6/8/2016

Troubleshooting Concrete Forming and Shoring

(four-part webinar)
Part 3 – Form Removal and Tolerances
This Webinar is sponsored by ACI. The ideas expressed, however, are those
of the speakers and do not necessarily reflect the views of ACI or its
committees. The audience is expected to exercise judgment as to the
appropriate application of the information.
Please adjust your audio level at this time.

WEBINAR

• For continuing education credit, attendance for the entire duration of the
webinar will earn you a certificate of completion for 2 PDH (0.2 CEU). Your
certificate will be available in ACI University under the Certificates tab
within two days.

• For those who cannot join us live; the on-demand recording and quiz will
be made available about a week after the LIVE presentation. Successful
completion of the quiz will earn the certificate.

• Certificates will be available in ACI University under the Certificates tab.

• Questions related to specific materials, methods, and services will be

addressed at the conclusion of this presentation.

WEBINAR 7

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American Concrete Institute is a Registered Provider with The American

Institute of Architects Continuing Education Systems (AIA/CES).
Credit(s) earned on completion of this online course will be reported to
AIA/CES for AIA members.

The online course based on this webinar is registered with AIA/CES for
continuing professional education. As such, it does not include content that
may be deemed or construed to be an approval or endorsement by the AIA
of any material of construction or any method or manner of handling, using,
distributing, or dealing in any material or product.

The American Institute of Architects has approved this course for

2.0 AIA/CES LU Learning Unit.

The American Institute of Architects has approved

this course for 2.0 AIA/CES LU learning unit.
ACI is an AIA/CES registered provider.

WEBINAR 8

Troubleshooting Concrete Forming and Shoring

Part 3 – Form Removal and Tolerances

Course Description:
This four part webinar will present content on Troubleshooting Concrete Forming and Shoring.
Presentations will cover forming systems and economics; loads and pressures; shoring, reshoring and
stripping; eliminating costly rework for out of tolerance alignment; techniques to avoid formed surface
imperfections; and avoiding problems resulting from premature shoring removal.

WEBINAR 9

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Troubleshooting Concrete Forming and Shoring

Part 3 – Form Removal and Tolerances

Learning Objectives:
• Discuss the standard form stripping times in ACI 347.
• Summarize the testing methods used to evaluate concrete strength for
determining formwork removal, including: field-cured cylinders, penetration
resistance, pullout test, break-off test, and the maturity method.
• Identify the importance of tolerances in concrete construction.
• Determine how and when to measure tolerances.

WEBINAR

Kim Basham, PhD, PE, FACI

Kim D. Basham, PhD, PE and President of KB Engineering,
LLC located in Cheyenne, Wyoming is a member of the
American Concrete Institute, The Concrete Society, American
Society of Concrete Contractors, and the American Society of
Civil Engineers. He is a member of ACI 306, Cold Weather
Concreting and instructor in the ACI certification program for
field technicians and craftsmen. He holds a Bachelor and
Master of Science in Structural Engineering from Virginia
Polytechnic Institute and State University and a PhD in
Structures from the University of Wyoming. Prior to founding
KB Engineering, he was a principal with Concrete Engineering
Specialists and worked as a structural engineer for Structural
Services, Inc. and Baker Concrete Construction. Dr. Basham
specializes in concrete design and technology, concrete
construction and troubleshooting, nondestructive testing,
forensic investigations, and concrete repair.

WEBINAR 11

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David Johnston, PhD, PE, FACI

Dr David Johnston, PhD, PE, and Edward I. Weisiger
Distinguished Professor Emeritus is the author of the 8th
edition of ACI SP4 Formwork for Concrete published in 2014.
He received his degrees at North Carolina State University, a
BS in Civil Engineering Construction Option, MS in Civil
Engineering, and PhD in Civil Engineering. Following 7 years
of industry experience as engineer and partner of firms in the
Connecticut/New York area, he joined the North Carolina State
University faculty where he served in the Department of Civil,
Construction, and Environmental Engineering until his
retirement.
He is a Fellow of the American Society of Civil Engineers, a
Fellow of the American Concrete Institute, an Honorary
Member of the Professional Construction Estimators
Association, and a member of the National Academy of
Construction.

