Contents

List of Tables xi
Acknowledgments xiii
Introduction xv

AL
Part 1: Construction Tolerances

RI
Chapter 1: Building Layout and Sitework 3
1–1 Horizontal Building Layout 3

TE
1–2 Vertical Building Layout 7
1–3 Concrete Paving 8
1–4 Asphalt Paving 10
1–5 Pedestrian Paving 13
MA
1–6 Grading and Sitework 15
1–7 Right-of-Way Construction 17
D

Chapter 2: Concrete 23
TE

2–1 Reinforcement Placement for Flexural Members 23

2–2 Reinforcement Placement in Walls and Columns 25
GH

2–3 Reinforcement Placement of Prestressing Steel 25

2–4 Concrete Slabs on Grade 29
2–5 Footings and Anchor Bolts 31
RI

2–6 Piers 32
2–7 Cast-in-Place Plumb Tolerances 35
PY

2–8 Cast-in-Place Sectional Tolerances 35

2–9 Cast-in-Place Concrete Elements in Plan 37
CO

2–10 Cast-in-Place Stairs 37

2–11 Glass-Fiber-Reinforced Concrete Panels 39
2–12 Architectural Precast Concrete Panels 41
2–13 Precast Ribbed Wall Panels 43
2–14 Precast Insulated Wall Panels 43
2–15 Hollow-Core Slabs 47
2–16 Precast Stairs 47
2–17 Precast Pilings 49
2–18 Prestressed Concrete Beams 49
2–19 Prestressed Single Tees 53
2–20 Prestressed Double Tees 55
2–21 Precast Columns 57
2–22 Prestressed Tee Joists or Keystone Joists 57
2–23 Precast Column Erection 59
2–24 Precast Beam and Spandrel Erection 61
2–25 Precast Floor and Roof Member Erection 63
vi Contents

2–26 Precast Structural Wall Panel Erection 63

2–27 Precast Architectural Wall Panel Erection 67
2–28 Glass-Fiber-Reinforced Concrete Panel Erection 69
2–29 Autoclaved Aerated Concrete 69
2–30 Tilt-Up Concrete Panels 73

Chapter 3: Steel 75
3–1 Mill Tolerances for W and HP Shapes 75
3–2 Mill Tolerances for Length of W and HP Shapes 79
3–3 Mill Tolerances for S and M Shapes and Channels 81
3–4 Mill Tolerances for Structural Angles and Tees 82
3–5 Mill tolerances for Pipe and Tubing 85
3–6 Steel Column Erection Tolerances 87
3–7 Location of Exterior Steel Columns in Plan 89
3–8 Steel Beam/Column Connections 91
3–9 Architecturally Exposed Structural Steel 91
3–10 Elevator Shaft Tolerances 94

Chapter 4: Unit Masonry 97

4–1 Concrete Unit Masonry Manufacturing 97
4–2 Concrete Unit Masonry Reinforcement Placement 99
4–3 Concrete Unit Masonry Construction 103
4–4 Prefabricated Masonry Panels 103
4–5 Brick Manufacturing 104
4–6 Brick Wall Construction 107
4–7 Glazed Structural Clay Facing Tile 107
4–8 Facing, Load-Bearing, and Non-Load-Bearing Clay Tile 112
4–9 Terra Cotta Manufacturing and Erection 115
4–10 Glass Block Manufacturing and Erection 116

Chapter 5: Stone 119

5–1 Granite Fabrication 119
5–2 Marble Fabrication 121
5–3 Limestone Fabrication 123
5–4 Granite and Marble Installation 125
5–5 Limestone Installation 127
5–6 Fabrication and Installation Tolerances for Slate 128
5–7 Cast Stone Fabrication and Installation 129
5–8 Interior Stone Wall Cladding 129

Chapter 6: Structural Lumber 133

6–1 Glued Laminated Timber Fabrication 133
6–2 Manufacturing Tolerances for Structural Lumber 133
6–3 Plywood Manufacturing 136
6–4 Particleboard Manufacturing 139
6–5 Fiberboard Manufacturing 141
6–6 Rough Lumber Framing 143
6–7 Wood Floor Framing and Subflooring 145
6–8 Metal-Plate-Connected Wood Truss Fabrication 146
 Contents vii

