TOLERANCE MANUAL

FOR PRECAST AND PRESTRESSED

CONCRETE CONSTRUCTION
MNL 135-00

PRECAST/PRESTRESSED
CONCRETE INSTITUTE
 TOLERANCES
FOR PRECAST AND PRESTRESSED CONCRETE
CONSTRUCTION
MNL-135-00

prepared by

PCI Committee on Tolerances

Kim Sorenson, RE., Chairman

Ted J. Gutt, P.E.

Michael W. LaNier, RE.
Jagdish Nijhawan, PE.
Jerald A. Schneider, PE.
Helmuth Wilden, RE.
2.0 Introduction
The tolerance information contained here has
been developed for use primarily by precast and pre¬
cast prestressed concrete producers, erectors, quali¬
ty control agencies, architects and engineers and re¬
lated or interfacing trades unless other tolerances are
noted in the project drawings or specifications.
In the event that the project tolerances are set by
the precast producer, rather than the architect/engi¬
neer, all involved parties agree in advance of any pro¬
duction, what the project tolerances will be. If toler¬
ances different from PCI standard tolerances are
used on a project, the specified tolerances on that
particular project should be shown on the project
shop drawings and, as applicable, on the erection
drawings. In lieu of showing tolerances on each shop
drawing, a tolerance drawing for the project can be
prepared to make the production personnel aware of
the project tolerance requirements.
The producer's personnel should review the con¬
tract documents and make sure that the specified tol¬
erances are appropriate to the individual compo¬
nents. If revisions are deemed necessary by the
review the architect/engineer should be notified by
the producer so that any proposed revisions can be
approved and/or implemented by the architect/engi¬
neer.
2.1 Groups of Tolerance Issues
Final component details for precast concrete
products should conform to three groups of toler¬
ances which have been established as part of the pre¬
cast concrete design process. These are product tol¬
erances, erection tolerances and interfacing
tolerances.
Product Tolerances
Product tolerances are defined as those toler¬
ances related to the dimensions and dimensional
relationships of the individual precast concrete mem¬
bers. Article 10.0 provides a compilation of recom¬
mended product tolerances for precast concrete
products. Articles 7.0 through 9.0 discuss the specifi¬
cation of these values and the methods of verifying
tolerances after casting.
Many times a control surface tolerance will control
over a feature tolerance. This concept is discussed in
detail in Article 6.0. The allowable variation for one
element of the structure should not be such that it will
cause another element of the structure to exceed its
allowable variations.
6
Erection Tolerances
Erection tolerances are defined as those toler¬
ances which are required for the acceptable match¬
ing of the precast members after they are erected. Ar¬
ticle 11.0 provides a comprehensive discussion of the
principles and considerations relative to precast con¬
crete erection tolerances. Additional information per¬
taining to erection tolerances that should be antici¬
pated in the tolerance specification review and
construction of precast concrete structures is pro¬
vided in Article 12.0.
Interfacing Tolerances
Interfacing tolerances are those tolerances which
are associated with other materials or building sys¬
tems in contact with or in close proximity to precast
concrete, both before and after precast erection. Ar¬
ticle 17.0 provides guidelines for the proper dimen¬
sional specification of interfacing materials in con¬
junction with precast product and erection
tolerances.
2.2 Tolerance Categories
There are six categories of tolerance issues for the
three tolerance groups given above. The principal
concern of each category is as follows.
Structural
To control the member dimensions and dimen¬
sional interface in order to assure that dimensional
variations do not change the loading configuration or
capacity of a member as assumed by the designer.
Tolerances which are critical for structural perfor¬
mance of members and or connections should be in¬
dicated as such by the architect/engineer on the proj¬
ect design drawings.
The architect /engineer should also indicate the
tolerances that stem from the requirements of overall
structural integrity.
Feasibility
To ensure acceptable performance of joints and in¬
terfacing materials in the finished structure and to en¬
sure that designs and details are attainable with avail¬
able manufacturing and construction techniques.
The established tolerances or required perfor¬
mance should fall within generally accepted limits
and should not be made more stringent, and there¬
fore more costly, than is absolutely necessary.
 Tolerances more restrictive than those discussed
in this document should be brought to the attention
of the architect/engineer to ascertain that they are
compatible and that the proposed restrictions can be
met. For example, a requirement which states that
"no bowing, warping, or movement is permitted" is
not practical or possible to achieve.
Visual
The variations in the finished product should be
controllable and result in an acceptable appearance.
Tolerances related to visual effects or aesthetics may
be significantly more stringent than those required for
structural or functional reasons. Tolerances which
are critical to project aesthetics should be indicated
as such by the Architect/Engineer.
Economics
To ensure a reliable and efficient rate of production
and erection by having a known degree of accuracy
in the dimensions of precast concrete products. The
cost of working to tighter than standard product toler¬
ances should be evaluated for cumulative cost effects
at the project level. That is, one should evaluate both
the cost increases and cost savings for member fab¬
rication, interfacing with subsystems and erection to
7
determine the most economical approach to han¬
dling the project tolerance requirements.
Legal
To avoid encroaching on property lines and estab¬
lish a tolerance standard against which the work can
be compared in the event of a dispute.
It is very important to agree on the project toler¬
ances in writing, particularly with special tolerances
or in situations with critical visual aesthetics. Similarly,
it is equally important to agree in advance how and
when these tolerances will be verified (with due con¬
sideration for measurement methods, measurement
locations, number of points to measure, support con¬
ditions, thermal conditions, and time of measure¬
ment).
Contractual
To establish a known acceptability range and as¬
sign responsibility for developing, achieving, and
maintaining mutually agreed tolerances for the proj¬
ect. The producer's quality control staff should under¬
stand what the producer's contractual obligations are
regarding project tolerances. The actual project tol¬
erances contractually agreed to may be different from
the charted values given here.
Fig. 12.1.1 Beam Erection Tolerances

