Handbook of Construction Tolerances

The comprehensive guide to construction tolerances, newly revised and updated

How much may a steel frame be out of plumb? What are the expected variations of a precast concrete panel? What is required to successfully detail finish materials on masonry?

Updating and expanding on its popular first edition, the Handbook of Construction Tolerances, Second Edition remains the only comprehensive reference to the thousands of industry standard tolerances for the manufacture, fabrication, and installation of construction materials and components-- including all-important accumulated dimensional variations.

Covering new materials and techniques developed since the book was first published, the Second Edition of this easy-to-use reference features:
* More than 100 drawings illustrating the tolerance concepts
* New sections on measuring compliance with tolerance standards; right-of-way construction; autoclaved aerated concrete; tilt-up concrete panels; interior stone wall cladding; structural insulated panels; decorative architectural glass; laminated architectural flat glass and bent glass
* New guidelines on how to incorporate tolerance requirements in drawings and specifications
* New information on how to apply tolerance information during contract administration

With the Handbook, architects, engineers, contractors, interior designers, lawyers, and others involved in the construction industry will be armed with the information they need to design and detail more accurately, write better specifications, establish normal practice and standards of care, supervise construction, settle worksite disputes, and save time and money at every stage of building.

List of Tables xi

Acknowledgments xiii

Introduction xv

Part 1: Construction Tolerances

Chapter 1: Building Layout and Sitework 3

1–1 Horizontal Building Layout 3

1–2 Vertical Building Layout 7

1–3 Concrete Paving 8

1–4 Asphalt Paving 10

1–5 Pedestrian Paving 13

1–6 Grading and Sitework 15

1–7 Right-of-Way Construction 17

Chapter 2: Concrete 23

2–1 Reinforcement Placement for Flexural Members 23

2–2 Reinforcement Placement in Walls and Columns 25

2–3 Reinforcement Placement of Prestressing Steel 25

2–4 Concrete Slabs on Grade 29

2–5 Footings and Anchor Bolts 31

2–6 Piers 32

2–7 Cast-in-Place Plumb Tolerances 35

2–8 Cast-in-Place Sectional Tolerances 35

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

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

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

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

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

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

DAVID KENT BALLAST, AIA, CSI, a registered architect, has owned Architectural Research Consulting in Denver since 1981. The consulting firm offers applied research, technical advice, specifications, and information management services to architects, interior designers, and others in the construction industry. Since 1987, Ballast has been an instructor in Interior Construction and Basic Drafting at Arapahoe Community College. He is the author of a number of books on construction technology.

The comprehensive guide to construction tolerances, newly revised and updated

How much may a steel frame be out of plumb? What are the expected variations of a precast concrete panel? What is required to successfully detail finish materials on masonry?

Updating and expanding on its popular first edition, the Handbook of Construction Tolerances, Second Edition remains the only comprehensive reference to the thousands of industry standard tolerances for the manufacture, fabrication, and installation of construction materials and components—— including all-important accumulated dimensional variations.

Covering new materials and techniques developed since the book was first published, the Second Edition of this easy-to-use reference features:

• More than 100 drawings illustrating the tolerance concepts
• New sections on measuring compliance with tolerance standards; right-of-way construction; autoclaved aerated concrete; tilt-up concrete panels; interior stone wall cladding; structural insulated panels; decorative architectural glass; laminated architectural flat glass and bent glass
• New guidelines on how to incorporate tolerance requirements in drawings and specifications
• New information on how to apply tolerance information during contract administration

With the Handbook, architects, engineers, contractors, interior designers, lawyers, and others involved in the construction industry will be armed with the information they need to design and detail more accurately, write better specifications, establish normal practice and standards of care, supervise construction, settle worksite disputes, and save time and money at every stage of building.