HB31 PDF

HB 31—2002
HB 31
Handbook
Handbook of building construction

tolerances—Extracts from building
products and structures Standards
Accessed by UNIVERSITY OF MELBOURNE LIBRARY on 24 Aug 2012
This Australian Standard was prepared by Committee BD-069, Accuracy in
Building Construction. It was published on 18 April 2002.
The following interests are represented on Committee BD-069:

Concrete Masonry Association of Australia
Housing Industry Association
Institution of Professional Engineers, New Zealand
National Precast Concrete Association Australia
Association of Consulting Engineers Australia
RMIT University
University of New South Wales
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HB 31—2002
Handbook
Handbook of building construction

tolerances—Extracts from building
Originated as HB 31—1992.
Second edition 2002.
COPYRIGHT
© Standards Australia International
All rights are reserved. No part of this work may be reproduced or copied in any form or by any
means, electronic or mechanical, including photocopying, without the written permission of the
publisher.
Published by Standards Australia International Ltd
GPO Box 5420, Sydney, NSW 2001, Australia
ISBN 0 7337 4157 6
HB 31—2002 2
PREFACE
This Handbook was prepared by Standards Australia. Its purpose is to identify, for persons
in the building design and construction industries, those Clauses in building Standards that
relate to tolerances. Extracts from available Commentaries are also included. Clause
numbers of the Commentaries correspond to those in the Standard to which they refer and
are prefixed by the letter ‘C’. It does not purport to be exhaustive in this respect and the
full Standards should be referred to for cross-referenced Clauses not included herein.
The Standards from which these extracts have been taken are currently available editions at
the time of publication of this Handbook. At some later time, those Standards may be
revised or amended. Users of the Handbook should, therefore, check on the status of the
original Standards before applying any of the extracts. Users should also consult original
Standards that are cited but not included in these extracts.
Since this Handbook is intended for use by design and construction personnel, it is expected
that the nominal sizes of components will be obtained by designers from manufacturer’s
catalogues and that they will be determined by constructors generally from the drawings.
Thus nominal sizes or ranges of sizes are not included for components with tolerances
quoted in this Handbook (unless the ‘tolerance’ Clauses are cross-referenced to the ‘sizes’
Clauses).
As it is not intended that this Handbook be used by fabricators, the tolerances on materials
used for fabrication are not included unless those tolerances are likely to be evident in
finished products.
3 HB 31—2002
TABLE OF CONTENTS
Standards Title Page

AS 4100 Steel structures 4
AS 4100 Supp 1 Steel structures—Commentary 14
AS 1397 Steel sheet and strip—Hot-dipped zinc-coated or 20
aluminium zinc coated
AS 3610 Formwork for concrete 21
AS 3610 Supp 2 Formwork for concrete—Commentary 37
AS 2876 Concrete kerbs and channels (gutters) – Manually or 46
machine placed
AS 3600 Concrete structures 47
AS 3600 Supp1 Concrete structures—Commentary 49
AS 2160 Contract for the supply and construction of a swimming 51
pool
AS 2160.1 Contract for the supply and construction of a swimming 52
pool—Concrete pool or spa
AS 3850.2 Tilt-up concrete and precast concrete elements for use in 53
building—Guide to the design, casting and erection of
tilt-up panels
AS/NZS 2908.1 Cellulose-cement products—Corrugated sheets 54
AS/NZS 2908.2 Cellulose-cement products—Flat sheets 55
AS 4455 Masonry units and segmental pavers 56
AS 3700 Masonry structures 58
AS 3700 Supp 1 Masonry structures—Commentary 61
AS 2796.1 Timber hardwood—Sawn and milled products—Product 62
specification
AS/NZS 2208 Safety glazing materials in buildings 65
AS 2047 Windows in buildings—Selection and installation 69
HB 31—2002 4 Extract of AS 4100—1998
Australian Standard
Handbook of building construction tolerances—Extracts from building
S E C T IO N 1 4 F A BR IC A T IO N
14.4 TOLERANCES
14.4.1 General
The tolerance limits of this Clause shall be satisfied after fabrication is completed and any
corrosion protection has been applied. Unless otherwise specified, the tolerance on all
structural dimensions shall be ±2 mm.
14.4.2 Notation
For the purpose of this Clause —
a 0, a 1 = out-of-square dimensions of flanges
a 2, a 3 = Diagonal dimensions of a box section
b = Lesser dimensions of a web panel
bf = Width of a flange
d = Depth of a section
d0 = Overall depth of a member including out-of-square dimensions
d1 = Clear depth between flanges ignoring fillets or welds
e = web off-centre dimension
l = Member length
∆f = out-of-flatness of a flange plate
∆v = Deviation from verticality of a web at a support
∆w = out-of-flatness of a web
14.4.3 Cross-section
After fabrication, the tolerances on any cross-section of a rolled section or a plate shall be
those specified in AS/NZS 3678 or AS/NZS 3679.1, as appropriate, in respect of depth,
flange width, flange thickness, web thickness, out-of square, and web off-centre.
For any built-up section, the deviations from the specified dimensions of the cross-section
shall not exceed the following:
(a) Depth of a section (d) (see Figure 14.4.3(1))
for d ≤ 900, ±3 mm
for 900 < d≤ 1800,  (d − 900) 
± 3 + mm
 300 
for d > 1800 ± 6 mm
© Standards Australia www.standards.com.au

Extract of AS 4100—1998 5 HB 31—2002
(b) Width of a flange (b f) (see Figure 14.4.3(1))

for all b f, ± 6 mm
(c) Out-of-square of an individual flange (a 0 or a 1 ) (see Figure 14.4.3(1))
for b f ≤ 600 mm, ± 3 mm
for b f > 600 mm,  b 
±  f  mm
 200 
(d) Total out-of-square of two flanges (a0 + a1) (see Figure 14.4.3(1))
for b f ≤ 600 mm, ± 6 mm
for b f > 600 mm, b 
±  f  mm
 100 
FIGURE 14.4.3(1) TOLERANCES ON A CROSS-SECTION
NOTES
1 Dimension d, d0, a0 and a1 are measured parallel to the centreline of the web. Dimensions bf and
(0.5bf ± e) are measured parallel to the plane of the flange.
2 Dimension d is measured at the centreline of the web.
(e) Out-of-flatness a of web ( ∆ w ) (see Figure 14.4.3(2))

d 1/150 mm for unstiffened web,
b/100 mm for stiffened web with intermediate stiffeners,
(f) Deviation from verticality of a web at a support ( ∆ v ) (see Figure 14.4.3.(2))
for d ≤ 900 mm ± 3 mm
for d > 900 mm,  d 
±   mm
 200 
www.standards.com.au © Standards Australia

HB 31—2002 6 Extract of AS 4100—1998
FIGURE 14.4.3.(2) TOLERANCES OF A WEB
(g) Tolerance on shape of a built-up box section (see Figure 14.4.3.(3))

A built-up box section shall not deviate at the diaphragm from the prescribed shape
by more than ±5 mm or ± [(a 2 + a 3 )/400] mm, whichever is greater, unless connection
requirements necessitate more stringent tolerances.
FIGURE 14.4.3(3) TOLERANCE ON SHAPE OF A BOX SECTION
(h) Off-centre of a web (e) (see Figure 14.4.3(4)) ±6 mm

FIGURE 14.4.3(4) TOLERANCE ON OFF-CENTRE OF A WEB
(i) Out-of-flatness of a flange ( ∆ f ) (see Figure 14.4.3(5))

for b f ≤ 450 mm  b 
±  r  mm
 150 
for b f > 450 mm ± 3 mm

Extract of AS 4100—1998 7 HB 31—2002
FIGURE 14.4.3(5) TOLERANCE ON OUT-OF-FLATNESS OF A FLANGE
14.4.4 Compression member

14.4.4.1 Straightness
A member shall not deviate about either principal axis from a straight line drawn between
end points by an amount exceeding l/1000 or 3 mm whichever is the greater.
14.4.4.2 Full contact splice
If the ends of two butting lengths of a member, or the end of a member and the contact face
of an adjoining cap plate or baseplate, are required to be in full contact, such a requirement
shall be deemed to be satisfied if the bearing surfaces are prepared so that when the abutting
member length or lengths are aligned to within the tolerance specified in Clause 15.3.3, the
maximum clearance between the abutting surfaces shall not exceed 1 mm, and shall also not
exceed 0.5 mm over at least 67% of the contact area.
14.4.4.3 Length
The length of a member shall not deviate from its specified length by more than ±2 mm.
14.4.5 Beam
A beam shall not deviate from a straight line drawn between the ends of the beam by more
than the following:
(a) Camber—measured with the web horizontal on a test surface (see Figure 14.4.5.1(a)).
The tolerance on specified camber shall not exceed l /1000 or 10 mm whichever is the
lesser.
(b) Sweep—measured with the web vertical on a test surface (see Figure 14.4.5.1(b)). The
sweep in plan shall not exceed l /1000 or 3 mm whichever is the greater.
14.4.5.2 Length
The length of a beam shall not deviate from its specified length by more than ±2 mm for
lengths less than 10 m, and ±4 mm for lengths greater than 10 m.
14.4.6 Tension member
A member shall not deviate from a straight line drawn between end points more than l/500,
where l is the length between end points.
14.4.6.2 Length
The length of a tension member shall not deviate from its specified length by more than
±2 mm for lengths less than 10 m, and ±4 mm for lengths greater than 10 m.

HB 31—2002 8 Extract of AS 4100—1998
FIGURE 14.4.5.1 MEASUREMENT OF CAMBER AND SWEEP


Extract of AS 4100—1998 9 HB 31—2002
S EC T ION 15 E R EC T IO N
15.3 TOLERANCES
15.3.1 Location of anchor bolts
Anchor bolts shall be restrained in position both in a vertical and a horizontal direction
during all setting-in operations
Anchor bolts shall be set out in accordance with the erection drawings. They shall
not vary from the positions shown on the erection drawings by more than the
following: (See Figure 15.3.1)
(a) 3 mm centre-to-centre of any two bolts within an anchor bolt group, where an anchor
bolt group is defined as the set of anchor bolts which receives a single fabricated steel
member.
(b) 6 mm centre-to-centre of adjacent anchor bolt groups.
(c) Maximum accumulation of 6 mm per 30 000 mm along an established column line of
multiple anchor bolt groups, but not to exceed a total of 25 mm. The established
column line is the actual field line most representative of the centres of the as-built
anchor bolt groups along a line of columns
(d) 6 mm from the centre of any anchor bolt group to the established column line through
that group
Anchor bolts shall be set perpendicular to the theoretical bearing surface, threads shall be
protected and free of concrete and nuts shall run freely on the threads.
The projection of the end of the anchor bolt from the theoretical bearing surface shall not be
more than 25 mm longer nor 5 mm shorter than that specified.

HB 31—2002 10 Extract of AS 4100—1998
FIGURE 15.3.1 TOLERANCES IN ANCHOR BOLT LOCATION
15.3.2 Column base

15.3.2.1 Position in plan
The position in plan of a steel column base shall not deviate from its correct value by more
than 6 mm along either of the principal setting out axes.
15.3.2.2 Level
The level of the underside of a steel base plate shall not deviate from its correct value by
more than ±10 mm.
15.3.2.3 Full contact
If full contact is specified, the requirements of Clause 14.4.4.2 shall be satisfied, unless
shims are used to reduce the measurable gaps to values specified in Clause 14.4.4.2.
Packs, shims and other supporting devices shall be flat and of the same steel grade at the
member. If such packings are to be subsequently grouted, they shall be placed so that the
grout totally encloses them with a minimum cover of 50 mm.

