 9437 9470
Australia, 1995.
BRISBANE OFFICE:
2 ASTM E1155M-87 Determining Floor Flatness Level 14, IBM Building
and Levelness Using the F-number System, 348 Edward Street
January 1991. Brisbane QLD 4000
TELEPHONE: (61 7) 3831 3288
3 ACI Committee 302.1R Guide for Concrete Floor FACSIMILE: (61 7) 3839 6005
and Slab Construction American Concrete MELBOURNE OFFICE:
Institute Manual of Concrete Practice, Part 2, 2nd Floor, 1 Hobson Street
2005. South Yarra VIC 3141
TELEPHONE: (61 3) 9825 0200
4 ACI 117-90 Standard Specifications for FACSIMILE: (61 3) 9825 0222
Tolerances for Concrete Construction and PERTH OFFICE:
Materials American Concrete Institute Manual of 45 Ventnor Avenue
Concrete Practice, Part 1, 2005. West Perth WA 6005
TELEPHONE: (61 8) 9389 4452
5 AS 3600 Concrete structures, Standards FACSIMILE: (61 8) 9389 4451
Australia, 2001. ADELAIDE OFFICE:
6 Concrete Finishes Section NATSPEC Reference Greenhill Executive Suites
Volume 1: Building Works, 2003. 213 Greenhill Road
Eastwood SA 5063
7 AS 2870 Residential slabs and footings, POSTAL ADDRESS:
Standards Australia, 1996. PO Box 229
Fullarton SA 5063
8 AS 3660.1 Termite management, Part 1: New TELEPHONE: (61 8) 8274 3758
building work, Standards Australia, 2000 FACSIMILE: (61 8) 8373 7210
EXTRACTIVE INDUSTRIES OFFICE
PO Box 243
FURTHER INFORMATION Henley Beach SA 5022
Further information on good concreting practices TELEPHONE: (61 8) 8353 8151
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Aggregates Australia website at www.concrete.net.au. TASMANIAN OFFICE:


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