WEBINAR 12

Troubleshooting Concrete Forming and Shoring

Form Removal

David W. Johnston
North Carolina State University
June 2016

WEBINAR 13

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Form Removal in Multi-story Buildings

WEBINAR 14

Resources

• ACI 301-10 Specifications for Structural Concrete

• ACI 318-14 Building Code Requirements for Structural
Concrete
• ACI 347R-14 Guide to Formwork for Concrete
• ACI 347.2R-05 Guide for Shoring/Reshoring of
Concrete Multistory Buildings
• ACI SP-4 8th Ed. (2014) Formwork for Concrete

WEBINAR 15

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Removal of formwork – vertical surfaces

ACI 301 Default
2.3.2.1 When vertical formed surfaces require finishing, remove
forms as soon as removal operations will not damage concrete.

2.3.2.2 Remove top forms on sloping surfaces of concrete as soon

as removal will not allow concrete to sag. Perform needed repairs
or treatments required at once and follow immediately with
specified curing.

2.3.2.3 Loosen wood formwork for wall openings as soon as

loosening operations will not damage concrete.

2.3.2.4 Do not damage concrete during removal of vertical

formwork for columns, walls, and sides of beams. Perform
needed repair and treatment required on vertical surfaces that
day and follow immediately with specified curing.

WEBINAR 16

Removal of formwork – horizontal surfaces

ACI 301 Default

• 2.3.2.5 Unless otherwise specified or

permitted, leave formwork and shoring in
place to support construction loads and
weight of concrete in beams, slabs, and
other structural members until in-place
strength of concrete determined in
accordance with 2.3.4 is at least fc′ .

WEBINAR 17

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Removal of formwork – horizontal surfaces

ACI 301 Default

• 2.3.2.5 …. Unless otherwise specified,

when shores and other supports are
arranged to allow removal of form-facing
material without allowing structural slab or
member to deflect, form-facing material
and its horizontal supporting members may
be removed at an earlier age.

WEBINAR 18

ACI 347R-14 Guide to Formwork for Concrete

• The Engineer/Architect should specify the

minimum compressive strength of the concrete to
be attained before removal of forms or shores.

• Determination of the concrete strength for form

removal should be based on the resulting effect
on the concrete structure:
• Overloading
• Cracking
• Excessive Early Creep Deflections

WEBINAR 19

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Slab Cracking

Excessive negative moment region cracking may be due to

early form removal, early shore loading, or structural
deficiency.

WEBINAR 20

Slab Deflection

Clearly the gap shown resulted from loading or creep after

the masonry wall was constructed and is not due to early
form removal.

WEBINAR 21

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ACI 347R - Form Stripping Time Guidelines

• Based on cumulative days or hours during which the

surrounding air is above 50 oF.
• Walls…………………………… 12 hr
• Columns…………………….… 12 hr
• Beam and girder sides………. 12 hr
• Pan Joist (30” wide or less).… 3 days
• Pan Joist (over 30” wide)……. 4 days
For further info and stripping times for slabs, see ACI 347R

WEBINAR 22

When can post-tensioned slabs be stripped?

• ACI 347R-14
• As soon as full post-tensioning has been applied
Special Considerations:
• Load redistribution that occurs on shores when slabs
and beams are post-tensioned.
• Factors to be considered:
• Members to be post-tensioned
• Design service dead loads and live loads
• Post-tensioning sequence & stressing levels
• See ACI 347.2R

WEBINAR 23

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Best to use strength as a basis

• Field cured cylinders account for

temperature differences (cold or hot)
• Faster stripping time → faster construction
schedule
• Faster stripping time → more economical
construction

WEBINAR 24

Contractors Consider

• Submitting a new mix design that

increases the 1 to 3 day strength
• Trade off in cost between concrete mix and
faster construction plus faster form reuse
• May suggest to increase design live load if
project is still in design phase

WEBINAR 25

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ACI 301-10 Section 2.3.4 Strength of Concrete

Required for Removal of Formwork

• 2.3.4.1 When removal of formwork,

reshoring, or backshoring is based on
concrete reaching a specified compressive
strength, concrete is presumed to have
reached this strength when test cylinders,
field cured the same as the concrete they
represent, have reached compressive
strength specified.

WEBINAR 26

2.3.4 Strength of Concrete Required for

Removal of Formwork

• 2.3.4.2 Alternatively, when specified or

permitted, use one or more of the methods
listed in 2.3.4.2.a through 2.3.4.2.d to
evaluate concrete strength for formwork
removal. Before using methods in
2.3.4.2.b through 2.3.4.2.d, submit data …
to demonstrate correlation of results of in-
place test with compressive strength …

WEBINAR 27

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ACI 301 - Concrete Testing for Form Removal

• 2.1.2.1.c Testing for formwork removal—

Submit data on method for determining
concrete strength for formwork removal in
accordance with 2.3.4.2 when a method
other than field-cured cylinders is
proposed.

