Method aluminum door & window

Doc. Title Method Statement of Aluminum Door & Window Work TOA-TOYO JOINT VENTURE

Doc. No CM – MS – BW - 025 Rev. No. 0 Date May, 2012 Construction of Port Facilities and Buildings for Cai Mep International Container Terminal

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CAI MEP INTERNATIONAL CONTAINER TERMINAL

METHOD STATEMENT OF

ALUMINUM DOOR & WINDOW WORK



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CONTENT

1. Purpose Page 3

2. Scope of Work Page 3

3. Reference Technical Specification Page 3

4. Shop Drawing Page 3

5. Work Procedure Page 4

6. Quality Control Page 7

7. Safety Control Page 7

Appendix 1



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1. PURPOSE The Purpose of this Method Statement is to describe the process of Aluminum door and

window works in compliance with all the required specifications, standards, and proper

construction procedures for the building finishing works of the project.

2. SCOPE OF WORK The scope of works are including the fabrication, delivery and complete installation of

Aluminum doors and windows, including glazing and finishing hardware for the buildings.

3. REFERENCE TECHNICAL SPECIFICATION • Refer to Division 03: Doors and Windows -– Part 4A – Volume 2 of Technical

Specification.

• Refer to Part 1 : General Requirements, Part 4A, Division 1 and Part 4B, Division 5 –

Volume 2 of Technical Specification.

4. SHOP DRAWING Shop drawings shall be submitted to the Engineer by separated document for review and

approval before carrying out the works.



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5. WORK PROCEDURE

5.1. General Flow Chart

Preparation Work

Approval of Materials & Shop Drawings

Fabrication Inspection

Transportation of Materials

Fabrication

Marking

Confirm Opening Size

Installation

Glazing & Sealing

Water tightness Test

Protection & Cleaning



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5.2. Detail Procedure

5.2.1. Approval of Materials & Shop Drawings The proposal of each materials shall be submitted to the Engineer for approval.

The Shop drawing for Aluminum Doors & Windows shall be submitted to the Engineer for

approval.

5.2.2. Fabrication 5.2.2.1. Fabrication in Factory

High quality windows can be effectively achieved by fabricating and assembling as many

components as possible in the factory. This helps to minimize site assembly where quality

control is more difficult.

The use of mechanical tools, including jigs and computerized machines are useful in

achieving the required fabrication tolerances.

Figure 1.1: Use of cutting and drilling machines

Computerised drilling machine Máy khoan nhiều đầu

Assembly of the window main frame and sash inner frame using a crimping machine

produces strong and quality joints. Sealant should be applied to the joining edges prior to

assembly for enhanced water tightness performance (Figures1.2).

Figure 1.2: Assembling of window frame (Crimping method)



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Crimping machine for mitre joint Application of sealant on mitre end

Joining of frame components Securing of frame

5.2.2.2 Protection All exposed parts of the aluminium frame/sections must be protected with suitable

protective tapes (Figure 3.1). The tapes used should not leave stains on the surface of the

frames nor damage the frame finishes during removal. Corrugated cardboard may be used

beneath the protective tape to give additional protection to the frame.

Figure 3.1: Protection of frames

For slender frame sections, styrofoam strips can be inserted to maintain the rigidity and

prevent deformation of the frames during delivery, storage and handling. In addition, corners

of frames should be protected to prevent damages during delivery and storage. All glazing

should also be protected with suitable materials.

Figure 3.2: Protection of frames for delivery



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5.2.2.3 Labeling All fabricated frames, window sashes and glass panels should be properly labelled for ease

of identification (Figure 4.1). The frames should be arranged in batches for delivery to site

(Figure 4.2). Suppliers should plan the delivery of windows in accordance with the

installation schedule to minimize storage and handling on site.

Figure 4.1: Labelling of frames, sashes and glass panels

Label on frames Label on sash/glass panels

Figure 4.2: Completed frames arranged in batches for delivery to site

5.2.3. Fabrication Inspection

Before delivery, frames and leaves need to be inspected to make sure material verification

as per submitted approved sample, correct dimension, good aluminum Surface Condition,

ect. with inspection checklist as per attached in attachment No.1 – Fabrication Inspection

Checklist.

