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Method aluminum door & window

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Method aluminum door & window

  1. 1. 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 CAI MEP INTERNATIONAL CONTAINER TERMINAL METHOD STATEMENT OF ALUMINUM DOOR & WINDOW WORK Page 1
  2. 2. 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 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 Page 2 Appendix 1
  3. 3. 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 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. Page 3
  4. 4. 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 Page 4 5. WORK PROCEDURE 5.1. General Flow Chart Preparation Work Approval of Materials & Shop Drawings Fabrication Fabrication Inspection Transportation of Materials Marking Confirm Opening Size Installation Glazing & Sealing Water tightness Test Protection & Cleaning
  5. 5. 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 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) Page 5
  6. 6. 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 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 Page 6
  7. 7. 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 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 Page 7 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.
  8. 8. 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 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. Page 8 • Handling
  9. 9. 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 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. Page 9 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.
  10. 10. 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 • 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 Page 10 Strap V-shaped timber wedge V-shape timber wedge Strap Level peg Plaster finished level peg
  11. 11. 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 Page 11 Check alignment of frame Check positioning of the frame with reference to wall 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).
  12. 12. 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 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. Page 12 Mitre joint Mitre joint Glass Splicing off part of the gasket (create a mitre joint) Gasket in fitted position
  13. 13. 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 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: Page 13
  14. 14. 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 ƒ 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 Page 14 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
  15. 15. 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 Page 15 (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
  16. 16. 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 Figure 1.2: Protection of frame throughout construction process Protective tape on window frame Page 16 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 & df Layer 2 remains infact Window frame Window frame
  17. 17. 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 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. Page 17 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.
  18. 18. 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 Appendix – 1 Inspection and Testing Plan Page 18
  19. 19. 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 ALUMINUM CAI MEP-THI VAI INTERNATIONAL PORT CONSTRUCTION PROJECT Package 1 : Construction of Port Facilities and Buildings for FACTORY INSPECTION CHECKLIST ITEMS TO BE CHECKED 1. Material verification as per submitted approved sample 2. Dimensional Check 3.Cutting joints Connection 4. Aluminum Surface Condition 5.Coated Paint/ Final Paint 6.Material Storage condition-Protection and Handling 7.Hardware and Accessories Cai Mep International Container Terminal Result of Inspection Sub - Contractor TTJV Consultant (JPC/NK) Page 19 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 8.Others Notes / Comments : Sign : Sign : Sign : Name : Name : Name : Date : Date : Date :
  20. 20. 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 Page 20 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 PROJECT Package 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 :

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