WEBINAR 28

ACI 318-14 and 301-10 Allow the Following

Test Methods

• Field Cure Cylinders (ASTM C31 & C 39)

• Cast-in-place Cylinders (ASTM C 873)

• Penetration Resistance* (ASTM C 803)

• Pullout Strength* (ASTM C 900)

• Maturity-Factor* (ASTM C 1074)

* require correlation to project concrete mix used

WEBINAR 29

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Need In-place Strength for …

• Form removal
• Application of post-tensioning
• Shore and reshore removal
• Application of shore loads for next level cast
• Rapid scheduling and safety

Especially during cold weather concreting

WEBINAR 30

Cold Weather Slows Strength Gain

From PCA’s Design &

Control of Concrete
Mixtures

WEBINAR 31

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Early Form Removal …

• Speeds up construction
• Requires less form/shoring inventory
• Allows other trades early access
• Earlier completion date
• Reduces Cost

WEBINAR 32

Contractors need a …

• Simple
• Economical
• Reliable

method to determine
in-place strength.

WEBINAR 33

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Field-cured Cylinders (ASTM C31 & C 39)

• Cured same as and with the structure

• Still have some temperature differences
• Commonly used - simple & economical
• Should be accurate IF cylinders are maintained
at same temperature as concrete in structure

WEBINAR 34

Field-cured Cylinders - Match Curing

Cylinders cured at same temperature as that measured in

concrete
• Temperature sensor in concrete member cast
• Controller
• On-site curing box with built-in heating/cooling system
to match water bath cure to concrete member
temperature.
Originally used in precast/prestress plants for verifying release
strength, but has been applied for stripping and construction loading
strength.

WEBINAR 35

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Field-cured Cylinders - Match-cure System

Controller can heat or cool Embedded sensors send concrete

water bath to follow measured temperature to controller by
concrete temperature hardwire or wireless relay

WEBINAR 36

Cast-in-place Cylinders (ASTM C 873)

Multi-part adjustable height 4 in. dia. mold. Required

cylinder height of 5 to 12 in.

WEBINAR 37

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Penetration Resistance (ASTM C 803)

Probe, charge, driver, and

measuring unit

WEBINAR 38

¼” Steel Probe Shot Into Concrete

Commonly called
Windsor Probe

WEBINAR 39

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Penetration Depth vs. Concrete Strength

WEBINAR 40

Pullout Test (ASTM C 900)

Pull machine with digital readout of

maximum pullout force.
Inserts are attached to form with
removable plug before concreting.
Can also be hand set & floated
into fresh concrete.

WEBINAR 41

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Pullout Test (ASTM C 900)

Pullout load can be

correlated to concrete’s
compressive strength

Shear cone failure

WEBINAR 42

Maturity Method (ASTM C 1074)

Thermal History vs. Strength

WEBINAR 43

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Using Maturity Method to Predict Concrete

Strength

The Strength-Maturity Relationship

• The maturity method is a technique for predicting
concrete strength based on the temperature
history of the concrete.
• Strength increases as cement hydrates. The
amount of cement hydrated depends on how
long the concrete has cured and at what
temperature.
• Maturity is a measure of how far hydration has
progressed.

WEBINAR 44

Using Maturity Method to Predict Concrete

Strength
• The most common expression used for maturity is the
M

Ta
T0
t

maturity, M:

   
• Where:
• Ta = average concrete temperature during each time interval
• T0 = datum temperature below which cement hydration is
assumed to cease (23 - 32 ºF determined by test). ASTM C 1074
• t = time intervals, usually hours or half hours
•  = summation of all the intervals of time multiplied by their
average temperature difference (Ta – T0).

WEBINAR 45

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Using Maturity Method to Predict Concrete

Strength
• Procedure to Develop Strength-Maturity Relationship
1. Prepare at least 15 cylindrical concrete specimens. The mix
proportions and constituents of the concrete shall be similar to those
of the concrete whose strength will be estimated using this practice.
2. Embed temperature sensors at the centers of at least two specimens.
Connect sensors to maturity instruments or to temperature-recording
devices.
3. Moist cure the specimens in a water bath or in moist room.
4. Perform compression tests at ages of 1, 3, 7, 14, and 28 days. Test
two cylinders at each age and compute the average strength.
5. At each test age record the average maturity for the instrumented
specimens.