Bldg. grid
datum

c c
A/~

Horizontal
primary
~ÿü control

rr surface
(at support)
4

Vertical primary
control surface"
n
Ledge
both sides Precast concrete
(N/A at inverted beam
tee beam) at inverted
ai
tee beam Support element

A- -V
Centerline of
steel support

Plan view Elevation

Precast element to: precast element, cast-in-place concrete, masonry, or structural steel

96
12.1 Beam Erection Tolerances

The primary control surfaces are usually as shown, although this needs to be confirmed on a
job-by-job basis.

a = Plan location from building grid datum ±1 in. [±25 mm]

a-i = Plan location from centerline of steel* ±1in. [±25 mm]

b = Bearing elevation* from nominal elevation at support:

Maximum low V? in. [13 mm]
Maximum high 'A in. [6 mm]

c = Maximum plumb variation over height of element:

Per 12 in. [300 mm] height 1A in. [3 mm]
Maximum at rectangular or L-beam V* in. [13 mm]
Maximum at inverted tee beam 3A in. [19 mm]

d = Maximum jog in alignment of matching edges:

Architectural exposed edges % in. [6 mm]
Visually non-critical edges 1/a in. [13 mm]

e = Joint width:
Architectural exposed joints ±Vi in. [±6 mm]
Hidden joints ±3A in. [±19 mm]
Exposed structural joint not visually critical ±Vz in. [13 mm]

f - Bearing length* (span direction) ±3A in. [±19 mm]

g = Bearing width* ±Vz in. [±13 mm]

Note: When bearing pads are used at unarmored edges they should be set back a minimum of Vfe
in. [13 mm] from the face of the support or at least the chamfered dimension at chamfered edges.

* For precast elements on a steel frame, this tolerance takes precedence over tolerance on dimen¬
sion "a".

* Or member top elevation where member is part of a frame without bearing ledges.
* This is a setting tolerance and should not be confused with structural performance requirements
set by the architect/engineer. The nominal bearing dimensions and the allowable variations in the
bearing length and width should be specified by the engineer and shown on the erection drawings.

