Beruflich Dokumente
Kultur Dokumente
HB 31
Handbook
Handbook
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.
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3 HB 31—2002
TABLE OF CONTENTS
Australian Standard
Handbook of building construction tolerances—Extracts from building
products and structures Standards
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
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∆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
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.
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14.4.5 Beam
14.4.5.1 Straightness
A beam shall not deviate from a straight line drawn between the ends of the beam by more
than the following:
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(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
14.4.6.1 Straightness
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.
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.
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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.
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}
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
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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.
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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.
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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
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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.
S E C T IO N 2 T H E S T E E L BAS E
S EC T ION 3 S UR F AC E F IN IS H
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.
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
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.
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
3 Liner details, pattern and EXCL SIA SIA EXCL EXCL Table 3.3.1
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
9 Distance between face OPT OPT OPT EXCL EXCL Table 3.4.2
steps
LEGEND:
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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.
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
3 Face step:
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
6 Out of plumb
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.
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.
TABLE 3.4.3
ACCEPTABLE DEVIATIONS FOR PRECAST CONCRETE UNITS
≥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
Other requirements As As
specified* specified*
Irregular curved or unusual shapes As As
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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
(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
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.
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S EC T ION 5 C ONS TR UC T IO N
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.
Plumb shall be measured from a point 300 mm from the top of the vertical surface to a
point 300 mm from the bottom.
(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).
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.
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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.
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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)’
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(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.
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.
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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.
(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.
www.standards.com.au © Standards Australia
HB 31—2002 42 Extract of AS 3610 Supp 2—1996
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
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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
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(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
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
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.
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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.
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S EC T ION 19 M A TER IA L AN D
C ONS TR UC TION R EQ U IR EMENTS
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.
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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.
(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
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Face-lifting ±20
bracing ±50
strongback ±5
Edge-lifting
Longitudinal ±20
Thickness ±5
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
TABLE 2.1
DIMENSIONAL DEVIATIONS OF MASONRY UNITS
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DW0 No requirement
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.
TABLE 2.2
DIMENSIONAL DEVIATIONS DETERMINED OVER 20 SEGMENTAL PAVERS
BY CUMULATIVE MEASUREMENT
Work size dimensions, mm
Category
Under 150 150 to 250 Over 250
DP0 No requirement
TABLE 2.3
DIMENSIONAL DEVIATIONS DETERMINED FOR SEGMENTAL PAVERS BY
INDIVIDUAL MEASUREMENT
Work size dimensions, mm
Plan Height
Category
Standard Standard
Mean Mean
deviation deviation
DP0 No requirements
±3.0 ±2.5
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TABLE 11.1
TOLERANCES IN MASONRY CONSTRUCTION
Non-structural
Item Structural tolerance
facework tolerance
(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
(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
any wall
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.
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.
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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.
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
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
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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.
7.4 TOLERANCES
At the time of machining, the tolerances on any dimension in thickness and width shall be
±0.5 mm.
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
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.
10.4 TOLERANCES
At the time of machining, the tolerances on overall thickness and on cover width shall be
±0.3 mm.
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.
TABLE 2.1
THICKNESS LIMITS FOR STANDARD NOMINAL THICKNESS OF GLASS
millimetres
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
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
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 — —
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
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
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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.
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HB 31—2002
70
NOTES
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71
NOTES
HB 31—2002
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HB 31—2002
72
NOTES
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