WEBINAR 46

Using Maturity Method to Predict Concrete

Strength
• Procedure to Develop Strength-Maturity Relationship
6. Plot the average compressive strength as a function of the average value
of the maturity. Draw the best-fit curve through the data. The resulting
curve is the strength-maturity relationship to be used for estimating the
strength of the concrete.

WEBINAR 47

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Estimating Strength Based on Maturity

1. Embed temperature sensors into the fresh concrete.
2. Connect sensor to maturity meter or temperature-recording
devices and activate the recording as soon as practicable.
3. Enter with measured field maturity value.
4. Read compressive strength.

Established maturity vs.

strength relationship

From ACI 306

Cold Weather
Concreting

WEBINAR 48

Maturity Measurement – Example Devices

Multi-channel maturity meter

Require continuous connection

Thermocouple wire is embedded

into concrete

WEBINAR 49

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Maturity Measurement – Example Devices

Plug in download/readout device

Embedded maturity logger

contains: memory chip,
temperature sensor,
microcomputer & battery

WEBINAR 50

Maturity Measurement – Example Devices

Plug in download/readout device

Embedded maturity logger

contains: memory chip,
temperature sensor,
microcomputer & battery

WEBINAR 51

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Maturity Measurement – Example Devices

Wireless link to nearby smartphone.
Load App with maturity-strength data from
ASTM C 1074 lab test.
Turn on maturity meter embedded in
concrete with App and check maturity and
strength when needed.

WEBINAR 52

Summary

• Field-cured Cylinders
• Cast-in-place Cylinders
• Penetration Resistance*
• Pullout Strength*
• Maturity Method*

* Requires lab calibration to actual mixture used

WEBINAR 53

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ACI 347R: Stripping Sequence for Two-way Slabs

WEBINAR 54

Stripping Safety

Accidents Usually Happen During Form

Removal NOT Form Placement

WEBINAR 55

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Stripping Safety

WEBINAR 56

Stripping Safety

WEBINAR 57

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Stripping Safety

WEBINAR 58

Stripping Safety

Forklift Pan Rack

Scissor lift
supporting worker
with pry tool

Worker with rod pry

tool

Watch person

WEBINAR 59

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Stripping Safety

WEBINAR 60

Questions?
Troubleshooting Concrete Forming and Shoring
Part 3 – Form Removal and Tolerances

Form Removal

WEBINAR 61

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Troubleshooting Concrete Forming and Shoring

Tolerances in Concrete Construction

Kim Basham
KB Engineering, LLC
June 2016

WEBINAR 62

What is a Tolerance?

1. Permitted variation from a

specified dimension or quantity.

2. Range of variation permitted in

maintaining a specified dimension.

3. Permitted variation from location

or alignment.

WEBINAR 63

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Why Do We Need Tolerances?

• No structure is exactly level,

plumb, straight and true.

• Perfection is not necessary.

• Gives both the designer and

contractor a communication tool.

WEBINAR 64

How are Tolerances Selected?

• Strength and function requirements

• Aesthetics
• Economic feasibility
• Relationship of all components
• Construction techniques
• Properties of materials
• Compatibility with other trades
• Job conditions
• Measurement accuracy
WEBINAR 65

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Who Should Interpret Tolerances?

• General Contractor

• Construction Manager

• Other Trades

• Owner

• Architect and Engineer

• Lawyers: Last Resort that shouldn’t be

WEBINAR 66

Tolerance Awareness

Construction Team must deal with tolerances

before construction commences:
• Identify tolerances

• Evaluate tolerance compatibilities

• Establish means to interpret tolerances

• Establish timing when to measure

• Establish acceptance criteria

WEBINAR 67

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Tolerance Interpretation

Reference Documents
• ACI 117-10 - Specification for Tolerances for Concrete
Construction and Materials and Commentary
• ACI 117.1R-14 - Guide for Tolerance Compatibility in
Concrete Construction
• ACI 301-10 - Specifications for Structural Concrete
• ACI 347-14 - Guide to Formwork for Concrete
• Tolerances for Cast-n-Place Concrete Buildings,
Suprenant, B. A. and Malisch, W. R., ASCC
WEBINAR 68

ACI 301 Specifications for Structural Concrete

1.7 Acceptance of structure

1.7.1 General
1.7.2 Dimensional tolerances
1.7.3 Appearance
1.7.4 Strength of structure
1.7.5 Durability

WEBINAR 69

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ACI 301 Specifications for Structural Concrete

1.7.2 Dimensional Tolerances

In General:

• Smaller size than permitted by the tolerances of ACI

117, may be considered deficient in strength.