6–9 Metal-Plate-Connected Wood Truss Erection 148

6–10 Prefabricated Structural Wood 150
6–11 Structural Insulated Panels 151

Chapter 7: Finish Carpentry and Architectural Woodwork 153

7–1 Manufacturing Tolerances for Board Lumber 153
7–2 Site-Built Cabinets and Countertops 155
7–3 Site-Built Stairs and Trim 156
7–4 Standing and Running Trim 158
7–5 Architectural Cabinets 160
7–6 Modular Cabinets 163
7–7 Countertops 163
7–8 Flush Paneling 167
7–9 Stile and Rail Paneling 170
7–10 Stairwork 172
7–11 Frames, Jambs, and Windows 174
7–12 Screens 176
7–13 Blinds and Shutters 177
7–14 Architectural Flush Doors 178
7–15 Stile and Rail Doors—Size and Flatness 181
7–16 Stile and Rail Doors—Joint Tightness and Flushness 183
7–17 Architectural Woodwork Installation 185

Chapter 8: Curtain Walls 189

8–1 Aluminum Curtain Wall Fabrication 189
8–2 Aluminum Curtain Wall Installation 191
8–3 Storefront and Entrance Manufacturing 193
8–4 Storefront Installation 195

Chapter 9: Finishes 197

9–1 Light-Gauge Framing for Gypsum Wallboard 197
9–2 Wallboard Partitions, Ceilings, and Trim 199
9–3 Glass-Reinforced Gypsum Products 200
9–4 Installation of Lath and Plaster 202
9–5 Floor and Wall Tile 204
9–6 Terrazzo Flooring 207
9–7 Wood Flooring 208
9–8 Stone Flooring 210
9–9 Acoustical Ceiling Installation 210
9–10 Linear Metal Ceiling Installation 213
9–11 Stainless Steel Ornamental Metal Products 214
9–12 Copper Alloy Ornamental Metal Products 216
9–13 Extruded Aluminum Tubes 218
9–14 Aluminum Rods, Bars, and Shapes 220

Chapter 10: Glazing 223

10–1 Manufacturing Tolerances for Flat Glass 223
10–2 Manufacturing Tolerances for Patterned and Wired Glass 223
10–3 Tempered, Heat-Strengthened, and Spandrel Glass 227
viii Contents

10–4 Sealed Insulated Glass Units 228

10–5 All-Glass Entrances 230
10–6 Decorative Architectural Flat Glass 233
10–7 Laminated Architectural Flat Glass 233
10–8 Bent Glass 235

Chapter 11: Doors and Windows 239

11–1 Standard Steel Doors and Frames 239
11–2 Insulated Steel Door Systems 239
11–3 Detention Security Hollow Metal Doors and Frames 241
11–4 Standard Flush Wood Doors 241
11–5 Standard Stile and Rail Doors 244
11–6 Wood Swinging Patio Doors 246
11–7 Installation of Wood Doors 246
11–8 Wood Windows 249
11–9 Aluminum Windows and Sliding Doors 251
11–10 Steel Windows 251

Part 2: Accommodating Construction Tolerances

Guidelines for Accommodating Construction Tolerances 255
Joint Design 255
Accumulated Tolerances 258

Chapter 12: Cast-in-Place Concrete Systems 261

12–1 Concrete Frame Tolerances 261
12–2 Joint Tolerances 263
12–3 Detailing for Cast-In-Place and Precast Systems 264
12–4 Detailing Brick on Cast-in-Place Concrete 266
12–5 Detailing for Stone on Concrete Systems 269
12–6 Detailing for Curtain Walls on Concrete Frames 271
12–7 Detailing Doors in Cast-in-Place Concrete 273
12–8 Detailing Windows in Cast-in-Place Concrete 275