5.2.4 Delivery, Storage And Handling

• Delivery

Before delivery, windows and theirs various components should be fully protected to ensure

the components remain in good condition until they are ready for installation.



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All materials for delivery should be verified against the quantity and batch number stated in

the delivery order. All required accessories, including friction stays, handles, locking devices,

fixing, etc. should be delivered together with the main components. Materials could be

packed in either steel pallets or skids.

Upon delivery on site, the materials should be checked for damages during transportation

and that the delivered materials are in compliance with the specifications. Any damaged or

incorrect materials should be returned to the factory.

Figure 1: Packing for delivery

• Storage

Delivery of materials should be carefully planned according to the installation schedule so

that only the required quantity of materials are stored on site, where the possibility of

damages is higher. Just-in-time (JIT) inventory management system is effective in

minimizing unnecessary handling, storage and damages to the materials.

Proper site storage is important in preventing damages to the window components. A

suitable storage location should be:

Sheltered from weathering and fallen objects; and

Located for ease of material handling and distribution.

Components should be placed on timber bases to avoid direct contact with the floor. Glass

panels should be stored in pallets with individual glass panel separated from one another by

protective sheets to avoid scratches and other damages. The glass panels should also be

protected from exposure to water which may result in “ rainbow” effect and jeopardize the

visual properties of the glass.

In addition, the various components should be arranged according to the installation

sequence to facilitate ease of retrieval, i.e. to minimise searching and unnecessary shifting

of material which may lead to damages.

• Handling



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Large window units and components which cannot be delivered via staircases should be

hoisted in pallets to each floor before distributing to the different areas for installation. In

cases where window frames need to be hoisted without the pallet, the frame should be

handled only at the designed strong points.

Large pieces of glass panel should be handled with care using suction cups as shown in

Figure 3.1

Figure 3.1: Proper handling of glass using suction cups.

• Transportation of Material

The each type of materials shall be transported to the site by truck and dump truck

5.2.5 Preparation Work a) Proper dimensional control and setting out of the wall opening are critical in ensuring

the quality of window installation. Precast facades provide superior dimensional

control than the cast in-situ RC walls and brickwalls and require less preparatory

works.

b) The use of cement grout to fill up large gaps should be avoided as this may lead to

cracks in the grout which would lead to water seepage through the building envelope.

5.2.6 Marking Reference line (R.L) should be set up at appropriate location to facilitate proper alignment

of the wall openings and installation of the window frames.

5.2.7 Confirm Opening Size Close dimensional control on wall opening should be exercised to ensure the gap

between the wall and window frame is within the range of 7-25mm wide.

5.2.8 Installation Window installation involves the fixing of window frame at an earlier construction stage and

subsequent installation of the window sashes. This is a highly workmanship dependent

process. Only trained and approved contractors can carry out installation and retrofitting of

windows.



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• Installation of frame on brickwall/ concrete wall Before installation of the window frame, the following checks should be carried out:

- Wall opening should be checked for any physical defects. Any defects should be rectified

before installation proceeds.

- Window frames should be checked for any damages. Defective frames should be repaired

or replaced prior installation.

Timber V-shaped wedges are commonly used to temporarily hold the window frame in position

within the wall opening as shown in Figure 2.1 The window frame is then checked for plumb,

levellness and alignment.

Figure 2.1: Use of V-shaped timber wedges for positioning of frame

Figure 2.2: Checking the plumb, levellness and alignment of window frame

Check plumb of frame Check alignment of frame

Strap

V-shaped timber wedge

V-shape timber wedge

Strap

Level peg Plaster finished level peg



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Check alignment of frame

After confirming the position of the frame, the galvanised straps are ramsetted to the wall.

When ramsetting the straps, the plumb line should be maintained to ensure proper alignment

of the frame.

The levellness and squareness of the installed frame can be checked by carrying out a

diagonal dimensional check as shown in Figure 2.3.

Figure 2.3: Fixing of window frame

Ramset the straps to the wall after confirming Check diagonal dimensions after

installation

• Installation of Finish Hardware

All hardware shall be installed in strict accordance with the manufacturer’s directions.