• Larger size than permitted by ACI 117 may be

rejected. Remove excess materials when required by
the Architect/Engineer.

• Inaccurately formed concrete surfaces that exceed

ACI 117 tolerances may be rejected.

WEBINAR 70

ACI 301 Specifications for Structural Concrete

1.7.2 Dimensional tolerances

1.7.2.1 Unless otherwise specified,

construction tolerances shall conform
to ACI 117.

WEBINAR 71

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ACI 301 Specifications for Structural Concrete

Reject Concrete
• Remove and Replace
• Reinforce with Additional Construction

Repair Concrete
• Maintain Minimum Specified Strength
• Meet Requirements for:
• Function
• Durability
• Dimensional Tolerances
• Appearance

WEBINAR 72

Doesn’t Meet Tolerances:

Be Practical – Let Reason Prevail

• Remove and replace

• Repair
• Pay for other issues
• Reason to hold contractor’s retainage
• ACI documents do not provide means
of assessing whether the tolerance has
an effect on function, performance or
appearance of the building

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Does out-of-tolerance work affect…

1. Strength ?
2. Function ?
3. Serviceability ?
4. Other Trades ?
5. Appearance ?

WEBINAR

Why Understand ACI 117?

Specification for Tolerances for Concrete Construction and Materials and Commentary

• Architect/Engineer may cite in project

specification

• ACI 301 - Specifications for Structural

Concrete cite ACI 117

• Used as an industry standard

WEBINAR 75

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ACI 117-10

• Foreword
• Side by side format
• Tolerances on left side
• Commentary on right side

WEBINAR 76

ACI 117-10: Contents

1. General Requirements
2. Materials
3. Foundations
4. Cast-in-place concrete for buildings
5. Cast-in place concrete at interface with
precast concrete (except tilt-up concrete)
6. Masonry concrete—removed in this version
7. Cast-in-place, vertically slipformed building
elements

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ACI 117-10: Contents

8. Mass concrete
9. Canal lining
10. Monolithic water conveying tunnels,
siphons, and spillways
11. Cast-in-place bridges
12. Exterior pavements and sidewalks
13. Chimneys and cooling towers
14. Cast-in-place nonreinforced pipe
15. Tilt-up concrete

WEBINAR 78

ACI 117-10 But First…

Section 1 – General

1.1 Scope
1.2 Requirements
1.3 Definitions
1.4 Referenced standards

WEBINAR 79

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ACI 117, 1.1 Scope

1.1.1 This specification designates

standard tolerances for concrete
construction.

1.1.2 The indicated tolerances govern

unless otherwise specified.

WEBINAR 80

ACI 117, 1.1.3 Scope

• A preconstruction meeting shall be held.

• All parties shall be given the opportunity
to identify any tolerance questions and
conflicts that are applicable to their work.
• Questions should be resolved before the
beginning of applicable construction.

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ACI 117, 1.2.3 Requirements

1.2.3 Tolerances are not cumulative.

The most restrictive tolerance
controls.

WEBINAR 82

ACI 117, 1.2.4 Requirements

• Plus (+) tolerance increases the amount or

dimension to which it applies, or raises a
deviation from level.

• Minus (-) tolerance decreases the amount or

dimension to which it applies, or lowers a
deviation from level.

• Where only one signed tolerance is specified

(+ or -), there is no limit in the opposing
direction.
WEBINAR 83

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ACI 117 Section 2 - Materials

2.2 Reinforcement Location
2.2.1 Placement of Std. Reinforcement Formed
Surfaces
Thickness is 4 in. or less . . . . . . ± 1/4 in.
Thickness over 4 in. but not over 12 in.
Vertical
. . . . . . . . . . . . . . . . . . . . . . . . . . . ± 3/8 in. Tolerance
Thickness is over 12 in. . . . . . . ± 1/2 in.
Horizontal
Tolerance
2.2.2 Concrete Cover
Thickness is less than 12 in. . . – 3/8 in.
Formed
Thickness is over 12 in. . . . . . . . – 1/2 in. Surface
Reduction in cover shall not exceed 1/3 of
specified concrete cover
Tolerance
Measured from formed surfaces. Specified
Cover
WEBINAR

WEBINAR
Where do we measure the concrete cover?