Chapter 13: Precast Concrete Systems 277

13–1 Combined Precast Concrete Frame Tolerances 277
13–2 Joint Tolerances 278
13–3 Detailing for Precast Systems 279
13–4 Detailing for Precast and Steel Systems 281
13–5 Detailing Masonry and Precast Systems 283
13–6 Detailing Doors in Precast Concrete 286
13–7 Detailing Windows in Precast Concrete 286

Chapter 14: Steel Frame Systems 289

14–1 Accumulated Column Tolerances 289
14–2 Accumulated Steel Frame Tolerances 290
14–3 Detailing for Steel Structural System Tolerances 293
14–4 Detailing for Precast on Steel 295
14–5 Detailing for Brick on Steel 295
 Contents ix

14–6 Detailing for Stone on Steel Systems 297

14–7 Detailing for Curtain Walls on Steel Frames 299

Chapter 15: Masonry Systems 303

15–1 Masonry Joint Tolerance 303
15–2 Detailing Brick and Masonry Systems 303
15–3 Detailing for Stone on Masonry Backup 305
15–4 Detailing Interior Stone on Masonry 306
15–5 Detailing Doors in Masonry 309
15–6 Detailing Windows in Masonry 309

Chapter 16: Timber and Carpentry Construction 313

16–1 Detailing Wood Joints 313
16–2 Detailing for Timber Columns 315
16–3 Detailing for Timber Beams 315
16–4 Detailing for Prefabricated Structural Wood 317
16–5 Detailing for Paneling on Site-Built Substrates 320
16–6 Detailing for Cabinetry and Site-Built Substrates 320

Part 3: Measuring Compliance and Documenting

Construction Tolerances
Chapter 17: Methods of Measurement 325
17–1 Measuring Devices 325
17–2 Measuring Length 326
17–3 Measuring Angles 327
17–4 Measuring Slopes 327
17–5 Measuring Flatness, Level, and Smoothness 329

Chapter 18: The Uncertainty of Measurement in Construction 333

18–1 The Expression of Measurement 334
18–2 Expressing Uncertainty 334
18–3 Units of Measure 338
18–4 Significant Figures and Rounding 339
18–5 Metric Conversion 340

Chapter 19: Documenting and Enforcing Tolerances 343

19–1 Documenting Tolerances on Drawings 343
19–2 Documenting Tolerances in Specifications 344
19–3 Contract Administration 344
19–4 Tolerances and Accessibility 344

Sources 347
Index 357
List of Tables

Table 1–1 Maintenance and Acceptance Tolerances, in Excess and in Deficiency, for
Metal Tapes
Table 1–2 Relative Positional Accuracies
Table 1–3 Relative Positional Accuracies for Land Title Surveys
Table 1–4 Recommended Tolerances for Right-of-Way Construction
Table 2–1 Clear Distance Tolerance to Side Forms and Soffits
Table 2–2 Horizontal Dimension Tolerance for Footings Cast against Soil
Table 2–3 Tolerances for Top Elevation of Structural Wall Panels
Table 2–4 Tolerances for Top Elevation of Architectural Wall Panels
Table 3–1 Permissible Variation in Camber and Sweep for W and HP Shapes
Table 3–2 Permissible Variation in Length for W and HP Shapes
Table 3–3 Permissible Variation for Length and Squareness for Milled Shapes
Table 3–4 Permissible Variation in Cross-Sectional Shapes for S, M, C, and MC Shapes
Table 3–5 Permissible Variation in Length for S, M, and Channel Shapes
Table 3–6 Permissible Variation in sizes for Angles and Tees
Table 3–7 Permissible Variation in Length for Angles and Tees
Table 3–8 Length Tolerances for Pipe and Tubing
Table 3–9 Twist tolerances for Square and Rectangular Tubing
Table 4–1 ACI masonry Reinforcement Placement Tolerances
Table 4–2 Dimensional Tolerances of Prefabricated Masonry Panels
Table 4–3 Brick Manufacturing Dimension Tolerances
Table 4–4 Brick Distortion Tolerances
Table 4–5 Face Dimension Tolerances for Glazed Clay Facing Tile
Table 4–6 Bed Depth (Thickness) Tolerances for Glazed Clay Facing Tile
Table 4–7 Distortion Tolerances For Glazed Clay Facing Tile
Table 4–8 Clay Facing Tile Manufacturing Dimension Tolerances
Table 4–9 Clay Facing Tile Distortion Tolerances
Table 5–1 Tolerances for Granite Veneer
Table 5–2 Finished Size Tolerances for Marble
Table 5–3 limestone Fabrication Tolerances
Table 6–1 Minimum Sizes of Dressed, Dry Dimensional Lumber
Table 6–2 Plywood Thickness Tolerances
Table 6–3 Tolerances for Particleboard
Table 6–4 Tolerances for Particleboard Flooring Products
Table 6–5 Structural Manufacturing Tolerances for Finished Trusses Units
Table 7–1 Minimum Sizes of Dressed, Dry Finish or Board Lumber
Table 7–2 Tightness and Flushness of Plant-Assembled Joints
xii List of Tables