Extract of AS 4100—1998 11 HB 31—2002
15.3.3 Plumbing of a compression member

The alignment and plumbing of a compression member shall be in accordance with
both of the following requirements:
(a) The deviation of any point above the base of the compression member from its
correct position shall not exceed height/500 or as follows, whichever is the
lesser:
(i) For a point up to 60 m above the base of the member .................. 25 mm.
(ii) For a point more than 60 m above the base of the member .....................
.................25 m plus 1 m for every 3 m in excess of 60 m up to a
maximum of 50 m.
(b) The deviation of the top of the compression member from its correct position relative
to the bottom of the member from one storey to the next shall not exceed storey
height/500.
15.3.4 Column splice
A column splice shall conform to the following requirements:
(a) The level of the centre-line of a column splice shall not deviate from its correct level
by more than ±10 mm.
(b) The position in plan of a column splice shall be in accordance with the plumbing
tolerances specified in Clause 15.3.3.
(c) The plan position of each spliced member relative to the other shall not deviate by
more than 2 mm from its correct position along either of the principal setting-out
axes.
15.3.5 Level and alignment of a beam
In erecting a structure, a beam shall be deemed to be correctly positioned when—
(a) all connections including splices are completed;
(b) the maximum sweep in the beam is less than l b /500, where l b is the length
between points of effective bracing or restraint;
(c) a beam is within ±10 mm of its correct level at connections to other members;
and
(d) a web of a beam is within ±3 mm horizontally of its correct position at
connections to other members.
15.3.6 Position of a tension member
A tension member shall not deviate from its correct position relative to the members
to which it is connected by more than 3 mm along any setting-out axis.
15.3.7 Overall building dimensions
The overall building dimensions shall not deviate from the correct values by more than the
following:
(a) Length (see Figure 15.3.7.1)
for ∑l c ≤ 30 m, ∑ ∆l c ≤ ± 20 mm
for ∑ l c > 30 m, ∑ ∆l
c ≤ ± {20 mm + 0.25 (∑ / c )
− 30 m m}

HB 31—2002 12 Extract of AS 4100—1998
(b) Height (see Figure 15.3.7.2)

for ∑ hb ≤ 30 m, ∑ ∆hb ≤ ± 20 mm
for ∑h b > 30 m, ∑ ∆h b {
≤ ± 20 mm + 0.25 (∑ h
b )
− 30 mm}
provided that—
(i) the distance between adjacent steel column centres (l c ) at every section does not
deviate by more than ± 15 mm from the correct length;
(ii) the vertical distance between tops of beams (h b ) at every section does not
deviate by more than ± 20 mm from the correct values; and
(iii) all other tolerances in this Section are complied with.
For the purposes of this Clause—
∑l C
= the correct overall length of steelwork, being the centre-
to-centre distance of the extreme columns as shown in
Figure 15.3.7.1, at any location along the building, and
∑h b
= the correct overall height of steelwork, being the vertical
distance from underside of column baseplate to the top of the
finished floor level shown in Figure 15.3.7.2, at any location
along the building
FIGURE 15.3.7.1 DEVIATIONS IN LENGTH (VERTICAL SECTION)

Extract of AS 4100—1998 13 HB 31—2002
FIGURE 15.3.7.2 DEVIATIONS IN HEIGHT (VERTICAL SECTION)


HB 31—2002 14 Extract of AS 4100 Supp 1—1999
S EC T ION C 14 F A BR IC AT ION
C14.4 TOLERANCES
C14.4.1 General
The tolerances specified are considered to be reasonable from the point of view of their
effect on member capacity, and are considered to be efficiently and economically attainable
by the fabrication industry. Tighter tolerances are only achievable at increased cost. The
tolerance provisions are reviewed in Ref.14 and compared to those in comparable overseas
Standards at that time. The comparison remains valid.
The tolerances specified are applicable to all members, whether of hot-rolled steel
sections or fabricated from plates.
It should be noted that tolerances as close as those specified in Clause 14.4.1 are not
necessarily required for all structures. The tolerances are however consistent with the
member design clauses, and should only be varied in special cases. The design engineer
may decide to allow wider or require tighter tolerances in particular cases and to allow for
this in the design and may specify accordingly in the contract documents. There may also
be circumstances where deviation from the specified tolerance has occurred during
fabrication, and where the engineer may elect to accept the member provided that the
structure is not adversely affected. When any deviation is permitted, an assessment should
be made of the effect of the deviation on the member design capacity.
C14.4.2 Notation
(See Clause C1.4.)
C14.4.3 Cross-section
The tolerances on specified cross-section dimensions for built-up sections are based on the
following:
(d) AS/NZS 3679.1 requirements for rolled sections.
(e) American Institute of Steel Construction 'Quality Criteria and Inspection Standards'.
(f) American Welding Society, 'Structural Welding Standard — Steel' AWS D1.1.
The tolerance on plate thickness should be as specified in AS 1365.

The tolerances in Clause 14.4.3 are self-explanatory, and are readily measured on site
C14.4.4 Compression member
C14.4.4.1 Straightness
The straightness provision is consistent with that required in AS/NZS 3679.1 for the
manufacture of rolled sections. The provision applies to both principal axes of a member
(i.e. to camber and sweep, see discussion in Clause C14.4.5).
It is intended that a straightness check during fabrication be carried out to ensure that any
out-of-straightness does not affect the ability of the erector to erect the structure.
C14.4.4.2 Full contact splice
Clause 14.4.4.2 calls for the column to be plumbed to the requirements specified in
Clause 15.3.3 and then the gap measured. The restrictions on the gap are summarized in
Figure C14.4.4.2. These restrictions are intended to convey the reality that at splices, a
perfect full-and-even contact fit cannot be achieved.

Extract of AS 4100 Supp 1—1999 15 HB 31—2002
The 1 mm maximum gap restriction has been specified in a number of previous editions of
the Standard and is consistent with a number of overseas Standards. The 0.5 mm maximum
gap over 67% of the bearing area has been introduced in order to ensure that contact is
relatively widely spread, and that no excessive settling of the column occurs during
erection, which may alter the column alignment outside the tolerance of Clause 15.3.3.
Experience has indicated that non-detrimental local yielding in a full contact splice
compensates for imperfect abutting surfaces.
Where gap restrictions are exceeded, shimming may be used to correct the problem at the
engineer's discretion.
Full contact splices may be readily achieved using cold-saw cutting techniques, and end
milling would only be resorted to in special cases (see Clause C14.3.2).
Tests (Ref.15) on spliced full-size columns with joints that had been intentionally milled
out-of-square, relative to either the strong or weak axis, have demonstrated that their
load-carrying capacities were the same as those for similar unspliced columns. In the tests,
gaps of 1.5 mm were not shimmed and gaps of 6 mm were shimmed with non-tapered mild
steel shims. Minimum size incomplete penetration butt welds were used in all tests. No tests
were performed on specimens with gaps greater than 6 mm. Accordingly, it seems
reasonable to permit shimming on gaps up to 6 mm, with gaps larger than this being
corrected by re-fabrication.
The criteria for fit of compression member connections are equally applicable to
connections at column splices and connections between columns and base plates.
FIGURE C14.4.2 FULL CONTACT SPLICES
C14.4.4.3 Length
The length tolerance is consistent with the normal clearance in holes (2 mm or 3 mm, see
Clause 14.3.5.2), and with the normal tolerance on a welded butt joint in a compression
member.

C14.4.5 Beam
The measurement of camber is made with the web of the section to be tested horizontal.
Camber is measured as illustrated in Figure 14.4.5.1(a) of the Standard.
The measurement of sweep is made with the web of the section to be tested vertical. Sweep
is measured as illustrated in Figure 14.4.5.1(b) of the Standard. Although this method works
satisfactorily for the majority of members where sweep tends to be minimal, it may give
unreliable answers on members with excessive sweep.
It should be noted that 'out-of-straightness' about the major axis within the limits of
AS/NZS 3679.1 can be used to advantage in providing natural camber in beams at no cost.
C14.4.6 Tension member
(No Commentary.)
C14.5 INSPECTION
The inspection of fabricated items should be appropriate to the importance of the member
and the structure. Inspection of the following may be appropriate:
(a) Grades of material.
(b) Cut surfaces.
(c) Holes.
(d) Contact splices.
(e) Condition of contact surfaces.
(f) Member sizes.
(g) Welding.
(h) Bolt grades and sizes.
(i) Tolerances.
(j) Corrosion protection.
The design engineer, or an appropriately qualified inspection representing him, should have
access at all reasonable times to all places where the work is being carried out, and should be
provided by the fabricator with all the necessary facilities, excluding specialized inspection
equipment, for inspection while the work is in progress, unless specified otherwise in the
contract documents. Inspection of welding should be in conformity with AS/NZS 1554.1 or
as nominated in the contract documents.
Unless otherwise agreed prior to the inspection, the inspection should be carried out at the
place of fabrication. The inspector should schedule his inspections by agreement with the
fabricator.
Inspections are often best carried out by specialist inspection services under the direction of
the design engineer.

S EC T ION C 15 E R EC T ION
C15.3 TOLERANCES
The tolerances specified in the Standard are considered to be reasonable from the point of
view of their effects on member capacity, and are considered to be efficiently and
economically attainable by steelwork erectors. Tighter tolerances are only achievable at
increased cost. The tolerance provisions are reviewed in Ref.4 and compared to those in
comparable overseas Standards at that time. The comparison remains valid.
It should be noted that tolerances as close as those specified in the Clause 15.3 are not
necessarily required for all structures. The tolerances are however consistent with the
member design clauses, and should only be varied in special cases. The design engineer may
decide to allow wider or require tighter tolerances in particular cases, and to allow for this in
design and may specify accordingly in the contract documents. There may also be
circumstances where deviation from the specified tolerance has occurred during erection, and
where the engineer may elect to accept the member provided that the structure is not
adversely affected. When any deviation is permitted, an assessment should be made of the
effect of the deviation on the member design capacity.
C15.3.1 Location of anchor bolts

One of the greatest problems faced by a steel erector on site is inaccuracy in the locations of
the anchor bolts.
The tolerances quoted come from American and Canadian practice, and can be readily
attained using reasonable care. It is intended that these be called-up in foundation drawings.
These tolerances should ensure satisfactory site erection without site rectification measures
being required, when using the 6 mm oversize hole permitted in column base plates in
Clause 14.3.5.2 with which the tolerances are compatible.
Several additional steps can be used to improve the site erector's position (Ref.5) —
(a) caging of anchor bolt groups;
(b) use of cored holes to allow adjustment in anchor bolt positions; and
(c) checking of anchor bolt positions by a surveyor before concreting.

C15.3.2 Column base
C15.3.2.1 Position in plan
The 6 mm tolerance is intended to provide for accurate positioning of the base and, in
conjunction with plumbing tolerances, to allow reasonable limits which still allow the steel
frame geometry to be held. These tolerances should assist in the subsequent fitting of other
building elements such as pre-cast or curtain wall facade panels to steel building frames.
C15.3.2.2 Level
The tolerance of ± 10 mm is consistent with the tolerance on beam position given in
Clause 15.3.5 of the Standard.
C15.3.2.3 Full contact
Load bearing steel packs under column base plates should be placed so that they are always
within the base plate plan dimensions and are enclosed by a minimum of 50 mm of grout.
This provision guards against the possibility of a pack being close to the edge of the concrete
pedestal, resulting in high local compressive stresses which may break off the concrete edge.

C15.3.3 Plumbing of a compression member

The tolerances in Clause 15.3.3 are the same as those used for some time in Australia
Clause 15.3.3 is in line with American practice. The angular misalignment of 1/500 should
also strictly apply to lengths between splices.
Figure C15.3.3 explains diagrammatically the provisions of Clause 15.3.3.
FIGURE C15.3.3 PLUMBING OF A COMPRESSION MEMBER
C15.3.4 Column splice

The ±10 mm level tolerance is consistent with the beam level tolerance of Clause 15.3.5. of
the Standard. The position of the splice in plan must lie within the tolerance envelope for
plumbing (see Figure C15.3.3). The tolerance on relative position of spliced members is the
general ±2 mm tolerance, and guards against out of alignment of a splice (see
Figure C15.3.4).

FIGURE C15.3.4 COLUMN SPLICE
C15.3.5 Level and alignment of a beam

The tolerance of ±10 mm on beam level is the recommended ISO tolerance. A beam will
normally be held to level more accurately at its connection by virtue of the normal
fabricating tolerances on the position of holes and cleats.
The tolerance on web position is in line with ISO recommendations.
The tolerance on sweep of L b /500 is greater than the sweep allowed in Clause 14.4.5 during
fabrication (l/1000). This extra tolerance allows for the pulling in of a beam at intermediate
connections during erection. A misalignment of l/500 should also strictly apply to lengths
between any splices in the beam.
C15.3.6 Position of a tension member
(No Commentary.)
C15.3.7 Overall building dimensions
Clause 15.3.7 nominates limits on the combined effects of the tolerances on the fabrication,
erection and construction of all steel elements incorporated in a building. Clause 15.3.7 is
based on a similar clause in EuroCode 3.

HB 31—2002 20 Extract of AS 1397 —2001
S E C T IO N 2 T H E S T E E L BAS E
2.5 DIMENSIONAL TOLERANCES.

2.5.1 General
The dimensional tolerances of the base steel, including width, thickness, flatness and camber
shall be in accordance with the requirements of AS/NZS 1365 for cold-rolled strip.
2.5.2 Specified thickness
The thickness of the steel base of the sheet or strip shall be specified, as this thickness is
required for design purposes. It shall be measured not closer than 50 mm to the sheared edge.

Extract of AS 3610—1995 21 HB 31—2002
S EC T ION 3 S UR F AC E F IN IS H
3.4 PHYSICAL QUALITY

3.4.1 General
The physical quality of the concrete surface shall be specified under a class number in
accordance with Table 3.3.1. If the class is not specified in the project documentation the
quality of the surface is not required to exceed Class 3.
3.4.2 Project documentation requirements for surface finish
The project documentation shall include, where appropriate, the information required in
Table 3.4.1.
3.4.3 Tolerances
3.4.3.1 General
The tolerances given in this Section shall be read in conjunction with those given in AS 3600.
These tolerances apply to the as-cast formed surface prior to surface treatment, if any.
NOTE: The tolerances in AS 3600 result from structural considerations, and may, in some instances,
be less stringent than those in this Section, which are concerned with surface finish and accuracy.
3.4.3.2 Measurement
The tolerances given in this Section shall apply to the permanent structure. Other than for those
cases where strain movement of the permanent concrete work is anticipated, the deviations
shall be measured on the surface of the concrete after removal of any forms or supports and
before any surface treatment. Where strain movement of the concrete is anticipated, they shall
be measured prior to removal of any forms or supports. Evaluation of the completed work shall
comply with the requirements of Clause 5.6.
NOTE: Requirements on the frequency and distribution of the measurement deviations are given in
Tables 3.4.2 and 3.4.3 and Clauses 3.4.5 and 5.6.
3.4.3.3 Critical face
Where a concrete element has several faces each with an equal class of surface finish, the
project documentation shall specify which faces take precedence in the checking of deviations.
Where the opposite faces are of different classes then the face with the higher quality shall take
precedence in the checking.
3.4.4 Acceptable surface defects and deviations.
Table 3.4.2 gives values for surface defects and deviations which represent the acceptable
minimum quality appropriate to each class.
3.4.5 Precast concrete elements.
3.4.5.1 General
The following shall apply to precast concrete:
(a) Clause 3.4.4, as appropriate, for the specified class of surface finish except for the
tolerances on 'flatness' and 'out-of-plumb' given in Table 3.4.2. Where the shape of a
precast unit is such that there is conflict between the above-mentioned Clauses and those
indicated in Item (b) below, Item (b) shall take precedence.
(b) Clauses 3.4.5.2 and 3.4.5.3.