All work shall be installed plumb and true and secured with proper fastenings so as to

make all work rigid and firm.

After installation, all finishing hardware shall operate and function smoothly and efficiently

in strict accord with their respective expected operating performance.

All works which are to receive hardware shall be inspected and any defect must first be

rectified before installing finishing hardware.

After has been properly fitted, all exposed items such as knobs, plates, pulls, locks, etc.

shall be removed until final coat of finish has been applied, and then hardware installed.

5.2.9 Glazing & Sealing

For better quality, glazing work should, as far as possible, be carried out by skilled installers

in the factory. The gasket used should be of a continuous length, with splices made at

appropriate locations for good fitting around the corners of the glass panel (Figure 2.1).

Check positioning of the frame

with reference to wall



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Figure2.1: Installation of gasket

Splicing of gasket to fit around corner of glass

When assembling frames, ensure that gasket fits properly to the glazing and the frames are

properly aligned.

The gaps between the window frame and wall must be properly sealed to prevent water

seepage at these locations. Depending on the size of the gap, waterproof sealant can be

used.

• Application of sealant Sealant could be used to seal the gap between wall and window frame if the gap size is

between 7-10mm.

Before the application of sealant, clean the aluminium window frame with white spirit using a

clean rag. The frame and wall surfaces around the gap should be protected with masking

tape to prevent the sealant from staining these surfaces and to obtain a neat sealant joint.

Backer rod should be used to achieve better compactness of the applied sealant. To obtain

a complete seal, apply sealant by pushing the bead forward into the joint cavity.

The joint should have continuous caulking to ensure that all areas are filled. Remove the

excess sealant and

tool the joint to achieve a smooth surface.

Mitre joint

Mitre joint

Glass

Splicing off part of the gasket (create a mitre joint)

Gasket in fitted position



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Figure 2.4: Application of sealant

Protection of the frame with masking tape Protection of the wall with masking

tape

Application of sealant

• Installation of window glazing It is recommended that glazing work for inner glass panels be carried out in the factory,

where higher work quality can be achieved. Where this is not possible, glazing work must be

carried out on site with proper handling and good workmanship. For fixed glass panels,

glazing is usually done on site.

This section will discuss the good practices to be adopted when carrying out glazing works

on site.

For glazing work in the factory, refer to Chapter 6 on Fabrication.

- Preparatory works before glazing The protective tapes should only be removed when glazing works is to be carried out. The

following verification works should be carried out prior to glazing work:



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Inner frame and associated hardware should be checked for defects. Damaged frames or

hardware should be replaced.

• Inner frame should be cleaned and free from dust and debris.

• Weep holes in the inner frames should be cleared of blockage to allow discharge of

incidental water.

5.2.10 .Water Tightness Test

Water seepage through windows is one of the major problems.

Laboratory tests are not able to detect water seepage problems caused by poor workmanship during installation of the window system. Field watertightness test should, hence, be carried out to verify the watertightness performance of the installed windows.

The following parameters are used in field watertightness test: Water intensity 300mm/hr 1 litre/min/m of joint

Wind Pressure 240 Pa = 35 psi

Nozzle inclination 900 to wall

Distance of nozzle from wall 300mm

Sample 1 sample = 2m length of joint

Spray duration 10mins No sign of seepage should be detected throughout the test.

Figure2.10: Conduct field watertightness test

Portable pump with hoses Lightweight nozzles



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(viewed from outside the building)

Figure 2.11: Detection of water seepage

Seepage through gasket Seepage through joint in frame 5.2.11 Protection and Cleaning Protection should be provided to all vulnerable surfaces such as the frames, glass panels, handles, etc. Protection of the windows starts in the factory and should remain intact throughout the construction process until the windows are scheduled for final cleaning and handling over. Material used for temporary protection must be compatible with the protected surfaces and should not stain the finishes of these surfaces. It is important that the life span of the protective tapes be considered to ensure that the quality of the tapes is maintained throughout the construction process.