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ACI 117 Section 4 -

Cast-in-Place Concrete for Buildings
4.1 Deviation from plumb
4.2 Deviation from location
4.3 Not used
4.4 Deviation from elevation
4.5 Deviation from cross-sectional dimensions
4.6 Deviation from formed opening width or height
4.7 Deviation from relative elevations or widths for stairs
4.8 Deviation from slope or plane
4.9 Sawcut depth in slab-on ground

WEBINAR 86

4.1 Deviation from Plumb

WEBINAR 87

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6” 6”
The face of the wall may deviate
horizontally ±6” from the location
shown on the drawings.
500’-0”

The face of the wall may deviate

horizontally from the location shown on
the drawings by an amount ±0.1% of
the height above the top of foundation.

83’-4”

The face of the wall may deviate horizontally

±1” from the location shown on the drawings.
Face of wall as shown on
drawings

Top of foundations as shown on

drawings
1” 1”

WEBINAR 88

4.1 - Deviation from Plumb

4.1.1 For heights less than or

equal to 83 ft 4 in. (25.4 m)

For lines, surfaces, corners,

arises and elements: the lesser
of 0.3% times the height above
the top of foundations as shown
on structural drawings or ±1 in.
(25 mm)

WEBINAR 89

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4.1 - Deviation from Plumb

4.1.1 For heights less than

or equal to 83 ft 4 in. (25.4 m)

For outside corner of an exposed

corner columns and control joint
grooves exposed to view: the
lesser of 0.2% times the height
above the top of foundations as
shown on structural drawings or
±1/2 in. (13 mm)

WEBINAR 90

4.1 - Deviation from Plumb

4.1.2 For heights greater

than 83 ft 4 in. (25.4 mm)

For lines, surfaces corners,

arises and elements: the lesser
of 0.1% times the height above
the top of foundations as shown
on structural drawings or ±6 in.
(152 mm)

WEBINAR 91

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4.1 - Deviation from Plumb

4.1.2 For heights greater than

83 ft 4 in. (25.4 mm)

For outside corner of an exposed

corner columns and control joint
grooves exposed to view: the
lesser of 0.05% times the height
above the top of foundations as
shown on structural drawings or
3 in. (76 mm)

WEBINAR 92

4.1 - Deviation from Plumb

4.1.3 Vertical edges of

openings larger than
12 in.

Measured over full height

of opening ½ in.

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4.2 - Deviation from Location

4.2.1 Horizontal deviation

• Vertical Elements, measured at
top of element foundation ±1
in. (25 mm)
• Other Elements ±1 in. (25 mm)
• Edge location of all openings
±1/2 in. (13 mm)
• Sawcuts, joints, & weakened
plane embedments in slabs
±3/4 in. (19 mm)
WEBINAR 94

4.2 - Deviation from Location

4.2.2 Vertical deviation

Elements ± 1 in.

Edge location of all

openings ± ½ in.

WEBINAR 95

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4.4 - Deviation from Elevation

4.4.1 Top surface of slabs

Formed suspended slabs, before removal of
supporting shores ±3/4 in. (19 mm)
Slabs on structural steel or precast concrete -- no
requirement

4.4.2 Formed surfaces before removal of shores

±3/4 in. (19 mm)

4.4.4 Top of walls ±3/4 in. (19 mm)

WEBINAR 96

4.5 - Deviation from Cross-Sectional

Dimensions
4.5.1 Thickness of elements,
except slabs, where specified
dimension is
12 in. or less +3/8 in. -1/4 in.

More than 12 in. and not more

than 36 in. +1/2 in. -3/8 in.

Over 36 in. +1 in. -3/4 in.

4.5.3 Thickness of suspended slabs -1/4 in.

WEBINAR 97

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4.6 - Deviation from Formed Opening Width

or Height

4.6.1 Opening width or

height: –1/2 in. +1 in. Width Deviation

Height
Deviation

Tolerance - ½ in.; +1 in.

WEBINAR 98

4.7 - Deviation from Relative Elevations or

Widths for Stairs
4.7.1 Stairs, measured along a line parallel to
the stair axis

Difference between largest and smallest tread or

riser in any flight shall not exceed 3/8 in.