HB 31—2002 22 Extract of AS 3610—1995
3.4.5.2 Tolerance classification for precast concrete

Tolerances for precast concrete shall be classified as follows:
(a) Tolerances in linear dimensions Tolerances in linear dimensions cover thickness, width,
length and cross-section (see Figure 3.4.1).
(b) Tolerances in angular dimensions Tolerances in angular dimensions cover squareness or
trueness to any specified angle (see Figure 3.4.2). Angular tolerance for squareness shall
be expressed in terms of the distance by which a shorter side of the precast unit deviates
from a straight line perpendicular to the longer side and passing through the corner of the
unit. Trueness to an angle other than 90 degrees shall be expressed in similar terms, but
setting the check line in the specified angle.
(c) Tolerances in profile Tolerances in profile cover flatness, straightness, warp and twist
(see Figure 3.4.3), as indicated below:
(i) Flatness tolerance shall be expressed as the maximum permitted distance by which
any point on a nominally-plane surface may be from a 3 m long straightedge placed
anywhere on the surface and parallel to the nominally-plane surface.
(ii) Straightness tolerance shall be expressed as the maximum distance by which any
point on an edge of a unit may be from a straight line drawn through the
extremities of the particular edge.
(iii) Warp tolerance shall be expressed as the maximum acceptable distance of any point
on a surface from a plane containing any three corners of the surface or points on
the perimeter of the unit. If the surface is not a rectangle these three corners shall
be those points on the surface which are the corners of a rectangle covering the
greatest possible surface area of the unit.
(iv) Twist tolerance shall be expressed as the rotation of one end relative to the other end or
relative to some other line or surface specified by the project documents.
(d) Hog tolerance for prestressed concrete units For precast concrete units subject to
prestressing, hog tolerance shall be specified. The relevant deviations shall be
calculated separately from those defined in (a), (b) and (c) above. However, the effects
and range of hog tolerance shall be included in the total accumulative tolerance.
NOTE: The sequence for checking the above tolerance Clauses is defined in Clause 5.6.3.1.
3.4.5.3 Tolerance values

Precast concrete shall be manufactured within the acceptable deviations given in Table 3.4.3.

Extract of AS 3610—1995 23 HB 31—2002
TABLE 3.3.1
APPLICABILITY OF SURFACE CLASSES
Class 1 Class 2 Class 3 Class 4 Class 5
Visual quality important Visual quality not significant
Visual
characteristics Highest quality Uniform quality and Good visual quality Texture not important. Alignment
when viewed as a
attainable. texture over large whole Good general alignment and texture
Subject to close ares. not important
scrutiny. Built to close
Best possible tolerances.
uniformity of Consistently good
texture. quality of edge and
Excellent quality of joint details
edge and joint
details
Suitable uses Selected small General external and General external and Surfaces concealed from Totally
elements. internal facades internal facades general view. concealed
Areas of special intended to be intended to be Surfaces to have thick areas.
importance in viewed in detail viewed as a whole applied finishes after
limited quantities. preparation
Elements contained
in a single pour
Applied finish Not applicable Reference should be made to permitted tolerances prior to selection Not suitable
of applied material
Situations Trafficable slopes, Formed tops of No restriction No restriction

where not to be soffits, formed tops slopes except where
used of slopes except means to dissipate
where means to entrapped air are
dissipate entrapped employed
air are employed,
liners. It is not
applicable where
treatment is to 100%
of surface
Colour control May be specified. Refer to Clause 3.6.3(b) for the limits of the Excluded
best colour consistency that can be expected
General If these classes are required they must be If these classes are not specified in the project documentation,
specified in the documentation selection of appropriate class is by the visual characteristics
and suitable uses set out above.
NOTE: Class 1 is the highest standard with the most rigorous specification and is only recommended for use in very special
features of buildings of a monumental nature.

HB 31—2002 24 Extract of AS 3610—1995
TABLE 3.4.1
PROJECT DOCUMENTATION REQUIREMENTS
FOR SURFACE FINISH
Class 1 Class 2 Class 3 Class 4 Class 5 Ref. Clause
1 Test panels:
For untreated surfaces TBS TBS OPT NA NA 3.6
If colour control TBS TBS TBS NA NA 3.6
If treated surfaces TBS TBS TBS NA NA 3.6
2 Tie rod pattern TBS TBS OPT EXCL EXCL
3 Liner details, pattern and EXCL SIA SIA EXCL EXCL Table 3.3.1
accuracy
4 Surface pattern details and SIA SIA SIA EXCL EXCL

accuracy
5 Surface treatment pattern SIA SIA SIA EXCL EXCL Table 3.3.1
of part of surface
6 Surface treatment of whole EXCL SIA SIA EXCL EXCL Table 3.3.1
7 Form face span and OPT OPT EXCL EXCL EXCL Table 3.4.2
direction of span
8 Critical faces of elements SIA SIA SIA SIA EXCL 3.4.3.3
9 Distance between face OPT OPT OPT EXCL EXCL Table 3.4.2
steps
10 Plum of elements height SIA SIA SIA SIA SIA

≥8m
11 Repairs OPT to ACC ACC ACC ACC 5.6.5

exclude
12 Colour control SIA SIA SIA EXCL EXCL` 3.5
LEGEND:
TBS To Be Specified—these are mandatory project documentation requirements for all work where the
particular class has been specified.
NA Not Applicable—these are matters which are not applicable to the particular class.
OPT Optional—these are matters which may be included in the project documents
EXCL Excluded—theses are matters which shall not be included in the project documents for the
nominated class of surface finish.
SIA Specify If Applicable—these are mandatory where the particular feature is included in the project
documentation.
ACC Acceptable—repairs to these classes are acceptable and shall not be excluded by the specification.

Extract of AS 3610—1995 25 HB 31—2002
TABLE 3.4.2
ACCEPTABLE MINIMUM QUALITY OF SURFACE
Quality of surface finish Class 1 Class 2 Class 3 Class 4 Class 5 Ref Clause
1 Blowholes (Appendix B) Photo 1(a), Photo 2(a), Photo 3(a), NA NA 5.6.2.1(a)

1(b) 2(b) 3(b)
2 Form face deflection Lesser of Lesser of Greater of Greater of NA 5.6.2.2(b)

2 mm or 3 mm or 3 mm or 3 mm or
span/360 span/270 span/270 span/270
TOLERANCE FOR STRAIGHT ELEMENTS WITH SMOOTH SURFACE,

IN MILLIMETRES
% of readings 95 100 90 100 80 100 70 100 70 100
3 Face step:
(a) within the element 1 2 2 3 3 5 5 8 5.6.2.2(c)
(b) at in situ construction joint 2 3 2 3 3 5 5 8 * *
4 Surface undulations
(a) l = 300
(a – b)≤ 1 2 2 4 3 4 5 7 * * 5.6.2.2(d)
(b) l = 1500
(a – b)≤ 2 4 3 6 5 7 8 10
5 Flatness
(a) 1.25 m grid 4 5 6 7 7 10 * * * *

5.6.2.2(e)
(b) at 5 m over 10 m (not 5 7 7 10 10 15 * * * *
applicable to precast concrete)
6 Out of plumb
(a) height < 3 m 3 5 4 6 5 7 * * * *

5.6.2.2(f)
(b) 3 <height <8 m (not applicable
to precast concrete) 6 8 8 10 10 12 * * * *
* Limited by AS 3600. NA indicates not applicable.

NOTES:
1 Tolerance values more stringent than those given in the Table shall not be specified for the whole area of the element, except
that in particular circumstances, and for small areas, more stringent tolerances may be given where applicable in the
documentation, e.g. details or descriptions of junctions with other trades, or works such as precast concrete or aluminium
shopfronts.
2 The Table provides tolerances for surface finish which are generally more stringent than those given in AS 3600. The project
documentation may also need to provide more stringent tolerances relating to deviations from specified positions and deviations
in specified dimensions.
3 Where tolerances are marked with an asterisk (*) this indicates that AS 3600 tolerances can generally be adopted. However
larger dimensions may require a maximum to be specified.
4 The values given in the Table for the acceptable minimum quality for a particular class may be relaxed and this shall be
signified by the use of ‘X’ suffix to the notation. Full details of such matters shall be given in the project documentation.
5 The tolerance values so specified by the use of the X suffix or permitted in construction shall not exceed the tolerance for
structural requirements specified in AS 3600.
6 Where surface treatment is specified, recognition should be made of the facility for the surface treatment to remove
irregularities. Less stringent tolerances may the be appropriate.
7 Unless otherwise specified, tolerances apply to in situ and precast concrete. Refer also to Clause 3.4.2. Wider tolerances may be
specified for all classes by using the ‘X’ suffix, but limited by Note 5 above.

HB 31—2002 26 Extract of AS 3610—1995
FIGURE 3.4.1 PRECAST CONCRETE—TOLERANCES IN LINEAR DIMENSIONS
NOTE: Out of squareness may affect measurement of tolerance in linear dimensions.
FIGURE 3.4.2 TOLERANCES IN ANGULAR DIMENSIONS
3.5 COLOUR CONTROL OF UNTREATED SURFACES

3.5.1 General
The control of the colour of concrete surfaces may only be imposed on surface finish
Classes 1, 2 or 3. Colour control shall be evaluated before any surface treatment is carried
out.
NOTE: Attention is drawn to Clause 3.3.2 which describes the notation to be used when colour
control is specified.
3.5.2 Concrete colour
Where colour control is required, the concrete for this work shall be specified as ‘special-
class concrete’ in accordance with AS 3600. The project documentation shall be consistent
with the achievement of the required colour.
NOTE: Methods for specifying concrete colour include tonal scales similar to that in Appendix B,
Figure B4, for grey concrete, laboratory samples, test panels, etc.
3.5.3 Range of tonal variations
For concrete which is grey in colour the tonal scale in Appendix B may be used. For concrete
of other colours or where the grey is not within the range of Figure B4, the project
documentation shall contain a means of determining and recording the acceptable tonal
range.
3.5.4 Acceptable tonal range
The acceptable tonal range for the permanent structure shall be determined from the accepted
test panel and the requirements of Clause 3.6.3(b). Where a tonal scale is used the tonal
range of the accepted test panel shall be recorded as set out in Clause 5.6.4.
Elements of the permanent structure that exhibit a range of tones, when evaluated in
accordance with Clause 5.6.4, which are not outside the range of tones recorded from the test
panel, shall be deemed to comply with Clause 3.5.

Extract of AS 3610—1995 27 HB 31—2002
NOTE: Profile factor may affect measurement of previous tolerances.
FIGURE 3.4.3 PRECAST CONCRETE — TOLERANCES IN PROFILE


HB 31—2002 28 Extract of AS 3610—1995
TABLE 3.4.3
ACCEPTABLE DEVIATIONS FOR PRECAST CONCRETE UNITS
Tolerance Acceptable deviation, mm

Description
classification Plus Minus
Linear Dimensions of <3m 3 3
dimensions flat panels Panel length or width ≥ 3 m <6 m 3 6
≥6m 6 6
Panel thickness at any location 3 3
Openings length or width 3 3
Dimensions of < 600 mm 3 3
units other than ≥ 600 mm 6 6
flat panels Cross-section overall dimensions
<1 500 mm
≥ 1 500 mm 10 6
Cross-section, dimensions of
parts such as webs, ribs or ≤ 1 500 mm 6 6
flanges
> 1 500 mm 10 6
Length, critical dimensions of abutting members 0 6
Length (mm) Length (mm)

<6m
Length, not critical 1 000 1 000
≥6m 6 6
Features in all Diameter or side dimensions of core holes, ducts or
3 3
units similar
Width or depth of grooves 2 2
Location of grooves and fastenings for window

3 3
frames, door frames and similar features
Location of grooves or strips for flashings 6 6
Location of electrical outlets and similar features 12 12
Other requirements As As
specified* specified*
Irregular curved or unusual shapes As As
specified* specified*
Position of individual connecting bolts, bolt holes,
projecting metal or other devices in any associated
3 3
group (e.g. the joint of two precast units), with
respect to their position in the group
Longitudinal location of any group of bolts, bolt
holes, projecting metal or other devices, with
6 6
respect of its true position in the unit in which the
group is cast
Up to 2 m on shorter side 3 3
Angular Squareness of
Over 2 m, up to 4 m 5 5
dimensions corners
Over 4 m 6 6
Length (mm) Length (mm)
Straightness of edges and flatness of surfaces
1 000 1 000
Profile Up to 5 m diagonal 6 6
Warp
Over 5 m diagonal 10 10
Twist per metre Width in 3 m length 10 10
* As given in the project documentation.