Figure 1.1: Protection of components for delivery and storage



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Figure 1.2: Protection of frame throughout construction process

Protective tape on window frame Box-up protection for bottom frame of full height window

Protection at access-prone location

Figure 1.3: Protection of window after installation

Protection of glass panel Protection of accessories It is good practice to adopt a multi-layer protection system, such that different layers of protective tape can be removed as installation progress on site (Figure 1.4).

Figure 1.4: Multi-layer protection system Two separate layers of protection on frame Removal of protective layer 1 for glass panel installation

Glass panel

Layer 2 remains infact

Glass panel

Layer 3 protection to protect l & d f

Layer 2 remains infact

Window frame

Window frame



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Installation of glass panel Glass protective tape (layer 3) is been applied to protect the glass panel and exposed frame. Layer 2 & 3 would be subsequently removed after the completion of all works. 6. QUALITY CONTROL 6.1. Inspection and Testing Plan

Before start Fabrication and Installation, Inspection and Testing Plan shall be established to

keep proper quality of the works in accordance with specification and standard. ITP shall be

submitted to the Engineer for approval.

6.2. Fabrication and Installation Inspection

Before deliver the materials to the site, fabrication inspection shall be conducted and after

finished installation, installation inspection shall be conduct with witnessed by the Engineer.

Sampling and Testing

7. SAFETY CONTROL 7.1. Fundamental Policy

“Safety is the First Priority"

7.2. Key Activities

• Implementation of Safety & Health Education

• Prevention of Human Error and Machinery Accidents

7.3. Development and implementation of Activity

• Implementation of Safety & Health Education

• Pick up hazardous factors of each work activity and always reflect them at the safety

meetings.

7.4. Point out them every day at the meetings in order to let individual worker to renovate his safety

consciousness

• Prevention of Human Error and Machinery Accidents

• Be consistent with inspection at beginning of works, regular maintenance of working

platform, machinery tools designation of working area.

7.5. Others

• Safety signboards and barricades shall be installed around working area if necessary.

Security guard should observe all passengers around the site.



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Appendix – 1

Inspection and Testing Plan



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Date :

No. :

Building Name : Location :

Inspected Item : ALUMINUM DOORS AND WINDOW Type: Aluminum Doors / Aluminum Window / Aluminum Louver

Shop Drawing No.:

Acceptable Rejected N/A Remark

Sign : Sign : Sign :

Name : Name : Name :

Date : Date : Date :

Notes / Comments :

Sub - Contractor TTJV Consultant (JPC/NK)

6.Material Storage condition-Protection and Handling

7.Hardware and Accessories

8.Others

ALUMINUM

1. Material verification as per submitted approved sample

2. Dimensional Check

3.Cutting joints Connection

4. Aluminum Surface Condition

5.Coated Paint/ Final Paint

CAI MEP-THI VAI INTERNATIONAL PORT CONSTRUCTION PROJECTPackage 1 : Construction of Port Facilities and Buildings for

Cai Mep International Container Terminal

FACTORY INSPECTION CHECKLIST

Result of Inspection

ITEMS TO BE CHECKED



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Date :

No. :

Building Name : Location :

Inspected Item : DOOR WORK

Shop Drawing No.:

Acceptable Rejected N/A Remark

Sign :

CAI MEP-THI VAI INTERNATIONAL PORT CONSTRUCTION PROJECTPackage 1 : Construction of Port Facilities and Buildings for

Cai Mep International Container Terminal

FINISHING WORK CHECKLIST

Result of Inspection

ITEMS TO BE CHECKED

TYPE: Steel Door/ Wooden Door/ Aluminum Door/ Steel Shutter

Door Works :

1. Material verification,type,size free from damage

2. Material handling and and storage

3. Installation:Location and plumbness

4. Accessories/Hardware

5.Free from damage

6.Door wooden trim ( for wooden door )

7.Others

Notes / Comments :

Sub - Contractor TTJV Consultant (JPC/NK)

Sign : Sign :

Name : Name : Name :

Date : Date : Date :

Method aluminum door & window

Documents

scope of work page

work procedure page

purpose page

shop drawing page

quality control page

process of aluminum

aluminum doors windows

safety control page