Method Statement for Curtain Wall-Glazed Installation

method statement for curtain wall-glazed installation

The method statement for curtain wall-glazed installation defines the procedure in carrying out the activity in accordance with the quality, project specifications, health, safety & environment (HSE) requirements, and approved shop drawings.

Site dimensions shall be verified and MEP clearance shall be obtained before the start of the work on site.

Scope

General Description

This describes the arrangement and methods for the fabrication and installation of the glazed curtain walls.

Definitions

Client-xxxxx
Project Management-Construction Management (PM-CM)-xxxxx
Construction Supervision Consultant (CSC)-xxxxx
Main Contractor-xxxx
MEP Contractor-xxxxx

References

Project Specifications
Approved Shop Drawings and Manufacturer’s Procedure
Approved Material Submittal

Abbreviation

PM – Project Manager
PE – Project Engineer
QC – Quality Control
HSE – Health, Safety, and Environment
ITP – Inspection Test Plan
IC – Inspection Checklist
MST – Method Statement
RA – Risk Assessment
QCP – Quality Control Procedure
INR – Inspection Request
QA/QC – Quality Assurance/Quality Control
MEP – Mechanical, Electrical, and Plumbing

Plant & Equipment

The equipment used for the above-mentioned work is:

Site Survey Equipment

General Hand Tools

Drill Machines (Light/Heavy Duty)

Drill Bits

Suction Pads

Glass Lifter

‘A’ Frame with Rubber Padding

Materials

The materials used for this work are:

Aluminum Profiles: Extruded Aluminium Profiles from Installux. All aluminum profiles are of powder coating from Jotun

Accessories: Related accessories and gaskets from Installux

Glass: Double Glazed glass

Sealant: as per requirement

Backer Rod: Backer rods as per requirement

Rockwool: 50mm thick Rockwool from

Flashings: 2mm thick aluminum sheet is used as flashing.

Anchorages: Anchorages as per structural calculation

Brackets: Brackets are manufactured according to the structural calculation by fabricating 8mm & 10mm thick steel sheets.

Site Planning & Preparation

An initial inspection of the area shall be conducted by a competent surveyor. Its purpose is to predetermine the control points and benchmarks used in locating the grid lines, which will be the basis of the layout plan for all elements. The installer will follow the preparation for bracket fixing.

Site survey and marking/lay-out will be done first for anchoring.

Any errors and inconsistencies in benchmark locations, levels, the vertical square of the openings, etc. will be recorded for necessary rectifications.

Installations in affected areas are set aside till such errors have been corrected.

Start the layout and marking of offsets (set-out lines) for elevations and grid lines, the surveyor will use yellow marking (or any other preferred color) for proper referencing of the curtain wall layout.

The actual dimension of the building’s perimeter and floor-to-floor height shall be verified so that the true site conditions will be adopted. Any changes and deviations shall be recorded in redline drawings and reflected in as-built drawings. Data gathered from the verification shall then be forwarded to the Engineering Department for the design and fabrication correction.

In the event that there are substantial deviations from the pre-set conditions, it shall be reported for immediate rectification.

Work Methodology

Make sure that the building is sufficiently readied to receive and enable aluminum works to commence.

The detailed method statement for curtain wall-glazed as mentioned in Section-Installation Method-Glazed Curtain Wall.

Organization, Responsibilities & Supervision

The site operation activities and control are executed by the following with their corresponding roles and supervision responsibilities.

The project engineer is responsible for the overall management of work and control of the staff in executing the work and will perform the following functions.

• To act as the main contact for the main contractor I client /consultant

• To ensure the progress of the project to the agreed program

• To coordinate with the design team

• To make decisions for the day to day project activities

• To control the activities of site engineer and site supervisor

• To ensure the implementation of safety regulations

The foreman will be responsible for:

• To supervise day to day progress of work

• To supervise the quality of work

• To ensure the progress and quality of installation

• To supervise the delivery and routing of materials into the building

• To ensure the implementation of safety regulations

The site surveyor will be responsible for:

• Site survey

• Marking of levels

• Establishing control work points

Workforce

Project Engineer-

The overall management of work and control of staff in executing the work is done by the Project Manager.
Coordinates and supervises the day-to-day work and ensures the progress and quality of work.

Supervisor/Foreman-

Coordinate and supervises the installation activities.

Aluminum fitters-

For fixing curtainwall

Glass Fitters-

For the installation of glass

Finishing Workers-

For the application of silicone and for finishing works.