Extract of AS 3610—1995 29 HB 31—2002
3.6 TEST PANELS

3.6.1 General
The requirements for the provision of test panels are as follows (see Table 3.4.1):
(a) Mandatory use Test panels shall be provided where any of the following have been
specified:
(i) Class 1 or Class 2 untreated surfaces.
(ii) Colour control.
(iii) Surface treatment.
(b) Optional use For work having Class 3 surface finish, test panels may be specified.
(c) Exclusion Test panels are not applicable to work having Class 4 or 5 surface finish,
and shall not be specified.
3.6.2 Details
Test panels for precast concrete shall comply with Item (a) below only; for other work they
shall comply with either Item (a) or (b):
(a) Separate test panels may be detailed and specified in the project documentation for
each of the three applications set out in Clause 3.6.1(a); alternatively, a single panel
may serve more than one application.
(b) If there are no details given in the project documentation, a test panel consistent with
the relevant surface area shall be required for conformity with this Standard. The
panel(s) shall incorporate all relevant features of the surface, e.g. the tie rod pattern
and type, joints to adjacent elements, grooves, rebates, openings and corners and shall
be consistent with the requirements documented for the permanent structure. The test
panel(s) shall be reinforced in a manner similar to the permanent work.
Where surface treatment is specified an additional test panel of a size appropriate to
the specified surface treatment shall be provided for use in accordance with
Clause 5.6.2.1(c).
3.6.3 Evaluation
Test panels shall comply with the following requirements:
(a) Physical quality The surface of the test panel, when evaluated in accordance with
Clause 5.6, shall comply with the requirements of Tables 3.4.1, 3.4.2 and 3.4.3 as
applicable.
(b) Colour control The tonal range of the accepted test panel shall be determined by the
use of either the tonal scale or the other means referred to in Clause 3.5.3. If this
tonal range is less than that given in Table 3.6.1 for the surface class specified, then
the acceptable tonal range shall be increased to equal at least the number of tones
given in Table 3.6.1.
TABLE 3.6.1
TONAL RANGES, GREY SCALE, APPENDIX B
Class Minimum tonal range

1 4 tones
2 5 tones
3 6 tones

HB 31—2002 30 Extract of AS 3610—1995
Where the concrete colour is such that the tonal scale is not suitable, then the approved
test panel shall be permitted to have tonal variations which are consistent with the
intent of Table 3.6.1.
NOTE: Due to the large number of factors that affect colour consistency, some colour
variations can always be expected.
(c) Surface treatment The surface treatment of the test panel shall comply with the
project documents in accordance with Table 3.4.2 and shall have acceptable surface
details and texture.

Extract of AS 3610—1995 31 HB 31—2002
S EC T ION 5 C ONS TR UC T IO N
5.6 EVALUATION OF COMPLETED WORK AND REPAIRS

5.6.1 General
For those cases where evaluation is called for, this Clause specifies the procedures for
checking that the completed off-form work, as-cast, or where appropriate, as-repaired,
complies with the relevant surface finish requirements of Clauses 3.4 and 3.5.
5.6.2 Physical quality

5.6.2.1 Surface appearance
Where it is required to check the completed work for compliance with the specified criteria,
evaluation of surface appearance shall include assessment of the following:
(a) Blowholes These shall be evaluated by comparison of the completed work with the
relevant photograph from Figures B1 to B3 of Appendix B for the specified class. The
1:1 scale photograph shall be held against the surface and viewed from a distance
which is not less than the greater of 2 m or the closest distance from which the subject
area will normally be observed when the project is completed.
NOTE: Figure 5.6.1 shows the correct way of comparing the photograph with the finished
work.
(b) Other defects For Classes 1, 2 or 3, any other defects (e.g. grout loss, honeycombing)
shall be repaired to the requirements of Clause 5.6.5.
(c) Surface treatment Surface treatment shall be evaluated by a visual comparison of the
completed work and the accepted test panel required for the specified class. For the
purpose of this evaluation the test panel shall be placed alongside the completed work
and both shall be viewed from a distance which is not less than the greater of 2 m or
the closest distance from which the subject area will normally be viewed when the
project is completed. To be acceptable the surface of the completed work shall show a
consistent surface texture within the acceptable variation of the surface treatment in
which the test panel is included. The tonal scale referred to in Clause 3.5.3 shall not
apply to this evaluation. If colour control is specified it shall be checked prior to the
surface treatment.
5.6.2.2 Measurable deviations
To ensure compliance with the appropriate requirements of Table 3.4.2, the measurements
set out below shall be taken. For off-form work these measurements shall be taken before
surface treatment, if any. The measurements are as follows:
(a) Form-face span The form-face span shall be checked by inspection of the formwork
prior to placing the concrete.
(b) Form-face deflection At least 10 readings shall be taken at regular intervals but not
closer than 300 mm. These shall be measured by placing a straightedge against the
concrete surface, in line with the direction of the span of the form face, and measuring
the gap between the concrete face and the straightedge as shown in Figure 5.6.2.
(c) Face steps Readings shall be at 200 mm intervals for the full length of the visible
step. The face step spacing shall be measured from visible step to step on the concrete
surface. Face steps shall be measured within a form (between construction joints) and
at construction joints by placing a 300 mm long straightedge against the concrete
surface at right angles to the line of the step and measuring the gap between the
concrete face and the edge of the straightedge as shown in Figure 5.6.3.

HB 31—2002 32 Extract of AS 3610—1995
(d) Surface undulations Surface undulations shall be ascertained by using two

straightedges, a short one of 300 mm and a long one of 1500 mm. The straightedge
shall be used systematically over the whole face of the element to ensure reasonably
even coverage, but shall not be used across construction joints. It is recommended that
for elements greater than 2 m in any direction, at least 30 readings be taken. Two
offsets, namely 'a' and 'b' are taken as shown in Figure 5.6.4 and the reading for
evaluation is (a − b), as listed in the appropriate part of Table 3.4.2.
(e) Flatness Flatness shall be measured on the critical face of the element. The readings
shall be used for evaluating any relative variations in the surface flatness or line of the
element. They shall not be used as an evaluation of the absolute position of the element
(see AS 3600).
The readings shall be taken using a suitable instrument, a stringline in still air
conditions or other equivalent method. For elements or series of element of the
permanent work that are intended to be straight, with any overall dimension not less
than 15 m, the check may be made along any straight line measuring more than 15 m.
It shall be measured in 10 m sections, with each overlapping by 5 m, and with the
variations from the straight determined by measurements at the ends and middle of
each 10 m section (see Figure 5.6.5).
The deviation is calculated as the reading at the middle of the section subtracted from
the mean of the readings at the two ends of the section.
Within these 10 m sections, and for elements less than 15 m, the flatness shall be
checked by taking measurements on a 1.25 m × 1.25 m grid with no measurements
taken within 300 mm of any edge of the element (see Figure 5.6.6).
The deviation at any point shall be taken as the difference between the offset reading at
that point and the mean of all of the offset readings taken for this area.
(f) Out-of-plumb This shall be checked on the critical face only. Readings shall be taken
along the length of the walls at not more than 5 m centres. Not less than two readings
shall be taken. Unless specified otherwise, the plumb of columns shall be checked at
two positions as follows:
(i) Rectangular columns— on adjacent faces, at two positions at right angles.
(ii) Circular columns and irregular shapes — at specified positions.
Plumb shall be measured from a point 300 mm from the top of the vertical surface to a
point 300 mm from the bottom.

Extract of AS 3610—1995 33 HB 31—2002
FIGURE 5.6.1 COMPARISON OF PHOTOGRAPH WITH FINISHED WORK

FIGURE 5.6.2 MEASUREMENT OF FORM-FACE DEFLECTION
5.6.3 Physical quality of precast concrete

5.6.3.1 Sequence
Where it is required to check the dimensional accuracy of precast concrete units for
compliance with the specified values, the sequence of checking shall be as follows:
(a) Check surface finish for compliance with tolerances specified in accordance with
Clause 3.4.5.1(a).
(b) Check linear dimensions for compliance with tolerances specified in accordance with
Clause 3.4.5.2(a). For prestressed concrete units, this check includes the hog.
(c) If the linear dimensions checked under Item (b) above comply with the specified
tolerances, check the angular dimensions for compliance with the tolerances specified
in accordance with Clause 3.4.5.2(b).

HB 31—2002 34 Extract of AS 3610—1995
(d) If the angular dimensions checked under Item (c) above comply with the specified tolerances,
check the profile for compliance with the tolerances specified in accordance with
Clause 3.4.5.2(c).
FIGURE 5.6.3 MEASUREMENT OF FACE STEPS
5.6.3.2 Procedures
The evaluation procedures specified in Clause 5.6.2.2 shall also apply to precast concrete, as
appropriate. Optical instruments, jig frames or string lines shall be used, as applicable. There
shall be adequate checking to ensure that all the units are consistent with the required
tolerances.
5.6.4 Colour evaluation
Where the colour range is being checked by use of a tonal scale similar to that in
Appendix B, Figure B4, the chosen tonal scale shall be held against the surface area being
examined and a comparison shall be made between the tonal scale and the concrete surface.
The light conditions at the time of evaluation and the period of time after the stripping of the
form before evaluation is carried out shall be consistent for all elements with similar
requirements.
Colour evaluation shall be carried out before any surface treatment.

For other cases the method of evaluation shall be appropriate to the means used to record the
permitted tonal range.
5.6.5 Repairs
5.6.5.1 General
Where the surface does not achieve the specified quality of finish, repairs are permitted for
all classes, except for the case where the project documents state that repairs to Class 1 are
not permitted (refer to Table 3.4.1, Item 11).
5.6.5.2 Repair technique
The proposed repair technique shall be satisfactory in the following respects:
(a) Structural characteristics.
(b) Durability
(c) Durability of adhesion
(d) Appropriateness of materials.

Extract of AS 3610—1995 35 HB 31—2002
(e) Appearance (including surface finish).

(f) Any additional criteria for the proposed technique which have been specified prior to
the performance of the repair work.
FIGURE 5.6.4 MEASUREMENT OF SURFACE UNDULATIONS
5.6.5.3 Evaluation
The element, when repaired, shall meet the criteria of Clause 5.6.5.2 in addition to any
specified requirements. These specified requirements may include physical quality and
colour.
FIGURE 5.6.5 FLATNESS MEASUREMENTS FOR ELEMENTS OVER 10 m LONG

HB 31—2002 36 Extract of AS 3610—1995
FIGURE 5.6.6 PATTERN OF MEASUREMENT FOR FLATNESS FOR ELEMENTS UP TO

10 m LONG

S E C T ION C 3 S U R FAC E F IN IS H
C3.4 PHYSICAL QUALITY
C3.4.3 Tolerances
C3.4.3.2 Measurement
As a performance standard, the emphasis is on the construction process. Accordingly the
tolerances are measured on the concrete surface for this is the final product and represents
the formwork in its service state, i.e. deflected and distorted under the forces of fluid
concrete placement and other construction activity.
The one exception to this is the case where some strain movement of the permanent
structure is expected (e.g. slab deflection). In these cases the relevant element must be
checked while it is sill being supported by the formwork.
C3.4.3.3 Critical face
The problems of conflict between surface and element thickness deviations and of
cumulative deviations are avoided by the requirement for the project designer to specify a
base position for the evaluation of deviations. This is known as the critical face. Where
more than one face of a concrete element has the same class specified, the project designer
is required to nominate which of these faces is to be the critical face. This does not prevent
both faces of the same element being specified as critical faces.
One example of a situation that dictates the selection of the critical face is the junction of
the formed face and the work of other trades such as joinery. Refer also to Paragraph C3.4.4
regarding tolerances at such junctions.
C3.4.4 Acceptable surface defects and deviations
The quality of workmanship and the various other factors needed to produce the specified
physical quality of the different surface classes are —
(a) quality and consistency of concrete materials;
(b) a very low and uniform level of moisture absorption of the form surface for colour
control (this is aided by the correct selection and use of a release agent)’
(c) a rigid and mortar-tight formwork structure (it is desirable to form and use
compressive joint types or suitable compressible sealant grooves at construction
joints to aid the achievement of mortar-tightness);
(d) good and consistent concrete compaction;
(e) careful and consistently-timed formwork stripping and surface curing;
(f) appropriate surface curing; and
(g) protection of the completed element.
Not withstanding the general rule, that a change to the given tolerance values should always
be a relaxation with the adoption of larger tolerances (dimensions or colour), there is one
case where small areas may be more stringent. A typical example is the junction between
the concrete surface and the work of other trades, e.g. door frames, modular ceilings, shop
fronts, skirtings, patterned floor finishes, tiling. The greater accuracy is only needed at the
junction or interface. Beyond that, the tolerances of the standard, with X suffix if
applicable, apply. These small areas of smaller tolerances should be listed in the
specification, or shown by way of suitable details in the project documentation.