Table 7–3 Flushness and Flatness of Cabinet Joints and Panels

Table 7–4 Joint Tolerances for Factory-Assembled Components
Table 7–5 Joint Tolerance for Separation between Factory-Assembled Backsplash
and Top
Table 7–6 Joint Tolerance for Factory-Assembled Components for Wood Veneer
Paneling
Table 7–7 Joint Tolerances for Factory-Assembled Components for Stile and Rail
Paneling
Table 7–8 Joint Tolerances for Factory-Assembled Joints for Stairwork
Table 7–9 Joint Tolerances for Custom Windows
Table 7–10 Joint Tolerances for Screens
Table 7–11 Joint Tolerances for Blinds and Shutters
Table 7–12 Tightness of Plant-Assembled Joints
Table 7–13 Flushness of Plant-Assembled Joints
Table 7–14 Wood-to-Wood Field Joints up to 118 Inches (3 m) above Finished Floor
Table 7–15 Wood-to-Nonwood Field Joints up to 118 Inches (3 m) above Finished
Floor
Table 7–16 Nonwood-to-Nonwood Field Joints up to 118 Inches (3 m) above Finished
Floor
Table 9–1 Tile Manufacturing Tolerances
Table 9–2 Required Tolerance for Plane of Substrate for Tile Installation
Table 9–3 Recommended Concrete Slab Tolerances for Wood Flooring
Table 9–4 Twist Tolerances for Stainless Steel Tube Sections
Table 9–5 Size and Squareness Tolerances for Stainless Steel Tee Sections
Table 9–6 Straightness Tolerances for Round Tubing
Table 9–7 Straightness Tolerances for Bars Made from Square-Sheared Metal
Table 9–8 Selected Tolerances for Extruded Aluminum Tube Sections
Table 9–9 Selected Tolerances for Aluminum Rods, Bars, and Shapes
Table 10–1 Allowable Tolerances for Clear, Flat Glass
Table 10–2 Tolerances for Patterned Glass
Table 10–3 Tolerances for Wired Glass
Table 10–4 Dimensional Tolerances for Tempered, Heat-Strengthened, and Spandrel
Glass
Table 10–5 Bow Tolerances for Tempered, Heat-Strengthened, and Spandrel Glass
Table 10–6 Dimensional Tolerances for Insulating Glass Units
Table 10–7 Length and Width Tolerances for Symmetrically Laminated Architectural
Glass
Table 10–8 Bow Tolerances for Laminated Glass
Table 10–9 Height and Girth Tolerances for Bent Glass
Table 10–10 Shape and Accuracy and Crossbend Tolerances for Bent Glass
Table 10–11 Maximum Twist Deviation for Bent Glass
Table 11–1 AWI Joint Tolerances for Factory-Assembled Windows
Table 12–1 Offset between Adjacent Pieces of Formwork Facing
Table 17–1 Approximate Correlations between F-Numbers and Straightedge Gaps
Table 18–1 Suggested Inch-Pound Measurement to SI Units