GRCA techNOTE | NOVEMBER 2020 13

GRC Tolerances
This techNOTE from The International Glassfibre
Reinforced Concrete Association (GRCA) focuses purely on
the expected variance regarding the physical dimensional
tolerances that should be allowed in the manufacture of
Glassfibre Reinforced Concrete (GRC / GFRC).
This is the thirteenth in a series of
technical notes covering aspects of
John Clarke MCIOB & GRCA Technical Working Group glassfibre reinforced concrete (GRC /
GFRC) technology.

Manufacturing Tolerances of Glassfibre Reinforced Concrete (GRC/GFRC) that includes structural movement,
deflection and constructional tolerances in
Amongst the various applications of the word tolerance, the Oxford English
addition but not limited to cladding,
Dictionary (1) best describes the use appropriate to this guidance as - “An
manufacturing and installation tolerances.
allowable amount of variation of a specified quantity, especially in the
4.1.3 (Prescriptive Specification) states
dimension of a machine or part.“.
alternatively the principle designer or
To elaborate further with reference to the construction industry, this is cladding designer should provide the
better defined as - A specified permissible variation from stated manufacturer with all relevant details
requirements such as dimensions and strength. including but not limited to tolerances.
In short, tolerances need to exist to accommodate characteristic variances Among the opportunities and benefits that
in both construction materials and workmanship. Comprehensively the off-site/pre manufacture in the
factors to consider are manufacture, installation and interfacing, with construction industry provides, by
designers having to make allowance in panel to panel joints for: manufacturing key elements in a factory
a. Deviation of structure (construction, dead loading); controlled environment, includes
b. Movement of structure (creep, column shortening, sway, shrinkage, improvements regarding accuracy and
etc.); quality. With GRC it is possible to
manufacture to relatively close tolerances,
c. Manufacturing deviation;
however it should still be appreciated that,
d. Installation deviation; as with in-situ concrete, some dimensional
e. Thermal actions; and variations may occur. Manufacturing
f. Performance limitations of jointing materials. tolerances should be stated in the contract
With regard to roles and responsibilities, BS 8297:2017 (2) 4.1.1. (Materials documents for all dimensions – length,
and components, Customer requirements, General) states the specifier width, thickness, squareness,
should provide the cladding designer with a performance and/or straightness/bow, warp/twist, size and
prescriptive specification. 4.1.2 (Performance Specification) states the location of apertures and grounds, in
principle designer should provide the cladding designer with information addition to cast in items.
If any dimensions fall outside these
tolerances, the following adverse and
detrimental conditions could result:
a. Eccentric loading conditions.
b. Reduction of bearing areas with the
consequence of distress to the GRC
panel.
c. Fixing problems.
d. Unacceptable aesthetic variations.
e. Delays in fixing and completion of the
works.
f. Interfacing problems with other
constructions and violation of
property lines.

The International Glassfibre Reinforced Concrete Association t: +44 (0) 330 111 (GRCA) w: grca.online
PO Box 1454, Northampton, NN2 1DZ, United Kingdom t: +44 (0) 330 111 4722 e: info@grca.online 1
 GRCA techNOTE | NOVEMBER 2020 13

Whilst it is usually unacceptable to exceed the specified tolerances the needs adjustment, or that a replacement
cladding works may still be acceptable. This will depend upon views taken mould should be constructed.
by the design professionals after they have had time to consider all of the
With improved accuracy there is less scope
ramifications of the tolerance(s) being exceeded.
for changes on site to make things fit
Manufacturing tolerances for GRC panels are predominantly determined beyond any installation tolerances so there
by production capabilities. Tolerances should not be too stringent as this is a need for a point of reference that
could result in unacceptable costs and delays. defines levels of acceptability. Recent
innovations such as the implementation of
Repeat operations in the manufacture of identical panels such as casting,
BIM and the use of clash avoidance
stripping and re-use of the moulds themselves, should not affect the
software paves the way for the manner in
mould producing panels that are within permissible tolerances. Regular
which pre-manufactured construction will
inspection of the moulds should be made to ascertain that either
further evolve.
acceptable tolerances can still be achieved, or identify that the panel