Difference in height of adjacent risers measured at

the nose shall not exceed 3/16 in.

Difference in depth of adjacent treads shall not

exceed 3/16 in.

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Cast-In-Place Stair Tolerances

Nosing (9/16 in. max. radius)

Riser Heights*
Riser A Riser Height = A + B
IBC: 4 to 7 in.

Tread B

Tread
Tread Depths*
Depth
IBC: 11 in. Minimum

*Tolerances 30o Max.

Landing
 3/8 in. between largest and smallest tread depth and Depth**
riser height in any flight of stairs (ACI 117, Life
Safety Code)
 3/16 in. between the height and depth of adjacent
risers and tread depths (ACI 117, Life Safety Code)
Landing
**Minimum Landing Depths
2% (1/4 in. per ft.) max. slope
IBC: 48 in. in any direction
*** ACI 117 4.8.1 Deviation from Slope or Plane

WEBINAR

4.8 - Deviation from Slope or Plane (ACI 117)

4.8.2 Formed surfaces

over distances of 10 ft.
All conditions, unless noted
otherwise in this section
±0.3%
Outside corner of exposed
corner column ±0.2% Out-of-plane
Deviation ≈ 3/8 in.
Contraction joint grooves in
concrete exposed to view
Specified Plane
±0.2%

WEBINAR 101

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ACI 301 Specifications for Structural Concrete

Maximum Deflection of Facing Forms

Exposed to Public: L/240 (2.2.2.4)

Architectural Concrete: L/400 (6.2.2.1.a)

WEBINAR 102

4.8 - Deviation from Slope or Plane

(ACI 117)
4.8.3 Formed surface irregularities (gradual or abrupt).
Abrupt irregularities shall be measured within 1 in. of the irregularity.
Gradual surface irregularities shall be measured by determining the
gap between concrete and near surface of a 5 ft straightedge,
measured between contact points.

Class A Surface +1/8 in.

Class B Surface +1/4 in.
Class C Surface +1/2 in.
Class D Surface +1 in.

WEBINAR 103

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Wall Tolerances

WEBINAR 104

Summary of Wall Tolerances

• Offset in adjacent pieces of formwork

• Abrupt or gradual irregularities
• Form finish
• Thickness
• Lateral alignment (location)
• Vertical alignment (plumb)
• Relative alignment (form bow or sway)

WEBINAR 105

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Elevated Slab Tolerances

What tolerances apply when placing

concrete on a …
metal deck- open web joist floor?
or
precast concrete floor?

Contractors, be wary of slabs that must be placed

level if you are required to set screed elevations

WEBINAR 106

Placing Concrete on Cambered Beams

Ref. ASCC Position Statement #38 – Topping Slabs over Prestressed Members, www.ascconline.org
Ref. ASCC Position Statement #39 - Concrete Floors Slabs on Cambered Structural Steel

WEBINAR 107

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Placing Concrete on Deflected Beams

Ref. ASCC Position Statement #24 - Tolerances for Suspended Concrete Slabs, www.ascconline.org

WEBINAR 108

Compatibility Between
Cast-in-place Concrete and Other Trades
ACI 117.1R-14 - Guide for Tolerance Compatibility in Concrete Construction

Contents
1. Introduction and Scope

2. Definitions

3. Tolerance Coordination and

Responsibility

4. Creating Tolerance Compatibility

5. Tolerance and Methods of

Accommodating Tolerances

WEBINAR 109

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ASCC Position Statement #18 –

Concrete Tolerance Coordination
• Specifiers must coordinate tolerances
in the project specifications
• Engineers/architects should be
responsible for coordinating tolerances
for concrete work
• Contractors coordinate their own work
but not others
• Identified tolerance compatibility issues
• Elevator walls
• Concrete walls to be plastered
• Steel vs concrete anchor tolerances
• Full-height curtain walls

WEBINAR 110

Precast & Prestressed Tolerances

WEBINAR 111

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Curtain Wall Tolerances

WEBINAR 112

AISC Tolerances

WEBINAR 113

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From AISC, Code of Standard

AISC Bolt Tolerances Practice for Steel Buildings and
Bridges (AISC 303-10), Section 7.5

Variation in elevation of the tops of Anchor Rods

shall be equal to or less than plus or minus 1/2
in. [13 mm].

Variation in dimension between the centers of any

two Anchor Rods within an Anchor-Rod Group
shall be equal to or less than 1/8 in. [3 mm].