HB 31—2002 38 Extracts of AS 3610 Supp 2—1996
Note 2 to Table 3.4.2 firstly refers to the tolerances being more stringent than those given
for surface alignment in AS 3600. The second sentence of the note acknowledges that the
tolerances of this Standard and those of AS 3600 serve quite different purposes. The
tolerances of this Standard apply only within the element and control its appearance but not
its location. This is controlled by AS 3600. The tolerances in AS 3600 will, however, often
be found to be insufficiently stringent, when in situ concrete interfaces with other trades,
e.g. precast concrete, curtain walls. As noted in AS 3600, more stringent tolerances on
dimensions and position should then be specified. Unlike this Standard, AS 3600 has not
restrictions on this.
Note 3 notes that tolerances marked with an asterisk (*) are limited by AS 3600. These
would be the tolerances on reinforcement cover and element depth or thickness. AS 3600
does not restrict these tolerances being made more stringent and this could be justified for
large elements.
Pertinent information relating to Item (a) is given in Paragraph C3.5.2. The other matters,
many of which area also important to colour control, which will be evident from the text,
are as follows:
(i) Concrete placement Consideration should be given to the following
(A) Placing In vertical elements the use of chutes or baffles is recommended to
ensure the concrete is placed and falls between the reinforcement. This reduces
segregation and the splashing of the mortar onto the forms.
(B) Placement rate In vertical elements, a minimum vertical rate of placement is
required to provide the pressure that assists in blowhole reduction. A minimum
rate of 2m vertically every hour is suggested
This is relatively easy to achieve in columns and other small elements, but
requires planning, and additional personnel and equipment, to achieve in large
walls. The high rate in walls will also assist in the elimination of the flow lines
and cold joints that occur due to the interruption of the pour.
(C) Vibration This must be done more consistently and thoroughly than for normal
concrete. In precast operations, good use can be made of table and form
vibrators, but these are not readily suited to on-site activity. The immersion
vibrator is the most suited to these situations.
Concrete should be vibrated from the bottom up to enable the air bubbles to
escape. When it is placed in layers, the vibration should continue through into
the lower layer to eliminate the segregation and colour trouble that normally
occurs at this location.
Vibration is also related to the rate of placing. The number of vibrators should
be adequate for the amount of concrete to be handled and the intended rate of
placement. Spare vibrators should always be available on site as backup.
Whilst vibration is important for all types and classes of finish, its extent and
systematic use is vital for work where the evenness of aggregate exposure is
demanded.
(ii) Formwork stripping For colour control it is important to expose the finished
concrete to the drying atmosphere at a common age. Concrete that is allowed to dry
faster may be lighter in colour.
It would be typical to expect the stripping of in situ concrete to occur within ±1/2 day
of that specified. However this will not suit all structures, or be possible with some
construction schedules. The accepted figure must therefore be worked for each
individual job or concrete element.

Where colour control is specified it is important to remove the forms as quickly as

possible.
At this time the concrete will have a low strength so stripping should be done
carefully to avoid damage to the concrete. Such damage is difficult to patch well
enough to meet surface finish criteria.
Forms should never be eased some time before stripping as this will permit variable
drying and consequently colour variations.
(iii) Curing As formwork is stripped at the earliest possible age, it is vital for strength,
durability and surface hardness that curing is applied immediately. Precast concrete is
normally given accelerated curing (e.g. low pressure steam, hot water curing) to allow
the early re-use of forms. Post-stripping curing may then be used.
The following comments on post-stripping curing are applicable to both precast
concrete and to in situ concrete:
(A) Water Water is a good curing medium and does not mar the surface, but it is
frequently impractical.
(B) Plastic Plastic can be used but it must be well held down to avoid wrinkles
and to prevent air movement under the plastic otherwise differential drying will
result and this will give colour variation.
(C) Curing compounds Curing compounds are good, but tend to change the colour
of the surface and will often cause bond problems. They should be carefully
investigated before use and checked out on the test panels. Where they are used
it is important to use the same compound from the same source and apply it at
the same age and at the same rate throughout the job if colour consistency is to
be achieved.
(D) Protective measures Curing should also be seen as a means of protecting the
finished surface against the consequences of construction e.g. mortar stain.
Protruding reinforcement should also be protected by wrapping or slurrying to
prevent rust discolouration from marring the surface.
FIGURE C3.4.1 JUNCTION WITH OTHER TRADES

HB 31—2002 40 Extracts of AS 3610 Supp 2—1996
C3.4.5 Precast concrete elements

C3.4.5.1 General
The type of surface finish required will depend on the nature of the unit, its final location,
and whether or not it is to receive an applied finish. The appropriate finish, which may vary
from face to face, should be carefully chosen and clearly specified. Surface finishes depend
on properly fabricated forms, and the project designer should clearly understand the
capabilities and limitations of form production.
It would be optimistic to imagine that every unit cast during the course of a contract will be
perfect. Minor defects and blemishes will sometimes occur, and the main operations in
making good these units are filling blow holes, removing stains and repairing mechanical
damage.
C3.4.5.2 Tolerance classification for precast concrete
In determining dimensional tolerances, the following should be taken into consideration:
(a) Tolerances should be based on the specific requirements of structural sufficiency and
dimensional accuracy, having regard to the size and type of unit.
(b) Tolerances should be measured with the unit orientated in the same attitude and
supported in the same manner as in the completed structure.
The effects of differential temperature in the unit should be taken into account when
tolerances are measured.
(c) Due regard should be given to the tolerances specified (or achievable) in the
supporting structure. These must be compatible with those required for the precast
elements (see also Ref. 15). In addition, the connections between the precast elements
and the permanent structure should make adequate allowance for the limitations
achievable in the permanent structure.

S EC T ION C 5 C ONS TR UC T ION
C5.6 EVALUATION OF COMPLETED WORK AND REPAIRS

C5.6.1 General
It is not the intention of these Clauses that all concrete work should automatically be
evaluated. It is expected that these procedures will only be used when there is some doubt
about the acceptability of a completed element.
The Clause covers the methods to be used in the evaluation of the completed concrete
elements for acceptance or rejection. It applies to work that has been repaired as well as to
the elements that may not require any rectification to reach the specified standard. This
Standard does not limit the number of times that evaluation may be carried out after repair.
The intention of the requirements is to lay down fair procedures for the evaluation of the
completed work, and to minimize the number of situations where subjective judgement is
required.
Experience has shown that those situations where judgement is based on personal opinion,
rather than quantitative measurement, are the ones that lead to disputes and accusations of
unfair treatment.
However, no set of requirements can possibly cover every circumstance. It is recommended
that the project designer check that guidance is provided on all the critical aspects of each
project. For example, not all the clauses apply to precast work, and judgement must be used
to check their suitability for each case. It may be necessary for the project designer to specify
extra procedures for particular cases. In these cases it is recommended to avoid, wherever
possible, writing specification clauses which call for the exercise of discretionary judgement.
C5.6.2 Physical quality
The physical quality of the surface of the concrete elements which require evaluation can be
considered under the following two categories:
(a) Those which require subjective evaluation, such as surface blemishes and texture (see
Paragraph C5.6.2.1, (a) and (b)).
(b) Those which can be evaluated dimensionally (see Paragraphs C5.6.2.2 (a) to (f)).
Table C5.6.1 gives information on physical irregularities and their possible causes.
C5.6.2.1 Surface appearance
Surface appearance is assessed in terms of the following:
(a) Blowholes Experience has shown that the evaluation of surface quality is difficult
when the requirements are expressed as—
(i) written descriptions of acceptable defects; or
(ii) stated levels of various sized blemishes per unit area.
The visual effect of any defect relates to its proximity to other defects as well as to its
size and nature.
To answer this problem the method adopted in the Standard has been the use of pairs
of photographs, at 1:5 and 1:1 scales, of examples of the maximum level of defects
permitted in each class. The photograph should be held up against the area being
evaluated to determine whether the surface of the element reaches its specified
standard. This still involves the subjective comparison of the photograph and the work,
but it is considered to be fairer and more accurate assessment than the use of numerical
parameters.
The viewing distance at which this comparison is made is very important. Defects
which would be considered most unsightly on surfaces which can be examined at close
quarters will become insignificant if the closest viewing distance is a lot greater, e.g.
the upper level walls of multistorey buildings that can only be examined from similar
buildings on the opposite side of the street. In these cases the defects can become
invisible to the naked eye.
One problem that cannot be adequately addressed by the use of these photographs is
the grouping of blowholes. Small blowholes that would be difficult to see from a
distance as individual defects, become very obvious when they are clustered in small
groups. This is a case where the subjective judgement of the project designer is
applicable.
TABLE C5.6.1
PHYSICAL IRREGULARITIES AND THEIR POSSIBLE CAUSES
Common term Description Possible causes
Blowholes Individual cavities usually less than 12 mm Formwork: Impermeable face: too flexible:poor
diameter. wetting characteristics; inclined top form
Release agent: Incorrect
Placing method: Poor compaction; slow pour rate;
external vibrators
Concrete mix: Too lean; course sand; low workability
Mortar or grout loss Sand textured areas usually associated with Formwork: Leaks at construction joints; formwork
a dark adjoining surface joints and ties rods
Honeycombing Coarse stony surface with air voids, lacking Formwork: Joints leaking
in fines. Concrete mix: Insufficient fines; low workability
Placing method: Inadequate compaction; segregation
Design: Reinforcement congestion; thin sections
Misalignment Surface face step, wave or bulge. Formwork: Lack or rigid backing at joints of forms
face material; lack of form rigidity; distortion during
form erection; damaged formwork
Plastic settlement Horizontal cracks usually located at These are usually caused by plastic settlement of
cracking reinforcement of changes in section concrete in tall uniform elements or shorter ones at
changes of cross-section i.e. at points of restraint of
settlement of concrete. Pay attention to concrete mix
and workability, placing method and possible

revibration.
Crazing A random pattern of fine cracks usually in Forms Form face of low absorption, smooth or
a network spaced from 5 mm to 75 mm polished
Concrete mix: High water/cement ratio and cement
rich mix
Curing: Inadequate
Stripping time: Too early especially in cold weather
Scaling, spalling or Scaling: Flaking off of the surface Formwork: Difficult to strip: excessively rough.
chipping, form scabbing Spalling Removal of surface layer Release agent: Inadequate.
Scabbing Adhesion of parts of the form Stripping time: Incorrect.
surface to concrete
Scouring Irregular eroded areas and channels leaving Concrete mix: Excessive water: insufficient fines, too
exposed stone or sand particles leas.
Placing methods: Water in the forms; excessive
vibration of high workability sixes.
Grain imprint The pattern of the grain of the plywood Formwork: Inadequately sealed surface of ply
veneer is viably imprinted on the concrete formwork leading to moisture penetration of the top
surface veneer of ply. (See Ref. 20)

(b) Surface treatment For work which is to have the surface treated in some way, e.g.
tooled or sandblasted, there will be two stages of evaluation. The first of these will be
when the concrete element has been poured and stripped. This evaluation for
dimensions and colour will be prior to the surface treatment. The requirements with
element to comply which are those of the specified class, usually Class 2 or Class 3.
The second evaluation, which is for textural uniformity only, is after the surface
treatment. The appearance of the treated surface is greatly affected by the incidence of
light on the surface. Therefore, in the comparison with the approved test panel, it is
essential that the test panel be placed adjacent to the subject area in a lighting situation
which is the same as that on the permanent work. It may be necessary for consideration
to be given to the time of evaluation, as the incidence of the light changes at different
times during the day.
C5.6.2.2 Measurable deviations
This Standard considers the dimensional aspects of concrete elements at two levels. The first,
which are outer limits, are those required for structural acceptability and, as referred to in
Clause 3.4.2, are contained in AS 3600. The second relates to the particular surface class and
its project documentation. If the project documentation does not specify the class of each
particular element, then the class is to be selected from Classes 3, 4 or 5 as appropriate to its
applicability as given in Table 3.3.1.
Specific comment on the individual items listed in Clause 5.6.2.2 is as follows:
(a) Form face span This is applicable only to Classes 1 and 2, and relates to the
repetitious shadow lines that can be created when light shines across the surface. It is
checked by inspection and measurement of the formwork prior to the pour.
(b) Form face deflection This matter is largely controlled by good formwork design, but
can only be checked after the pour. The procedure is simple and only involves placing
a straightedge across the surface and measuring the visible gap. As the deflections are
the result of structural action and not workmanship it is not expected that there would
be any discernible variation between readings over a spacing of 300 mm. The readings
are spaced accordingly.
(c) Face steps. Face steps in the completed concrete surface generally arise from either—
(i) misalignment at the junction of two concrete element or
(ii) within the area of a form, from misalignment of the form face materials.
Even in Class 1, a 1 mm face step is permitted in the case of Item (ii). This is due to
the manufacturing tolerances of plywood being ±3% of the thickness, (i.e. 1 mm for
17 mm sheet). The permitted values are given in Table 3.4.2.