97
Fig. 12.2.1 Floor and Roof Member Erection Tolerances

BIdg. grid
dalum
BIdg. grid -(J)
dalum

Hollowcore plan Double tee plan

(£ o1 steel support
Primary control surlace
lor carpet direct
of steel support
u
Ho owcore Double tee
Support Support
member member —
Primary control surface Primary control surface
To allow for for topped deck w/ To allow for for pretopped tee
-3/«" tolerance exposed underside -3/<" tolerance
[-19 mm]
Bearing pad by design
[-19 mm]
-I V-T 4 Bearing pad by design
[19mm) Holdback as req'd [19mm] Holdback as req'd
-
—| BIdg. elevation datum |
Hollowcore elevation Double tee elevation

Precast element to: precast, cast-in-place concrete, masonry or structural steel support

98
12.2 Floor and Roof Member Erection Tolerances

The primary control surfaces are usually as shown . A majority of the time there is no designated
vertical primary control surface, and in some scenarios there are no primary control surfaces at all.
This needs to be determined on a job-by-job basis.

a = Plan location from building grid datum ±1 in. [±25 mm]

a! = Plan location from centerline of steel support* ±1 in. (±25 mm]

b = Top elevation from building elevation datum at member ends:

Covered with topping ±.%. [±19 mm]
Pretopped tee/carpet direct hollow-core ±'A in. [±6 mmj
Untopped roof ±% in. [±19 mm]

= Maximum jog in alignment of matching edges

(both topped and untopped construction) 1 in. [25 mm]

= Joint width:
0 to 40 ft. member ±1/2 in. [±13 mm]
41 to 60 ft. member ±3A in. [±19 mm]

.........
61 ft. plus member ±1 in. [±25 mm]

e = Differential top elevation as erected {for units of same design and length):
Field topped % in. [19 mm]
Pretopped tees at driving lanes/carpet direct hollow-core 'A in. [6 mm]
Untopped roof1' % in. [19 mm]

f = Bearing length* (span direction) ±% in. [±19 mm]

g = Bearing width* (n/a for hollow-core) ±y? in. [±13 mm]

h = Differential bottom elevation of

exposed hollow-core slabs5 % in. [6 mm]

Note: When bearing pads are used at unarmored edges they should be set back a minimum of 1/2
in. [ 13 mm] from the face of the support or at least the chamfered dimension at chamfered edges.

* For precast concrete erected on a steel frame building, this tolerance takes precedence over toler¬
ance on dimension "a".
1 1t may be necessary to feather the edges to ±% in. [±6 mm] to properly apply some roof mem¬
branes.

* This is a setting tolerance and should not be confused with structural performance requirements
set by the architect/ engineer. The nominal bearing dimensions and the allowable variations in the
bearing length and width should be specified by the engineer and shown on the erection drawings.
§
Untopped installations will require a larger tolerance.

99
Fig. 12.3.1 Column Erection Tolerances

d d

o Bldg. grid
datum

-4fO
Plan view

Splice
Vertical primary
control surface

Horizontal primary
control surface
(at first corbel)

Bldg. elevation
datum

Bldg. grid
Bldg. elevation
datum
datum
Elevation Elevation

100
12.3 Column Erection Tolerances

The primary control surfaces are usually as shown, although this needs to be confirmed on a
job-by-job basis.

a = Plan location from building grid datum:

Structural applications ±'/2Ín. [±13mm]
Architectural applications ±% in. [±9mm]

b = Top elevation from nominal top elevation:

Maximum low Vá in. [13 mm]
Maximum high Va in. [6 mm]

c = Bearing haunch elevation from nominal elevation:

Maximum low Vz in. [13 mm]
Maximum high V« in. [6 mm]

d = Maximum plumb variation over height of element (element

in structure of maximum height of 100 ft. [ 30 m]) 1 in. [25 mm]

e = Plumb in any 10 ft. [3 m] of element height in. [6 mm]

f = Maximum jog in alignment of matching edges:

Architectural exposed edges V* in. [6 mm]
Visually non-critical edges Vz in. [13 mmj