Helpers-

To help in the installation, unloading, and shifting of materials

Health, Safety & Environment

HSE Contractor Requirements

The following HSE requirements are applicable to the Method Statement for Curtain Wall Installation and Risk Assessment.

• General Safe Work Practices

• Housekeeping Requirements

• Emergency Preparedness

• Personal Protective Equipment

Protective & Safety Equipment

The following HSE requirements applicable to the Method Statement for Curtain Wall and Risk Assessment

• Safety Helmet

• Safety Shoes

• Safety Glasses

• Hand Gloves

Information to personnel

Pre-task briefing to be given to the personnel involved in the activity. Supervising staff including Engineers to be made aware of this Method Statement for Curtain Wall by providing an approved copy.

Permit Requirements

All necessary permits are identified in the safety manuals and will be obtained prior to commencement of works

Environmental Issues

Environmental Impact Assessment

As shown in the Risk Assessment of the activities, this will have an impact on the environment such as contamination of air and water and accordingly to be mitigated.

Operational Instruction

Technical Data & Physical Sample

Technical data & physical samples required for this work as per the specification had been submitted to the consultant for approval. Drawings will be made according to the approved profiles. The fabrication and installation will be done according to the approved profiles and drawings.

• Aluminum profiles & accessories for curtain wall. All the aluminum profiles, accessories, and gaskets are from Installux.

• Glass

Glazing is from Saint-Gobain (or as per approved material)

• Aluminum finish

All aluminum finishes are of powder coating from Jotun.

• Rockwool insulation:

Azel Rockwool

• Silicone sealant:

• Brackets, anchor bolt, and through bolt:

Brackets & anchor bolts as per structural calculation

Aluminum Shop Drawing

Based on the design calculation detailed shop drawings showing elevations and sectional details will be prepared. Shop drawings will show details of fabrication and assembly details. Profile details will show the detailed dimensions and size of sections used and details of material used via the type of material, supplier, and other relevant details. Shop drawings are prepared in AutoCAD. Shop drawings will be forwarded for approval with design calculations and consultants’ comments will be reviewed and resubmitted for final approval.

Structural Calculation

The project specifications and drawings are carefully reviewed and based on the design wind load and other structural parameter structural calculations are made and suitable sections for aluminum and glassworks will be proposed. Brackets, anchors, secondary supports, etc. for curtain walls will be designed as per specification and the structural calculation and in the line with international and industry norms/standards.

Installation Method-Glazed Curtain Wall

Protection

Before the fabrication process of the aluminum frames starts, a team of workers would apply top-quality plastic protective tape to all the profiles. The protective tape will ensure that the profiles are not damaged or scratched during handling in the factory, transportation to the site, and installation, thus guaranteeing a final product of high quality.

Glass Protection:

Polyethylene sheets are used to protect the installed glass. This sheet will be removed only at the time of glass cleaning prior to site handover.

Fabrication

All the fabrication works will be carried out at the factory by trained workers, supervised by experienced technicians, and hence is subject to quality control procedures. Although most of the manufacturing operations are carried out at the factory under the supervision and control of the quality officer, nevertheless, a small-equipped workshop could be erected at the site for handling any minor required adjustments or modifications.

Reinforcement is used for transom and mullion and is installed in required areas as per approved drawing (Spandrel areas where sunscreen is coming, for example, Resident Housing Spandrel Areas).

Fabrication of Brackets:

The wall brackets and shoe brackets are designed as per the structural calculation of the curtain wall. An 8 mm thick steel plate is used for the fabrication of brackets. The jig is used for the fabrication of brackets. The jig is manufactured as per the dimension required for the brackets by using adequate clearance.

Steel plates are first to cut into required sizes and holes or slots are made as per the requirement. Plates are clamped to the jigs and tack welding is done within the jig. The bracket is removed from the jig and full welding is done from outside the jig. Polishing is done to remove spatters and inspection is done.

Galvanizing is done on the fabricated brackets to prevent corrosion.

Transportation

Once the site conditions enable the start of the installation of the aluminum frames, the units will be transported to the site and stored in the storage area. All gaskets and accessories are also stored in their original packing thus preventing any damage or scratches.

Particularly, the EPDM gaskets are stored in their cardboard boxes, not touching the ground, in order to avoid any damage by moisture or humidity.

Site Installation

• Prior to installation work, provide the clearances and handover of the areas in writing as required for installation to proceed. example grid lines, floor level, elevation, and fully erected scaffolding with floorboard on all working areas.

• All fabricated units are brought and placed at their respective locations manually.

• Site survey and marking/lay-out will be done for the first fix/anchoring.

