Project:

Installation Method Statement

Quality Assurance
Logistic plan
for
Façade Activities
at

PROJECT :

CLIENT :

ARCHITECT :

FAÇADE CONSULTANT

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CONTENTS:

TABLE OF CONTENTS

1. Introduction 7
2. Scope of Work
3. Site clearance 8
4. Survey
5. List of Equipment’s 9
6. Equipment Location 13
7. Vehicle entry and unloading area 13
8. Material movement and stacking location plan 14
9. Methodology 15
Unitized Curtain Wall double hight 15
Openable panels 19
Glass Railing 24
Aluminum perforated sheet 28

10.Methodology - Production 30
Inspection on incoming delivery of profiles 30
Inspection of coating 30
Panel fabrication 31
Panel Glazing 31

11.Methodology – Site activities 35

Method statement for Concealed works 35
MS – Smoke Seal application 36
MS – Quality Check Insulations 39
MS – Pull-out test at site 40
MS – Façade protection 45
MS – Site cleaning 46
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MS & check list for vents and openables 48

MS – Scrap removal 49
MS – Demobilization 49
MS – House Keeping 50
Attic Stock handover procedures 50

12.Progress Reports and Review meetings 49

Weekly Progress Reports 51
Monthly Progress Reports 51
Daily Progress Reports 51
Weekly Review Meetings 52

13.Request For Information 52

14.Sealant 53
15.Documentation 53
16.Quality Records 54
17.Toolbox Meetings 54
18.Control & monitoring of measuring devices 55
19.Inspection and Testing 55
20.Log of Rejections and Rejection of materials 58
21.Sample board submission with list of approved materials 61
22.Visual Mockup – Method Statement 62
23.Factory/Site Inspection Appeal Format 63
24.Work progress Flow Chart 64
25.Debit Note Format 65
26.Format for Corrective and Preventive action plans 66
27.Format for Micron thickness Inspection 68
28.Procedure for Handing over69

1. INTRODUCTION

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FAÇADE CONTRACTOR’S RESPONSIBILITIES:

The Façade Contractor’s responsibility includes the design, procurement, fabrication and
installation of all Windows, Curtain Wall in accordance with the Specification and hand over
of the façade works as mentioned in the contract.
Facade Contractor is responsible for the following items:
 Supervision of all Façade/Windows activities and shall nominate a suitably qualified
staff member to be responsible for supervision. Qualified Staff will be available full time
on the site.
 Co-ordination of work with the overall project requirements, including all areas of
interfaces with internal finishes and external finishes.
 Site survey of the Façade/windows.
 Fixing of Sub-Frames.
 Fabrication, Installation and Handover of Windows / UCW and other items as per
scope.

2. SCOPE OF WORK

SCOPE OF FAÇADE / WINDOWS CONTRACT WORKS:

The scope of work includes design & engineering, supply and install including testing of
materials and performance, fabrication, quality control, Transport, storage, protection, final
clean and hand over the products as listed below.

The above scope is covered for all

A. UNITIZED CURTAIN WALL SYSTEM DOUBLE HIGHT
B. ALUMINIUM SLIDING WINDOW
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C. DOOR SYSTEM
D. CASE MENT WINDOWS
E. GLASS & RAILLING
F. ALUMINIUM PERFROTED SHEET
G. M S WORK

For each area of element, the following shall be included:

 Brackets and other connections to the structural frame
 Sub-frames or framing required to connect façade/windows elements on to permanent
structure.
 Glazing, Sealants
 General flashings, as per requirement
 Finishes, coatings, and surface treatments

SITE CLEARANCE

1. As the construction works are completed by the Client, the floors will reach a stage
where they are ready for the Curtain wall brackets & Panels to be installed. All external
obstructions, such as
Scaffolding, debris, M&E materials, brick works etc. have to be removed.

2. The completed floors will require the following criteria to be met so as to enable the
Façade work to proceed.

At non-storage areas, the floors must be cleared of all obstruction at least 4 mtr. Away from
the edge of the slabs.

3.On the storage floor the area must be clear of other contractor’s material, M&E
equipment etc. Internal brick walls must not be constructed at these areas.

4.All concrete work is to be completed as per the shop drawings.

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5.Grid lines on the floor and benchmark levels on columns are given.

6.Safety lines or railings, which support worker lanyards, are to be provided around the
building perimeter.

7.Any waterproofing if required by client should be completed to the correct sequence.

8.Almech will hold an inspection of the worksite and inform the Client of any corrective or
incomplete works.

1.1 General

1.The unitized curtain wall is normally installed in a sequence from the lowest floor.

2.Once the floors are released, bracket installation can proceed and can be completed.

3.Any concrete formwork must be removed and obstructions cleared, for example Rebars
from edge of slab.

4.Concrete must be cured before brackets are installed and excessive honey combing
repairs or grouting to slab edges must be completed.

5.Overcast concrete must be hacked back to its correct alignment and position.

6.Basically, areas free from obstruction, intact concrete and good surface condition can
allow quick bracket installation and UCW panels fixing.

7.Block work walls at the storage area must not be built.

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SITE SURVEY AND SETTING OUT

1.As the structure progress and the floors are cleared of obstruction, ALMECH will check
the client’s grid points relative to each column & floor level. This is done to ensure accuracy
of setting-out during the project. All clear floors are required prior to starting of our works.
This is to enable a thorough check of plumb ness of the Main Contractor grid.

2.Any discrepancies, which may be detected, will be notified to the Client for
correction or Adjustment. Once the grid lines are confirmed the Curtain wall brackets are
permanently installed.

3. Grid lines are established by the client and should be easily definable. These reference
lines should be sufficient to reference the building line around the totally perimeter of the
building. That is 1meter offset from grid lines or 500mm reference lines from building or
structural face.