101
Fig. 12.4.1 Structural Wall Panel Erection Tolerances

|" BIdg. grid

datum

Vertical primary
control surface
Horizontal
primary
control
surface
g-*" *
fJ ,_ÿl
t
— -h

Precast
concrete
panel

E
"e
CO

Cast-in-place .
2
o
T. foundation or
precast
°
b
BIdg.
b
I

concrete Elevation
— Cast-in-place or support ~~
Datum"
precast concrete
IKJB
n=TT@n=Mi=m-
— Nominal joint width

Plan Section Elevation

Precast element to precast or cast-in-place concrete or masonry

BIdg. grid
j-«— h
datum
Vertical primary
control surface
Horizontal
primary
conlrol
V
surface

Support member

'10

é=í-
Steel BIdg. grid
structure datum

9 of steel structure Section

n Nominal joint width
Plan Elevation

Precast element to structural steel

102
12.4 Structural Wall Panel Erection Tolerances

The primary control surfaces are usually as shown, although this needs to be confirmed on a
job-by-job basis.

a = Plan location from building grid datum ±'/z in. [±13 mm]

±V¿ in. [±13 mm]

a-i = Plan location from centerline of steel support

b = Top elevation from nominal top elevation:

Exposed individual panel ±V4 in. [±13 mm]
Non-exposed individual panel ±% in. [±19 mm]
Exposed relative to adjacent panel ±Vz in. [±19 mm]
Non-exposed relative to adjacent panel ±3A in. [±19 mm]

c = Support elevation from nominal elevation:

Maximum low 1/2 in. [13 mm]
Maximum high V* in. [6 mm]

d = Maximum plumb variation over height of

structure or over 100 ft. which ever is less* 1 in. [25 mm]

e = Plumb in any 10 ft. of element height % in. [6 mm]

f = Maximum jog in alignment of matching edges V& in. [13 mm]

g = Joint width (governs over joint taper) ±% in. [±9 mm]

h = Joint taper over length of panel Vfe in. [13 mm]

h-io = Joint taper over 10 ft. length % in. [9 mm]

i = Maximum jog in alignment of matching faces:

Exposed to view % in. [9 mm]
Non exposed to view 3A in. [19 mm]

j = Differential bowing or camber as erected

between adjacent members of the same design V2 in. [13 mm]f

* For precast buildings in excess of 100 ft. tall, tolerances "a" and "d" can increase at the rate of Va
in. [3 mm] per story to a maximum of 2 in. [50 mm].
t Refer to Article 8 for description of bowing tolerance.

103
Fig. 12.5.1 Architectural Walls/Spandrel Erection Tolerances

BIdg. grid
datum Horizontal primary
control surface

Vertical primary
control surface

4 of steel BIdg.
elevation
support
_ Support datum
member

Plan view Side view Elevation view

Walls Walls Walls

BIdg. grid
datum Horizontal primary '10
control surface

Vertical primary
control surface <> <>

BIdg.

i
of steel elevation
support _ Support datum
member Ar- At-

Plan view Side view Elevation view

Spandrels Spandrels Spandrels

104
12.5 Architectural Walls/Spandrel Erection Tolerances

.................
The primary control surfaces are usually as shown, although this needs to be confirmed on a
job-by-job basis.

a = Plan location from building grid datum* ±1/2 in. [±13 mm]

a-i = Plan location from centerline of steel support ±1/2 in. [±13 mm]

b = Top elevation from nominal top elevation:

Exposed individual panel ±% in. [±6 mm]
Non-exposed individual panel ±Vi in. [±13 mm]

c = Support elevation from nominal elevation:

Maximum low Vz in. [13 mm]
Maximum high V* in. [6 mm]

d = Maximum plumb variation over height of structure

or 100 ft. [30 m] whichever is less* 1 in. [25 mm]

e = Plumb in any 10ft. [3 m] of element height V* in. [6mm]

f = Maximum jog in alignment of matching edges:

Exposed relative to adjacent panel V* in. [6 mm]
Non-exposed relative to adjacent panel in. [13 mm]

g = Joint width (governs over joint taper) ±% in. [±6 mm]

h = Joint taper maximum 3/e in. [9 mm]

h-10 - Joint taper over 10 ft. [3 m] length Vi in. [6 mm]

i = Maximum jog in alignment of matching faces V* in. [6 mm]

j = Differential bowing or camber as erected between

adjacent members of the same design % in. [6 mm]

k = Opening height between spandrels ±% in. [±6 mm]

* For precast buildings in excess of 100 ft. tall, tolerances "a" and "d" can increase at the rate of Va
in. [3 mm] per story to a maximum of 2 in. [50 mm],

t For precast elements erected on a steel frame, this tolerance takes precedence over tolerance on
dimension "a".

105
Fig. 12.6.1 Single and Double Stadium Riser Erection Tolerances

Riser unit
Theoretical
(£of support

Bldg. grid or
datum (typ)

s
,_J.
i
h Vertical primary
control surface

To allow for
-1" (-25 mm} Plan view
tolerance
I-
(25 mm) — Holdback as required
Shims per design

Horizontal primary
control surface

Bldg. grid or
datum (typ) Elevation view
Horizontal primary
control surface e
Vertical primary
ITU-T! g°n
control surface

t~T
ZJ
Riser cross section

106
12.6 Stadium Riser Erection Tolerances
The primary control surfaces are usually as shown, although this is something that needs to
be confirmed with the contractor on job-by-job basis.

a = Plan location from building grid line datum ±1 in. [±25 mm]

b = Plan location from theoretical centerline of

support structure ±1 in. [±25 mm]

c = Top elevation from building elevation datum at

members end. (This datum may be adjusted to
accommodate existing field conditions.) ±'/2 in. [±13 mm]

d = Maximum jog in alignment of matching edges

at the horizontal primary control surface Vk in. [6 mm]

e = Maximum jog in alignment of matching edges

at the vertical primary control surface Vz in. [13 mm]

f = Bearing in span direction -1 in. [-25 mm]

g = Joint width (horizontal) at end of piece (Joint

width needs to be V* in. [6mm] minimum) ±n/z in. [±13 mm]

h = Joint width (Joint width needs to be % in. [6 mm) minimum in either case)

...........................
............
90° angle ±1/2 in. [±13 mm]
Joint width at skewed ends ±5/e in. [±16 mm]

j = Differential camber (at mid-span as erected) between adjacent members of the same de¬
sign ±3/i6 in. [±5 mm] per 10 ft. [3 m] of member length.

k = Differential sweep (at mid-span as erected) between adjacent members of the same de¬
sign ±3/i6 in. [±5 mm] per 10ft. [3 m] of member length.

Note: Local building codes may require more restrictive riser height tolerances which could also
affect product tolerance.

107
Fig. 12.8.1 Stair Unit Erection Tolerance

Plan view
Building grid
or datum (typ)

Primary control surface

Intermediate landing

Line of topping
pan (if applicable)

Elevation view

110
12.8 Stair Unit Erection Tolerance

The primary control surface for stair units is the top of landing at floor levels. Tolerances listed
below are the same whether landings are monolithic or separate pieces.

a = Plan location from building grid line datum ±Vi in. [±13mm]

b = Differential elevation as erected* ±3/s in. [±9mm]

c = Joint width ±3A in. [±19 mm]

d = Maximum jog in alignment of matching edges 1 in. [25 mm]

e = Maximum jog in alignment of stair tread nosings

(This tolerance overrides "d" if needed) V2 in. [13 mm]

f = Maximum jog in alignment of matching edges

at the primary control surface* % in. [9 mm]

g = Bearing (in span direction) ±3A in. [±19 mm]

Note: Local building codes may require more restrictive riser height tolerance which could also af¬
fect product tolerance.

* At stair units that have pre-topped precast landings, the maximum jog between stair units as well
as from stair unit to finish floor can not exceed V* in. However, units which have landings that are
topped have more leeway. This needs to be discussed and agreed upon with the general contrac¬
tor.

111