(d) Surface undulations In addition to the above deformations it is recognised that
gradual, not abrupt, deviations may occur in the surface from other causes. The
deviations may be over a short distance, or may be more gradual and only discernible
over 1.5 m. Accordingly, two checks are called for, one with a 300 mm straightedge
the other with a 1500 mm straightedge. In all cases random readings are taken with an
offset straightedge and the difference between the maximum and minimum reading at
each location is the reading. For acceptance, all the readings must be equal to or less
than the higher value shown in Table 3.4.2 and the stated percentage must conform to
the lower figure.
(e) Flatness In addition to the above checks, there are two tests for the overall flatness of the
elements, as follows:
(i) The first test is for long elements or a sequence of in situ elements that are
intended to be straight. The deviation within 10 m lengths is checked by offset
readings at the ends and the middle, and the net deviation taken as the difference
between the mean of the readings at the ends of the 10 m length and that at the
middle. To keep control of any general deviation, the 10 m lengths must overlap
by 5 m.
These lines may be taken in any direction where the length of the line is
compatible with this requirement and where there is seen to be need for a check.
(ii) Within these 10 m lengths the second check for flatness applies. This is carried
on a 1.25 m × 1.25 m grid with the outer rows not closer to the edges than 300
mm. As before, the offset readings are related to those at the corners of the 5 m
grid to obtain the true deviation.
The check on flatness gives the deviations of a continuous grid of surface locations.
Within these grid lines the other checks for deviation apply i.e. face span and
deflection, face steps and surface undulations, apply.
(f) Out- of- plumb The important aspect here is the determination of the critical face (see
Clause 3.4.2.3). For walls, the critical face should be one face as nominated in the
project documentation. For columns, the critical faces should be two selected adjacent
faces. In this way the out-of-plumb check also monitors the possibility of a spiral twist
but does not conflict with the tolerances on thickness of elements.
TABLE C5.6.2
COLOUR VARIATIONS AND POSSIBLE CAUSES
Common term Description Probable causes

Inherent colour variation Noticeable differences in the colour of Materials: Change in source or type
areas having other similar physical Concrete mix: Incomplete mixing; segregation or
characteristics variation proportions; variation in water/cement
ratio
Hydration discolouration Significant variations in colour with Forment: Variable absorbency; leaking of forms
quite dark areas caused by localized Release agent: Uneven or inadequate application
variations in water/cement ratio Curing: Uneven; relaxation of formwork before
stripping
Aggregate transparency Dark blotches of the size similar to Formwork: Too flexible
large aggregate Concrete mix: Gap graded; low sand content
Placing method: External vibration
Negative aggregate Light coloured areas of the size similar Materials: Aggregate dry or lightly porous
transparency to the aggregate Curing: Too rapid drying
Segregation Speckled or flecked surface varying in This is scouring over larger areas of the surface.
discolouration colour Refer to Table C5.2
Dye discolouration or Discolouration from materials in the Forms: Stains on the form surface—sawdust;
contamination mix e.g. timber, stains, pyrites timber stains; hardwood forms; rust
Release agent: Impure or incorrect
Materials: Contaminated
Protection Inadequate
Curing Materials: Contaminated
Release agent Cream or brown discolouration Release agent: Excessive amount; low viscosity;
discolouration sometimes showing sand or coarse impure; applied unevenly
aggregate
Dusting Light coloured, dusty surface which Curing: Inadequate (rapid-drying)
may weather to expose surface Release agent: Incorrect agent: excessive
aggregate application
Stripping of forms: Too early
Retardation Matrix near the colour of sand and Formwork: Retarder on surface; reaction with
lacking durability timber constituents
Release agent: Incorrect agent; incorrect
application
Line bloom or White powder or bloom on the surface Release agent: Incorrect type
efflorescence Curing: Uneven
C5.6.3 Physical quality of precast concrete.

C5.6.3.1 Sequence
It is important to check the dimensional accuracy of precast concrete in the order specified as
each of the subsequent types of deviations can affect the resulting measurement of the
preceding ones.

The angular dimensions (Item (c)) need only be checked if the unit is acceptable for surface
finish (Item (a)) and linear dimensions (Item (b)).
The profile (Item (d)) need only be checked if the unit is acceptable for both linear and
angular dimensions.
The age of the unit at which the checks are made is most important and needs to be arranged
between the project designer and the precaster. Obviously the acceptance/rejection criteria
needs to be imposed at the earliest possible time after production of the unit. For tooled
surfaces, they need to be checked prior to tooling. However, there are many practical
situations in a precast yard that need consideration, and for reasons of damage and economy
it is recommended that matters such as multiple handling of panels to enable the checks to be
done are avoided. Improper storage of panels and differential temperature movements during
storage will have a considerable effect on profile tolerances and need to be taken into
account as part of the evaluation.
Where a test panel has been used, it is recommended that the tolerances be assessed on that
element and approved before site work proceeds.
It is also recommended that, whenever possible, the tolerances are checked with the unit
oriented and supported in the same attitude as in the completed structure. If this cannot be
done, then the method may need to be determined by arrangement between the project
designer and the precaster before the work commences.

HB 31—2002 46 Extract of AS 2876 —2000
9 TOLERANCES
Unless otherwise specified, all surfaces shall be finished in conformity with the lines, grades,
thicknesses and cross-sections specified, within the following limits:
(a) Irregularities in the surface of the bedding layer shall not exceed 10 mm under a
straightedge 3 m long, subject to any necessary allowance on vertical curves. The level
of the bedding layer shall not deviate by more than 5 mm above or 10 mm below the
design level.
(b) The finished concrete shall not vary from horizontal alignment or level by more than
10 mm at any point. The finished work shall not deviate at any point more than 5 mm
under a straight edge 3 m long. Deviation on vertical curves shall not exceed 5 mm in
3 m from the true vertical curve.
(c) Profile dimensions shall not differ by more than 5 mm, except that the overall width
shall not differ by more than 15 mm.

Extract of AS 3600—2001 47 HB 31—2002
S EC T ION 19 M A TER IA L AN D
C ONS TR UC TION R EQ U IR EMENTS
19.2 MATERIAL AND CONSTRUCTION REQUIREMENTS FOR REINFORCING

STEEL
19.2.2 Fabrication
(a) Reinforcement shall be fabricated to the shape and dimensions shown in the drawings
and within the following tolerances:
(i) On any overall dimension for bars and fabric except where used as a fitment:
(A) For length ups to 600 mm............................................... −25, + 0 mm.
(B) For lengths over 600 mm ............................................... −40, + 0 mm.
(ii) On any overall dimension of bars or fabric used as a fitment:
(A) For deformed bars and mesh .......................................... −15, + 0 mm.
(B) For plain round bars and wire......................................... −10, + 0 mm.
(iii) On the overall offset dimension of a cranked column bar.......... −0, + 10 mm.
(iv) For the sawn or machined end of a straight bar intended for use as an
end-bearing splice, the angular deviation from square, measured in relation to
the end 300 mm, shall be within ................................................. 2°.
(b) Bending of reinforcement shall comply with Clause 19.2.3.
(c) Welding if required shall comply with AS 1554.3. Tack welding not complying with
that Standard shall not be used.
19.5 TOLERANCES FOR STRUCTURES AND MEMBERS

19.5.1 General
For the purposes of the strength requirements of this Standard, the position of any point on
the surface of a concrete member shall comply with Clause 19.5.2. More stringent tolerances
may be required for reasons of serviceability, fit of components, or aesthetics of the

structure.
For formed surfaces the tolerances given in AS 3610 take precedence, unless those in
Clause 19.5.2 are more stringent. For uniformed plane surfaces, the flatness tolerances and
the methods for measuring them shall be detailed in the project specification, and shall be
not greater than the relevant values given in Clause 19.5.2.
19.5.2 Tolerances for position and size of structures and members
19.5.2.1 Absolute position
The deviation from the specified position shall not exceed the following:
(a) In plan, for a point on the surface of a column or wall at any floor level —
(i) in the first 20 storeys of any building.......................................... 40 mm horizontally; and
(ii) for subsequent storeys, an increase of 15 mm horizontally for each additional
10 storeys or part thereof.
(b) In elevation, for a point on the top surface of a floor or the soffit of a beam or slab
adjacent to a column or wall ................................................................ 40 mm vertically.

HB 31—2002 48 Extract of AS 3600—2001
19.5.2.2 Floor-to-floor plumb

In any column or wall, the deviation from plumb, measured floor-to-floor, shall not exceed
1/200 times the dimension between the floors or 10 mm, whichever is the greater.
19.5.2.3 Deviation from specified dimensions
The deviation from any specified height, plan, or cross-sectional dimension, shall not exceed
1/200 times, the specified dimension or 5 mm, whichever is the greater.
19.5.2.4 Deviation from surface alignment
The deviation of any point on a surface of a member, from a straight line joining any two
points on the surface, shall not exceed 1/250 times the length of the line or 10 mm,
whichever is the greater.
19.5.3 Tolerance on position of reinforcement and tendons
The deviation from the specified position of reinforcement and tendons shall not exceed the
following:
(a) For positions controlled by cover —
(i) in beams, slabs, columns and walls .......................................... −5, + 10 mm;
(ii) in slabs-on-ground ............................................................... −10, + 20 mm; and
(iii) in footings cast in the ground ................................................ −20, + 40 mm;
where a positive value indicates the amount the cover may increase and a negative
value indicates the amount the cover may decrease.
(b) For positions not controlled by cover, namely —
(i) the location of tendons on a profile ............................................. 5 mm;
(ii) the position of the ends of reinforcement ................................. 50 mm; and
(iii) the spacing of bars in walls and slabs and of fitments in beams and
columns10% of the specified spacing or 15 mm, whichever is greater.

S EC T ION C 19 M A TER IA L AND

C ONS TR UC TION R EQ U IR EMENTS
C19.2 MATERIALS AND CONSTRUCTION REQUIREMENTS FOR

REINFORCING STEEL
C19.2.2 Fabrication
The tolerances within which reinforcement must be fabricated are intended to ensure
concrete cover over the steel.
Example: Beam fitment, R10 bar with 30 mm cover.
For a 400 × 300 beam, with scheduled dimensions would be 340 × 240 mm. Fabricated
dimensions would range between 340 × 240 maximum to 330 × 230 minimum, i.e., 10 mm
less all around.
For the effect of placing tolerances, see C19.5.3.
C19.5 TOLERANCES FOR STRUCTURES AND MEMBERS

In the past, there have been numerous difficulties regarding the application of Clauses
covering tolerances. Therefore, a completely new approach has been adopted, with tolerances
considered in two categories.
The first category specified is for tolerances on position and sizes of structures and their
members, to ensure that the strength requirements of the Standard are not adversely affected.
These should be regarded as absolute maximum values, as smaller values are expected and
usually achievable with normal good building practice.
The second category, for which values are not specified in the Standard, applies to
serviceability, constructability, or aesthetic considerations and, as indicated in the Clause,
these will generally need to be more stringent than the first category. Because surface
tolerances are usually project specific, particularly unformed surfaces, it is essential that
appropriate values are given in the project specification, as required by the second paragraph
of Clause 19.5.1. When specifying tolerances, it is most important to ensure they are
adequate and possible to achieve. In this regard it should be realized that errors in
measurements may vary from ±3 mm if carried out by a licensed surveyor to ±10 mm if

carried out by a semi-skilled tradesman.
Other factors which will need to be covered in a project specification include methods of
measuring tolerances, the basis for acceptance and rejection of completed work, and when
and what number of measurements are to be made. Useful information in this respect is given
in Reference 21.
C19.5.2 Tolerances for position and size of structures and members
The philosophy of Clause 19.5.2 is that measurements can only be made to the surfaces of
members and it is unreasonable to use tolerances to centre-lines. Any point on the surface of
a member (Clause 19.5.2.1) must lie within a tolerance-sphere from its specified or
theoretical position. For buildings up to 20 storeys, this sphere is of radius 40 mm. This
precludes the building being built in the wrong location and puts an absolute limit on out of
plumb. The datum needs to be clearly specified, and measurements made at an appropriate
time and manner to exclude secondary effects such as thermal building movement.
Clauses 19.5.2.2, 19.5.2.3 and 19.5.2.4 ensure that variation in dimensions, when measured
within the building on completed members, should be within acceptable tolerances. The
Clauses specifically cover plumb, specified dimensions of members, and surface alignment.

For cross-sectional dimensions, differentiation has not been made between fully formed
members (column cross-section) and partially unformed members (top surface of slab).
Measurement of suspended floor flatness need to be made before formwork is slackened to
avoid secondary effects of slab deflections.
C19.5.3 Tolerance on position of reinforcement and tendons
In Clause 19.5.2, the tolerance is specified as a ‘deviation’ which means that the position and
size of a member is effectively an equal plus or minus tolerance. By contrast, in
Clause 19.5.3, the tolerance on the location of reinforcement or tendons is related to the
cover to the nearest surface. The negative values therefore indicate that the specified cover
can be reduced by the tolerance. This is a major change for AS 1480 where ‘the cover was
not to be encroached up’. The cover requirements specified in Section 4, therefore, take into
account the possibility of reduced cover due to the negative tolerances allowed in this Clause
by having an undersize tolerance of 5 mm included in the values of cover given in
Clause 4.10.3.
For example, for exposure classification A2, the minimum required concrete strength is
25 MPa. for which the minimum cover was established as 25 mm. Inclusion of an allowance
of 5 mm for reduction of the cover gives the tabulated values of 25 MPa/30 mm cover.
Using the example given in Paragraph C19.2.2, the fitment dimensions after fabrication are
in the range—
340 × 240 mm maximum, to 330 ×230 mm minimum.
The allowable placing envelope for the scheduled size of 340 × 240 mm would therefore be;
340 –5, +10, and 240 –5, +10, and since to negative sign means ‘decrease in cover’, this
becomes 345 ×245 maximum, to 330 × 230 minimum, as shown in Figure C19.5.3.
FIGURE C19.5.3 PLACING ENVELOPE

Extract of AS 2160 1984 51 HB 31—2002
The Contractor shall adhere to the dimensions of the pool as set

ACCEPTABLE 14 out in the Customer approved plans or as varied by agreement
TOLERANCES within ± 5 percent of the agreed water depth and within
AND DAMAGES + 5 percent, −1.5 percent of the agreed length and within
+10 percent, −2.5 percent of the agreed width of the pool. The
Contractor shall not be liable to rectify or make any financial
compensation adjustment for any variation in these dimensions
where such variation is within the applicable tolerance stated
above
In the event of any variation in the length or width of the pool being
outside the applicable tolerance stated above, then a calculation
shall be made of the nominal area of the pool as constructed and the
Customer shall be entitled to claim from the Contractor the
compensation rate for each square metre (or a proportionate amount
thereof for each part square metre) difference between the nominal
area as constructed and the nominal area that would have been
provided if the Contractor had adhered to the agreed dimensions.
In the event of any variation in the depths of the pool of between

5 percent and 10 percent outside the water depths shown on the
plans, the Customer shall be entitled to claim from the Contractor
one half of the compensation rate in respect of the nominal area
affected by such variation
In lieu of paying any such amounts to the Customer, the Contractor

shall have the option of rectifying the works at no expense to the
Customer so as to bring the dimensions or depths into conformity
with the plans and specifications. Such rectification work shall be
completed within a reasonable time after the Contractor receives
notice of the Customer’s complaint regarding dimensions or water
depths.
Upon completion of the pool, the top of the finished or structural

coping (whichever is agreed in Clause 2.1 to be provided) shall be
within + 70 mm, −40 mm of the agreed height in relation to the
datum point and level to within ± 15 mm along the water’s edge.