GRC Manufacturing Tolerances

In general, manufacturing tolerances should be within the following limits and as illustrated in the annex to this
document:
a) Linear Dimensions (i.e. Length and Height, see Fig. 1)
i) <= 3 m: ± 3 mm
ii) > 3 m : ± 6 mm.
b) Edge returns (Fig. 1): + I2 mm - 0 mm.
c) Thicknesses (see Detail A Fig. 1)
i) Architectural facing thickness (min 3 mm ): +2 mm - 0 mm
Note: This may not be possible for heavier aggregate/textured finishes. In such instances indicative samples may be
referenced to establish acceptable variances.
ii) backing mix: + 5 mm - 0 mm
iii) depths of integral ribs: + 10 mm - 5 mm.
d) Angular variation of side moulds (see Detail B, Fig. 1)
i) <=75 mm depth: ± 1 mm
ii) >75 mm depth: ± 1.5 mm.
e) Variations from square (see Fig. 1)
Difference in lengths of diagonals or other similar criteria: 3 mm for 2 m or below, or 6 mm for above 2 m.
f) Bowing (see Fig. 2): <= L / 250.
g) Openings within panel face (see Fig. 1): ± 5 mm.
h) Location of opening within panel (see Fig. 1): ± 3 mm.
i) Stud Frames (see Fig. 3), should be fabricated within the following tolerances:
i) vertical and horizontal lengths alignments: 6 mm per 3 m or part thereof
i.e. for 5 m length frame tolerance would be 12 mm
ii) spacing of framing members: ± 10 mm
iii) squareness of frame, (difference in diagonals): 10 mm
iv) overall lengths of frame: ± 10 mm
Note: It may be necessary to adjust the jigs used to fabricate the stud frames, prior to the frames being galvanised,
to offset some of the distortions due to the galvanising process.
j. Warping (see Fig. 4)
Maximum permissible warp of one corner out of the other three should be not be more than 5 mm/m distance from
the nearest adjacent corner.
Note: However, it may be possible to erect the panel within installation tolerances via connection adjustments.
Note: The above is not an exhaustive list. In addition to this, it should be recognised that more complex designs often
require further consideration and evaluation

The International Glassfibre Reinforced Concrete Association t: +44 (0) 330 111 (GRCA) w: grca.online
PO Box 1454, Northampton, NN2 1DZ, United Kingdom t: +44 (0) 330 111 4722 e: info@grca.online 2
 GRCA techNOTE | NOVEMBER 2020 13

Specific tolerances
PD CEN/TR 15739 (3) identifies the natural characteristics and variances in
precast concrete products and states the level of expectation and means of
evaluating variances within the finish, before being hastily and incorrectly
identified as defects.
It provides the opportunity to specify acceptable project specific
parameters beyond the general manufacturing standards stated within this
techNOTE, such as Flatness (overall and local), Texture and Colour. These
parameters can be evaluated from reference to mock-up/sample panels in
addition to manufacturers experience and understanding of the
capabilities and limitations of the materials and products themselves.
(3)
Annex B and C of PD CEN/TR 15739 provide example documents that
can be integrated into a project and utilised as reference documents to
identify the level of performance to be expected.
It is important to understand that zero tolerance is not achievable. The
professional design team should determine and specify tolerances in
accordance with current Standards and normal practice. In so doing, the
team must appreciate that some of these specified tolerances may not be
realised. Panels should not be rejected because they do not conform
exactly to the specified tolerances. Means and ways of accepting them
ought to be considered first. It is imperative that any proposed deviations
in tolerances do not affect the long term integrity of the panels or become
unacceptable with regard to aesthetic considerations.
Revisions to details and/or fixings are likely to cause delays and incur costs.
Inevitably, some conflict(s) may result, but public health and safety are
paramount and must not be compromised whatever the outcome.
The specifier should identify, and draw attention to, any project specific
tolerances beyond those stated within this techNOTE in order to establish
the feasibility of them being achieved in the manufacturing process.

techNOTE 13 References:
1. Oxford University Press: “Oxford English Dictionary”.
2. British Standards Institution: “BS 8297 Design, manufacture and
installation of architectural precast concrete cladding. Code of
practice”.
3. British Standards Institution: “PD CEN/TR 15739: Precast Concrete
Products- Concrete Finishes Identification”.

The International Glassfibre Reinforced Concrete Association t: +44 (0) 330 111 (GRCA) w: grca.online
PO Box 1454, Northampton, NN2 1DZ, United Kingdom t: +44 (0) 330 111 4722 e: info@grca.online 3
 GRCA techNOTE | NOVEMBER 2020 13

The International Glassfibre Reinforced Concrete Association t: +44 (0) 330 111 (GRCA) w: grca.online
PO Box 1454, Northampton, NN2 1DZ, United Kingdom t: +44 (0) 330 111 4722 e: info@grca.online 4