• Structural shims (plastic/fiber) are used as a standard way to incrementally position and adjust the curtain wall elements to maintain the level of the brackets.

• Separators are used between anchorages & adjacent materials to prevent corrosion.

The dielectric material is used as an insulator.

• The wall bracket and shoe bracket will be fixed in the required areas.

• Mullions with brackets are fixed at require areas as per approved drawings are fixed.

• Finished size transoms are fixed to the connection brackets of the mullion.

• Glazing support bracket, insulator, and inner gaskets are installed as per the manufacturer’s recommendation.

• Glass is installed as per the manufacturer’s recommendation and the outer gasket and pressure plate are fixed.

• Cover cap is fixed over the pressure plate.

• Installations are carried out in conformity with installation and approved shop drawings as per the system supplier’s recommendation.

• The glass tempered mark will be installed as per project specification. (Tempered mark logo)

• Glass installation will be done with manual glass lifting or machine glass lifting. In the case of a glass lifting machine, provide a crane to hook the glass lift during the glass installation work.

• Suction pads and hand gloves are used for glass installation.

Confirmation of Instructions to Operatives Form

The personnel involved in the project confirm the receipt of the Method Statement for Curtain Wall and had the contents explained and are aware of the HSE requirements.

Cleaning & Handover

Protective tape will be removed from the aluminum frame as soon as it is required. The polyethylene sheet will be removed from the installed glass before cleaning of glass. The final cleaning will be done prior to progressive joint inspection with the consultant on an area-by-area basis.

Protection of the installed units will be maintained until the acceptance of the handover certificate of the project.

Distribution of Method Statement for Curtain Wall-Glazed Installation Document

Copies of this MST should be issued to the following for information and action after approval:

Consultant

Main Contractor

Project Manager

Site Engineer

Safety Engineer

Supervisor/Foreman

Quality Control/Quality Assurance

Contractual Requirements

Quality assurance requirements as per the contract are covered under the QA program for the timely inspection and detail ITP-Inspection and Test Plan as per project specification.

Inspection & Testing

Quality control is a primary concern in the installation of curtain walls. Quality Control and quality assurance are strictly monitored during every stage of production from procurement of materials to the final finished product.

Qualified and experienced inspectors in the factory carry out routine and spot checks to assure a good quality product. The quality control and assurance procedure are based on the requirements of ISO 9001:2015.

When the production team supervisor considers that the work will be ready to be inspected, he informs the foreman of the coordination team. The work coordination team foreman then comes to control the works on-site and reviews all the items mentioned in the Inspection and Test Plan (ITP).

At this point, if the coordination team supervisor discovers any defects, he requests the production team to correct them. As soon as he ensured that the work is satisfactory, he fills an Inspection Request form (INR) and gives it to the project team as per standard instruction mentioned on the INR.

The project engineer organizes his team so that the inspection is carried out on the next day and assigns the foreman to carry out the inspection. If necessary, the project engineer highlights the sensitive points of the inspection to his foreman before the inspection. In case of necessity, the inspection may be done the same day.

The project engineer/ foreman checks that all the reference documents are correct and that the quality criteria are properly defined. He then transmits the original INR to the supervision consultant/ main contractor for information on the inspection details (works, date, and time of inspections which could be carried out).

The supervision consultant signs the “receipt”, keeps the original and gives back a copy to the main contractor’s Quality Department.

The inspection on site is implemented by Construction Department as scheduled in INR with the site engineer and one supervisor of the supervision consultant/ main contractor if required.

At the end of the inspections, the foreman checks that all the persons concerned have signed the Inspection Checklist (IC), and prepares the report of inspection contained INR, IC, Delivery Note. Once the inspection has been completed. The foreman forwards to the Engineer the report to review. The Engineer consultant keeps the copy and gives back the original with comments if necessary to the main contractor Quality Department. The project engineer shall ensure that all the comments have been taken into account.

Follow up & Evaluation

Performance of the work is followed up by QA audit and Project Management/Consultant review.

Verification Records

Initial Records Requirements

The following records will be maintained in a file for future checking and submission:

Inspection Request

Material Inspection Request

Mill Certificates

Site Test Reports

Approved Shop Drawing

Redline Drawings

Records During Construction

Inspection Checklist

Completion Certificate Package

The following certificates will be compiled and submitted after work completion:

Site Test Reports

Mill Certificates

As-Built Drawings

Gondola Certificate

Monorail Test Report

Hoisting Machine Certificate

Pull Out Test Report

Water Test Report

Filing Arrangements

All documents will be classified and be kept in files.

Project documentation and records shall be maintained until the completion and handing over of the project.

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