HB 31—2002 52 Extract of AS 2160.1—1998
TOLERANCES 15 This Clause is not designed to apply to a situation where the

AND DAMAGES variation in the dimensions from those appearing in the drawings or
specifications have been requested by the Customer or required by
regulatory authorities. The Clause does not restrict or remove any
right or remedy the Customer may have at common law or under
statute where the variation in the depth of the pool is greater than
10% outside the water depth that the Contractor had agreed to
provide.

Extract of AS 3850.2—1990 53 HB 31—2002
S EC T ION 3 D ES IGN O F P ANELS
3.7 DESIGN AND DOCUMENTATION FOR ERECTION AND TEMPORARY

BRACING
3.7.7 Tolerances
Recommended tolerances on as-cast panels, casting bed, inserts and location are as follows:
(a) As-cast panels The recommended tolerances on as-cast panels are as set out in
Table 3.7.1.
TABLE 3.7.1
RECOMMENDED TOLERANCES ON AS-CAST PANELS
Tolerance (mm)
Panel size Edge
(m) Planeness Squareness Thickness
Width Height straightness (See
(See Note 1) (See Note 2) (See Note 3)
Note 3)
<3 +0, –5 ±5 ±5 ±5 ±5 ±10

≥3<6 +0,– 10 ± 10 ±5 ± 15 ±7 ± 10
≥6 + 0,– 12 ± 10 ±5 ± 15 ± 10 ± 10
NOTES:
1 Tolerance value refers to the deviation of any point on the face from the intended line.
2 Value is measured as tolerance in length of diagonal.
3 The deviation from the intended line should not exceed 5 mm in any 3 m.
(b) Casting bed The recommended tolerance on deviation from planeness of the casting
bed, measured in any direction using a 3 metre straightedge as set out
in AS 3610 ............................................................................................ 5 mm.
(c) Inserts The required tolerances on the location of inserts are as set out in AS 3850.1, as
follows:
TABLE 6.4
INSERT LOCATION TOLERANCES
Type of insert Tolerance mm
Face-lifting ±20
bracing ±50
strongback ±5
Edge-lifting
Longitudinal ±20
Thickness ±5
In addition, the recommended tolerance on the location of fixing inserts ......... ±5 mm

(d) Location The recommended tolerance on the deviation of the panel from the specified
final position in the structure ............................................................................ 5 mm
The effects of cumulative tolerances should be considered. It is recommended that the total
accumulation of tolerance be not greater than 20 mm. Where more stringent tolerances are
required, they should be specified.
The visual impact of panel misalignment may be reduced by the use of various details, e.g.
arrises.

HB 31—2002 54 Extract of AS 2908.1—2000
PART 1 CORRUGATED SHEETS
6 DIMENSIONS AND TOLERANCES

The dimensions and tolerances on corrugated cellulose-cement sheets shall be as follows:
(a) Length: is 1200 mm to 3000 mm rising by increments of 300 + 5, - 10 mm.
(b) Width:
(i) Class 1: ............................................................................. 1080 + 10, −5 mm.
(ii) Class 2: ............................................................................. 1150 + 10, −5 mm.
(iii) Class 3: .......................................................................... …1105 + 10, −5 mm.
(c) Thickness: when measured at T, as shown in Figure 1:..................... 6.0 + 1.5 −0 mm.
(d) Pitch: when measured at P, as shown in Figure 1:
(i) Class 1: ............................................................................... 150 + 0, −10 mm.
(ii) Class 2: ............................................................................... 180 + 0, −10 mm.
(iii) Class 3: ............................................................................... 210 + 0, −10 mm.
(e) Depth: when measured at D, as shown in Figure 1:
(i) Class 1: .............................................................................. 50 + 0, −6 mm.
(ii) Class 2: .............................................................................. 60 + 0, −8 mm.
(iii) Class 3: ............................................................................ 75 + 0, −10 mm.
FIGURE 1 DEPTH, PITCH AND THICKNESS MEASURING POINTS

Extract of AS 2908.2—2000 55 HB 31—2002
S EC T ION 5 A C C EP TANC E AN D
GEOMETR IC A L C HAR AC TER IS T IC S
5.1 DIMENSIONAL AND GEOMETRICAL CHARACTERISTICS

5.1.1 Nominal length and width
5.1.1.1 Flat fibre-cement sheets are normally available in nominal lengths up to 3 000 mm
and nominal widths up to 1 250 mm. Sheets of greater nominal lengths and widths may be
supplied.
5.1.1.2 Preferred nominal dimensions for length and width may be specified in national
standards taking into account that the dimensions of the sheets are determined largely by
the purpose for which they are intended.
NOTE 2: The nominal dimensions (width and length) specified in national standards may be
increased by 20 mm to 30 mm (oversize sheets) for application where the sheet is required to be
cut by the user.
5.1.2 Thickness
Flat fibre-cement sheets are normally available in thicknesses from 3 mm to 30 mm,
although thicknesses outside this range may be supplied. Preferred thicknesses may be
specified in national standards.
5.1.3 Tolerances on dimensions
Tolerances on nominal dimensions are as follows:
(a) on length and width (indicated by d):
d ≤ 1 000 mm: ± 5 mm
1 000 mm < d ≤ 1 600 mm: ± 0.5%
d > 1 600 mm: ± 8 mm
These tolerances do not apply to oversize sheets.
The measurement method is given in 8.1.1.2.
(b) on thickness, e:
e ≤ 6 mm: ±0,6 mm
e > 6 mm: ± 10%

For sheets without texture on the exposed face the maximum difference between extreme
values of the thickness measurements within one sheet shall not exceed 15% of the
maximum measured value.
NOTE 3: Tighter tolerances may be adopted by agreement between the manufacturer and the
purchaser.
5.1.4 Tolerances on shape
5.1.4.1 Straightness of edges
The tolerance on the straightness of edges is 3 mm/m for the relevant dimension (length or
width) The measurement method is given in 8.1.1.4.
5.1.4.2 Squareness of edges
The tolerance on squareness of sheets is 4 mm/m.
NOTE: 4: Tighter tolerances may be adopted by agreement between the manufacturer and the
purchaser.

HB 31—2002 56 Extract of AS/NZS 4455:1997
S EC T ION 2 P R ODUC T R EQU IR EMENTS
2.2 DIMENSIONAL DEVIATIONS FROM WORK SIZE

2.2.1 Methods
AS/NZS 4456.3 sets out the two following methods for measuring the dimensions of
masonry units and segmental pavers:
(a) Determination of cumulative dimensions.
(b) Determination of dimension of individual units.
The manufacturer shall select the method appropriate to the manufacturing process and the
operating quality assurance program.
2.2.2 Dimensional consistency between deliveries
For dimensional categories DW1, DW2, DPA1 and DPA2, the dimensions of units taken
from all deliveries of units of the one type and the subject of a single order shall not differ
by more than 40 mm over 20 units.
2.2.3 Masonry units
Masonry units shall be categorized for dimensional deviations, determined in accordance
with AS/NZS 4456.3 (see Table 2.1). Masonry units shall comply with category DW1,
unless otherwise declared by the supplier or agreed between the supplier and purchaser.
Where the intended character of the masonry product is to an overall irregular or rough
surface the units shall comply with category DW0. Where it is intended that only the face or
faces of a unit are irregular, units shall comply with DW1, except that dimensional
deviations shall not apply to the width of the unit provided the average width is not less
than 90% of the work size, determined for any plane parallel to its bed.
NOTE: Typical overall irregular units are dry or wet rumbled. Typical irregular-faced units are
split face, profiled, textured or rock-face.
TABLE 2.1
DIMENSIONAL DEVIATIONS OF MASONRY UNITS
Work size dimensions, mm

Category
under 150 150 to 250 over 250
DW0 No requirement
DW1 (see Note 1) ±50 ±90 ±100
DW2 (see Note 1) ±40 ±60 ±70
DW3 By agreement between supplier and purchaser
DW4 (see Note 2) Standard deviation of not more than 2 mm and is the difference between the
mean and the work size of not more than 3 mm
NOTES:
1 Refer to AS/NZS 4456.3, Test Method 3A, for DW1, DW2. The values given are measured over
20 units.
2 Refer to AS//NZS 4456.3, Test Method 3B, for DW4.

Extract of AS/NZS 4455:1997 57 HB 31—2002
2.2.4 Segmental pavers

Segmental pavers shall be categorized for dimensional deviations, determined in accordance
with AS/NZS 4456.3 and Table 2.2 or Table 2.3. Segmental pavers shall comply with either
category DPA1 or DPB1, unless otherwise declared by the supplier or agreed between the
supplier and purchaser.
TABLE 2.2
DIMENSIONAL DEVIATIONS DETERMINED OVER 20 SEGMENTAL PAVERS
BY CUMULATIVE MEASUREMENT
Category
Under 150 150 to 250 Over 250
DP0 No requirement
DPA1 ±50 ±60 ±75
DPA2 ±40 ±50 ±60
DPA3 By agreement between supplier and purchaser
TABLE 2.3
DIMENSIONAL DEVIATIONS DETERMINED FOR SEGMENTAL PAVERS BY
INDIVIDUAL MEASUREMENT
Plan Height
Category
Standard Standard
Mean Mean
deviation deviation
DP0 No requirements
±3.0 ±2.5
DPB1 2.0 3.0
DPB2 2.0 ±2.5 3.0 ±2.0
DPB3 By agreement between supplier and purchaser

HB 31—2002 58 Extract of AS 3700—2001
S EC T ION 11 TO LER ANC ES IN MA S ONR Y
11.5 TOLERANCES IN MASONRY

11.5.1 General
All structural masonry shall be built to the specified dimensions within the structural
tolerances given in Table 11.1
For non-structural facework masonry the facework tolerances given in Table 11.1 shall
apply.
For structural facework masonry the tighter tolerance given in Table 11.1 shall apply.

Extract of AS 3700—1998 59 HB 31—2002
TABLE 11.1
TOLERANCES IN MASONRY CONSTRUCTION
Non-structural
Item Structural tolerance
facework tolerance
(a) Horizontal position of any masonry element ±15 mm ±15 mm

specified or shown in plan at its base or at each
storey level
(b) Relative displacement between load-bearing ±10 mm ±10 mm

walls in adjacent storeys intended to be in
vertical alignment
(c) Maximum deviation from plumb within a storey The lesser of ±10 mm per 3 m ±10 mm
from a vertical line through the base of the of height or 0.05 times the
member thickness of the leaf
(d) Maximum deviation from plumb in the total ±25 mm ±25 mm

height of the building (from the base)
(e) Maximum horizontal or vertical deviation of a ±5 mm ±3 mm

surface from a plane surface (bow) when
measured as described in Clause 11.5.2
(f) Deviation (step) of any exposed brick surface Not applicable 2 mm

from any adjacent exposed brick surface. The
bow provision of Item (e) above also applies
(g) Deviation of bed joint from horizontal, or from ±10 mm in any 10 m length. ±10 mm in any
the level specified or shown in elevation ± 15 mm in total 10 m length,
±15 mm in total
(h) Deviation from specified thickness of bed joint ±3 mm ±3 mm
(i) Minimum perpend thickness 5 mm 5 mm
(j) Deviation from specified thickness of perpend ±10 mm max. ±5 mm average
(k) Maximum difference in perpend thickness in No limit 8 mm

any wall
(l) Deviation from specified width of cavity ±15 mm ±15 mm
NOTES:
1 Items (h), (i), (j) and (k) are not applicable to thin-bed mortar joints.
2 Items (i) and (j) are not applicable when perpend joints are not filled with mortar as is the case with
some horizontally cored masonry that is not required to resist horizontal bending.

HB 31—2002 60 Extract of AS 3700—2001
11.5.2 Measurement of bow

Where required, bow shall be measured in accordance with Appendix A.
11.5.3 Reinforcement and tendons
Unless otherwise specified, the reinforcement and tendons shall be held during the grouting
operation within the following tolerances:
(a) Across the thickness of a wall ...................................................................... ±5 mm.
(b) Along the length of a wall, for vertical bars, or
up the height of a wall, for horizontal bars .................................................. ±50 mm.
(c) In a column or pier....................................................................................... ±5 mm.
These tolerance shall not be applied to reduce the distance between any reinforcement and
tendon and the nearest bar or grout surface below the value specified in Clauses 5.7.2, 5.7.3
and 8.3.4.
11.6 SITE CONTROL

Site control shall be achieved by ensuring that the relevant provision of this Standard are
complied with. Where doubt exists that the required properties are been achieved,
specimens representative of the masonry shall be made up and assessed for compliance with
strength requirements in accordance with Clause 11.7.4, and appropriate action shall be
taken.