Accumulated variation in dimension

between centers of anchor-rod
groups along the column line through
multiple anchor-rod groups shall be
equal to or less than ¼ in. per 100 ft
[2 mm per 10 000 mm], but not to
exceed a total of 1 in. [25 mm].

WEBINAR 114

2.3.4 Anchor Bolts in Concrete (ACI 117)

2.3.4.1 Top of anchor bolt from specified elevation

Vertical deviation ±1/2 in.

2.3.4.2 Centerline of individual anchor bolts from

specified location*
3/4 in. and 7/8 in. bolts ±1/4 in.
1 in., 1¼ in. and 1½ in. bolts ±3/8 in.
1¾ in., 2 in., and 2½ in. bolts ±1/2 in.
*Based on using oversized holes in base plates per the AISC Design Guide 1: Base
Plates and Anchor Rod Design and recommendations of the Structural Steel
Educational Council, Ref. ASCC Position Statement #14 – Anchor Bolt Tolerances,
www.ascconline.org

WEBINAR 115

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AISC
Structural Steel Educational Council

States the following…

If bolts are misplaced up to 1/2 inch, the

oversized base plate holes normally allow the
base plate and column to be placed near or
on the column line.

If the bolts are misplaced by more than 1/2

inch, then corrective work is required.

WEBINAR 116

2.3 - Placement of Embedded Items

Horizontal deviation ± 1 in.

Vertical deviation ± 1 in.
Deviation from plane ± 1/2 in.
(Relative to as-built wall)

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Balcony Drainage

• After it rains, the balcony drains in wrong

direction

• The formwork placement is often accused

of being at fault

• Did the formwork create these problems?

WEBINAR 118

Plan View – Interior Balcony

4 5

23’- 0”

1’ – 6” Balcony
1’- 0”

A
7’- 0”

½”
27’- 0”

8” slab

WEBINAR 119

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Section – Interior Balcony

A
See Plan

Metal Stud Wall

Balcony See Plan

Brick Wall
See Details
Slope
½”

8”
7”

Concrete Slab
Column

WEBINAR 120

Deflected Shape – Interior Balcony

A
See Plan

Metal Stud Wall

Balcony
See Plan

Brick Wall
See Details

½”
8”
7”

Concrete Slab
Column

WEBINAR
Ref. ASCC Position Statement #19 - Balcony Drainage, www.ascconline.org 121

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Plan View – Cantilever Balcony

4 5

23’- 0”

Balcony
1’- 0” 7’- 0”

8’- 0”
½”
A

27’- 0”
8” slab
122

WEBINAR

Section – Cantilever Balcony

A
8’- 0” See Plan

Metal Stud Wall

Balcony See Plan

Brick Wall
See Details
Slope
½”
8”
7”

Concrete Slab
Column

WEBINAR 123

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Deflected Shape – Cantilever Balcony

A
8’- 0” See Plan

Metal Stud Wall

Balcony
See Plan

Brick Wall
Wrong
See Details Slope

½”
7”

8”
Concrete Slab
Column

WEBINAR 124

Elevator Tolerances
for Cast-in-place Concrete
5.4 in
36 floor
Elevator Tolerance
3.4 in A clear plumb hoistway with
20 floor
variations not to exceed 1”
at the first 20 floors and
2 in 100 ft
1/32 inch increase for each
additional floor up to a
maximum of 2”.

± 1 in
WEBINAR

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Openings Formed By Floors and Columns

WEBINAR 126

Fitting Metal Curtain Walls

WEBINAR 127

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Opening Tolerances for Metal Curtain Walls

Opening Tolerances
Edge locations ± 1/2 in.
Size -1/2 in. + 1 in.

?
Deviations: Elevation & Horizontal Location
Slabs ± 3/4 inch
Columns ± 1 inch ?
WEBINAR 128

Questions?
Troubleshooting Concrete Forming and Shoring
Part 3 – Form Removal and Tolerances
This webinar is sponsored by the American Concrete Institute (ACI).
Thank you to our presenters: David Johnston and Kim Basham.
Please use the question feature to submit your questions.
To earn continuing education for this webinar go to www.ACIUniversity.com.
WEBINAR 129

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Next Webinar
Troubleshooting Concrete Forming and Shoring
Part 4 - Formed Surface Finishes and Formed Surface Defects
June 16, 2016 at 1 PM Eastern
www.ACIUniversity.com.

WEBINAR 130

63