Extract of AS 3700 Supp 1-1999 61 HB 31—2002
S EC T ION C 11 T O LER A NC ES IN MA S ONR Y
C11.5 TOLERANCES IN MASONRY

C11.5.1 General
Tolerances in masonry construction are required to allow for variation in product size and
construction techniques. The tolerances specified in Table 11.1 are to ensure both the
satisfactory structural performance of the masonry and, where applicable, the appearance of
face masonry.
Tighter tolerances than those called up in Table 11.1 may be needed when requirements,
such as those at material property boundaries, are to be met.

HB 31—2002 62 Extract of AS 2796.1—1999
S E C T ION 3 S T R IP F LO OR ING
3.1 GENERAL
This Section sets out the product requirements for strip flooring.
NOTE: Strip flooring is intended for internal use and is tongued and grooved to provide a
continuous surface when laid.
3.4 TOLERANCES
At the time of machining, the tolerance on any dimension in the thickness and width of the
piece shall be as follows:
(a) Overall thickness — ±0.5 mm.
(b) Dimensions in thickness other than overall thickness — ±0.3 mm provided that —
(i) any mismatch does not exceed 0.5 mm (see Figure 3.2(a)); and
(ii) the clearance between tongue and groove is not more than 0.6 mm nor less than
0.3 mm (see Figure 3.2(b)).
NOTE: With secret nail profile, it is important that the groove side of the board is held
in close contact with the supporting material. This may be achieved if C T does not
exceed CG by more than 0.1 mm (see Figure 3.2(c)).
(c) Dimensions in width, including cover width — ±0.3 mm.
NOTE: AS 2796.2 gives limits on missing or damaged tongue and groove.
FIGURE 3.2 ILLUSTRATION OF THE EFFECTS OF TONGUE AND GROVE

CLEARANCES

Extract of AS 2796.1—1999 63 HB 31—2002
S E C T IO N 4 L IG HT D EC K ING
4.4 TOLERANCES
At the time of machining, the tolerance on any dimension in the thickness and width of the
piece shall be ±0.5 mm.
S EC T ION 5 P AR QUET F LO OR ING
5.4 TOLERANCES
The actual dimensions of the parquet products shall not differ from the ordered dimensions
by more than the amounts specified in Table 5.1.
NOTE: AS 2796.2 provides limits on missing or damaged tongue and groove.
TABLE 5.1
PARQUET TOLERANCES
Type Length tolerance Width tolerance Thickness tolerance

mm mm mm
Wood blocks ± 0.5 ± 2.0 over 1 m of blocks ±0.5
to be placed edge to edge
Mosaic finger — — −0 + 0.7
Mosaic panel ± 0.5 ±0.5 —
S EC T ION 6 LIN IN G B OAR DS
6.4 TOLERANCES
At the time of machining, the tolerances on any dimension in the width and thickness of the
piece shall be ±0.5 mm, provided that the clearance between tongues and grooves is not
more than 1 mm nor less than 0.25 mm and any mismatch does not exceed 0.5 mm.
NOTE: AS 2796.2 provides limits on missing or damaged tongue and groove.
S EC T ION 7 DR ES S ED BOAR DS , J O INER Y

AND MOU LDIN G
7.4 TOLERANCES
At the time of machining, the tolerances on any dimension in thickness and width shall be
±0.5 mm.

HB 31—2002 64 Extract of AS 2796.1—1999
S E C T IO N 8 C LA DD IN G, FAS C IA A ND
BAR GE BOAR DS
8.4 TOLERANCES
At the time of sawing or machining, he tolerance on any dimension in the thickness and
width of the piece shall be as follows:
(a) Where both width surfaces have a sawn finish ..............................................±1.5 mm
(b) Where at least one of the wide surfaces has a dressed finish ..........................±0.5 mm
S EC T ION 9 S AW N B OAR DS FOR

FEEDS TOC K (DR ES S ING )
9.3 TOLERANCES
At the time of grading the actual dimensions shall be —
(a) not more than 2 mm below an ordered nominal cross-section size; or
(b) where specified, not less than the agreed cross-section size.
9.4 GRADE
The grade shall be as specified in Clause 1.5.
NOTE: Consideration may be taken during grading of sawn boards for feedstock of the final
product into which the feedstock is to be manufactured. The following are examples of grading
considerations for feedstocks:
(a) Want or wane may be excluded from the final product but acceptable on the feedstock,
provided it will be dressed when producing the final product.
(b) The size of a knot in relation to the feedstock board may be acceptable, but in relation
to the final product may not be acceptable.
S E C T ION 1 0 O VE R LAY S T R IP F LO OR ING

10.4 TOLERANCES
At the time of machining, the tolerances on overall thickness and on cover width shall be
±0.3 mm.

Extract of AS/NZS 2208—1996 65 HB 31—2002
S EC T ION 2 D IM ENS ION AL S P EC IF IC AT IO NS
2.1 GENERAL
This Section sets out the required thickness, size tolerance, squareness of rectangular panels
and flatness of panels for safety glass in order to comply with this Standard.
NOTES:
1 For safety material other than safety glass (i.e. plastic), the manufacturer’s recommendation
should be followed.
2 Prior to furnacing, toughened safety glass should be finished to a minium standard whereby all
edges are arrised. Arrised edges are formed by grinding a chamfer or bevel approximately
1 mm wide on all sharp edges and corners.
2.2 THICKNESS REQUIREMENTS

2.2.1 General
The thickness obtained shall be within the limits provided in Table 2.1, measured in
accordance with Appendix C.
2.2.2 Standard nominal thickness of safety glass
Safety glass, as specified in this Standard, refers to safety glass having a standard nominal
thickness. Limits on the standard nominal thickness of various types of glass are given in
Table 2.1.
2.2.3 Non-standard thickness of glazing material
Thicknesses of safety glass other than those specified in Table 2.1 may be utilized and shall
not be a cause for rejection provided that the product meets all other appropriate test
requirements of this Standard.
NOTE: The use of non-standard thickness will require interpolation to satisfy the requirements of
AS 1288.

HB 31—2002 66 Extract of AS/NZS 2208—1996
TABLE 2.1
THICKNESS LIMITS FOR STANDARD NOMINAL THICKNESS OF GLASS
millimetres
Standard nominal Glass thickness limits

Type of glass
thickness Minimum Maximum
Toughened glass, and 3 2.8 3.2
heat-strengthened glass 4 3.8 4.2
5 4.8 5.2
6 5.8 6.2
8 7.7 8.3
10 9.7 10.3
12 11.7 12.3
15 14.5 15.5
19 18.0 20.0
25 23.5 26.5
Laminated glass 5.38 4.6 5.4
6.38 5.6 6.4
8.38 7.6 8.4
10.38 9.6 10.4

12.38 11.6 12.4
16.38 15.4 16.6
Toughened laminated 6.38 5.6 6.4
glass, and heat- 8.38 7.6 8.4
strengthened laminated
glass
10.38 9.6 10.4
12.38 11.6 12.4
Patterned glass, 3 2.5 3.9
toughened patterned 4 3.5 4.5
glass, and heat-

strengthened patterned 5 4.5 5.5
glass
6 5.5 7.0
10 9.0 10.8
12 11.0 13.5
Wired glass 6 5.0 6.8
NOTES:
1 For glass that does not satisfy the thickness tolerances for the standard nominal thickness specified
above, the minimum glass thickness shall be marked.
2 Linear interpolation as defined in AS 1288 shall apply for non-standard thickness.
3 Glass thickness limits specified for laminated glass exclude interlayer thicknesses

2.3 SIZE TOLERANCE REQUIREMENTS

Tolerance on sizes for all safety glass shall be as specified in Table 2.2.
TABLE 2.2
SIZE TOLERANCE FOR GLASS OF STANDARD NOMINAL THICKNESS
millimetres
Tolerance limits
Standard nominal
Non-patterned Patterned
thickness
< 1200 ≥ 1200 < 1200 ≥ 1200
3 ±2 ±2 ±3 ±4
4 ±2 ±2 ±3 ±4
5 ±2 ±2 ±3 ±4
6 ±2 ±2 ±3 ±4
8 ±2 ±2 ±4 ±5
10 ±2 ±3 ±4 ±5
12 ±2 ±3 ±4 ±5
15 ±2 ±3 — —
19 ±2 ±3 — —
25 ±2 ±3 — —
NOTE: For non-standard glass thicknesses, interpolation will be required.
2.4 SQUARENESS OF RECTANGULAR PANELS—REQUIREMENTS

The squareness of rectangular panels shall be such that the difference between the two
diagonals does not exceed 5 mm for panels where the largest dimension is less than 1200 mm
and 10 mm for all other panels.
2.5 FLATNESS REQUIREMENTS

The flatness of panels shall be within the following limits:
(a) Localized warp 1.0 mm over any 200 mm span.
(b) Overall bow and warpage as given in Table 2.3.

HB 31—2002 68 Extract of AS/NZS 2208—1996
TABLE 2.3
FLATNESS LIMITS FOR GLASS OF STANDARD NOMINAL THICKNESS
millimetres
Standard nominal Bow
thickness 0 to 1500 1501 to 3000 3001 to 5000
3 1 in 200 1 in 150 —
4 1 in 200 1 in 150 —
5 1 in 300 1 in 200 1 in 200
6 1 in 350 1 in 250 1 in 200

8 1 in 400 1 in 300 1 in 250
10 1 in 400 1 in 300 1 in 250
12 1 in 400 1 in 300 1 in 250

15 1 in 400 1 in 300 1 in 250
19 1 in 400 1 in 300 1 in 250
25 1 in 400 1 in 300 1 in 250
NOTES:
1 Flatness measurements shall be checked against a straightedge with the panel standing within 5° of vertical
and measurement taken horizontal.
2 For non-standard glass thicknesses, interpolation will be required.
2.6 EDGEWORK
Prior to heat treatment, glass shall be arrised on all edges.
NOTES:
1 Arrised edges are formed by grinding a chamfer or bevel of approximately 1 mm wide on all
sharp edges and corners.
2 Care should be exercized when handling glass to prevent edge damage and subsequent fracture.
Particular care is required when handling toughened safety glass as damaged edges may result
in spontaneous glass fracture.

S EC T ION 6 C ONS TR UC T IO N
6.2 TOLERANCES
The sizes of rectangular window assemblies shall be within a tolerances of ±3.0 mm of the
agreed sizes, and the maximum difference between diagonals shall be 4 mm.

HB 31—2002
70
NOTES
71
NOTES
HB 31—2002
HB 31—2002
72
NOTES
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HB 31—2002

Handbook of building construction

The following interests are represented on Committee BD-069:

Keeping Standards up-to-date

Handbook of building construction

Standards Title Page

© Standards Australia www.standards.com.au

(b) Width of a flange (b f) (see Figure 14.4.3(1))

FIGURE 14.4.3(1) TOLERANCES ON A CROSS-SECTION

2 Dimension d is measured at the centreline of the web.

(e) Out-of-flatness a of web ( ∆ w ) (see Figure 14.4.3(2))

www.standards.com.au © Standards Australia

FIGURE 14.4.3.(2) TOLERANCES OF A WEB

(g) Tolerance on shape of a built-up box section (see Figure 14.4.3.(3))

FIGURE 14.4.3(3) TOLERANCE ON SHAPE OF A BOX SECTION

(h) Off-centre of a web (e) (see Figure 14.4.3(4)) ±6 mm

FIGURE 14.4.3(4) TOLERANCE ON OFF-CENTRE OF A WEB

(i) Out-of-flatness of a flange ( ∆ f ) (see Figure 14.4.3(5))

© Standards Australia www.standards.com.au

FIGURE 14.4.3(5) TOLERANCE ON OUT-OF-FLATNESS OF A FLANGE

14.4.4 Compression member

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FIGURE 14.4.5.1 MEASUREMENT OF CAMBER AND SWEEP

© Standards Australia www.standards.com.au

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FIGURE 15.3.1 TOLERANCES IN ANCHOR BOLT LOCATION

15.3.2 Column base

© Standards Australia www.standards.com.au

15.3.3 Plumbing of a compression member

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(b) Height (see Figure 15.3.7.2)

FIGURE 15.3.7.1 DEVIATIONS IN LENGTH (VERTICAL SECTION)

© Standards Australia www.standards.com.au

FIGURE 15.3.7.2 DEVIATIONS IN HEIGHT (VERTICAL SECTION)

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The tolerance on plate thickness should be as specified in AS 1365.

© Standards Australia www.standards.com.au

FIGURE C14.4.2 FULL CONTACT SPLICES

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© Standards Australia www.standards.com.au

C15.3.1 Location of anchor bolts

(c) checking of anchor bolt positions by a surveyor before concreting.

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C15.3.3 Plumbing of a compression member

FIGURE C15.3.3 PLUMBING OF A COMPRESSION MEMBER

C15.3.4 Column splice

© Standards Australia www.standards.com.au

FIGURE C15.3.4 COLUMN SPLICE

C15.3.5 Level and alignment of a beam

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2.5 DIMENSIONAL TOLERANCES.

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3.4 PHYSICAL QUALITY

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3.4.5.2 Tolerance classification for precast concrete

3.4.5.3 Tolerance values

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Situations Trafficable slopes, Formed tops of No restriction No restriction

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2 Tie rod pattern TBS TBS OPT EXCL EXCL

4 Surface pattern details and SIA SIA SIA EXCL EXCL

8 Critical faces of elements SIA SIA SIA SIA EXCL 3.4.3.3

10 Plum of elements height SIA SIA SIA SIA SIA