4. Any official plan indicating the grid line values and reference must be submitted to
ALMECH.

5.Centers of the mullions/brackets are marked on the concrete slab together with a
reference line to the building façade. The curtain wall brackets are fixed to the inserts using
these reference lines.

6.Level datum’s are to be provided on selective columns or core wall by the Main
Contractor. Not too many datum’s are required, at least three per floor. Checks on these
lines will be carried out floor by floor to ensure consistency and accuracy.

General

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1.It is advantageous to survey all floors so as to produce a coordinated façade alignment.

2.Normally, brackets are set-out and checked for the other Accuracy of this work is of
paramount importance for the successful installation of the curtain wall, where as the
bracket once set out is the reference or base for the installation works.

3.Tolerance for grid lines should be within + 3mm for all floors.

Logistic Plan

3. LIST OF EQUIPMENTS
 Scaffolding – As per requirement
 RSP Gondola
 Vacuum Glass Cup Holder
 Boom lift If Required
 Floor crane /Winch Machine

 SCAFFOLDING

 CUP LOCK OR BREASING SYSTEM.

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FIGURE 1: SCAFFOLDING

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FIGURE 2: SCAFFOLDING

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GONDOLA

 VACUUM GLASS CUP HOLDER

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FIGURE 3: VACUUM GLASS CUP HOLDER

 BOOM LIFT

 FLOOR CRANE OR WINCH MACHINE

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3. EQUIPMENT LOCATION

 Scaffolding: Scaffolding will be used wherever required. Mostly, the windows are fixed from
inside the floor and at cases wherever needed scaffolding will be fixed from outside or
inside, as per requirement. Scaffolding will be used for erection of Windows, Curtain wall.

 Gondola: Temporary suspended working platform (‘gondola’) is a common type of rigging

system that uses outriggers or overhead supports. It is temporarily assembled on a building
and dismantled when façade access is no longer required. The purpose of gondola for this
project to the fenestration of unitized and semi unitized panels and all other external façade
grade works

 Vacuum Glass Cup Holder: Vacuum Glass Cup holder will be used only for fixing of Glass.

 Boom Lift: Aerial platform attached to an arm that extends up, forward and down. It can be
used at confined spaces, lifting one worker up to hard-to-reach areas.

4. VEHICLE ENTRY AND UNLOADING AREA

1. Vehicle entry and Unloading location at Ground Level to be discussed with Client before
starting a work at site.
2. The Windows and other materials / frames shall be dispatched to site as per the
requirement and priority set.
3. Storage area shall be constructed as per location given by client and all materials shall be
unloaded and stored in the prescribed area.

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MATERIAL MOVEMENT AND STACKING LOCATION PLAN

1. The Aluminum, Glass & Hardware will be unloaded from Vehicle at temporary unloading
location (on Ground Floor) manually with proper safety and precautions.
2. Loose Glass, Aluminum and Other loose materials will be shifted to the store or required
floor manually.
3. Aluminum frames Shifting:
a. Aluminum frames shall be lifted & shifted to stores/location with all the necessary safety
precaution.
b. Proper packing arrangement will be provided to ensure there is no damage to the
aluminum extrusions and glass while unloading.
c. The aluminum frames will be unloaded and shifted (using labours) to the required
location.
d. Foam or Rubber Separator will be used as Packing Material in between aluminum frames
4. Stacking of materials:
a. Aluminum Frames /section - This will be shifted to the required floor prior to installation
and will be stacked on floors only on temporary basis.

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5. METHODOLOGY

I. UNITIZED CURTAIN WALL SYSTEM DOUBLE HIGHT WITH SLIDING SHUTER

Unitized curtain wall is an enclosing structure consisting of prefabricated glazed or solid

panels which are transported to site from a factory and coupled together with minimum
field installation works / UCW system frame with spandrel panels will install with Floor
crane from location P6 above amenities floor slab and sliding shutter will be installed
from inside support with glass shucker.

A. Examination

 Site Verification Conditions: Examine and correct conditions of area to receive the Work
prior to installation. Comply with the following requirements.

 Masonry surfaces shall be visibly dry and free of excess mortar, sand and other
construction debris.

 Metal surfaces shall be dry, clean, free of grease, oil dirt, rust and corrosion, and welding
slag, without sharp edges or offsets at joints.

B. Installation
 A material hoist must be installed inside the building (by client) to be used for lifting the
Materials, Panels, Glasses etc.
 The Installation of the above can be phased out as per the requirement.
 Based on the Structural Calculations and Requirements of the Project, Pull-out test will be
carried out on the specified Anchor Fasteners.

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 Then the designed Brackets for the system will be fixed as per the requirements and
based on survey with the required spacing. Brackets shall be fixed from inside the
buildings with the necessary hardware. The drilling of the holes on the concrete surface
will be carried out with the help of Hammering Machine. After Installation of the
Brackets, Inspection Alignment will be carried out in X, Y & Z axis.
 To Install the Starter Panel or outer frame, all required Panels will be fixed with the
Brackets on the Beam / Slab and then aligned.
 The Stored Panels will be shifted manually or with the help of Moving trolley or manually
till the point where it needs to be hoisted.
 The Panels will be lifted at the required place with the help of Hoist, an additional bracket
is provided to hold the panel rigid. Vacuum Gripper will be provided at the outside face of
the glass to avoid the panel sway. The vacuum gripper will be pneumatically /
electrically / Manually/ operated and the wire ropes for the same will be designed based
on the project specification.
 On the individual elevation, erection of the panels will be carried out horizontally or
vertically on each floor based on the priorities.
 The required panels are lifted to the required height and level and then fastened with the
brackets provided.
 The Panels will be protected with the Protective Tape to avoid dust collection on it.

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FIGURE 4: UCW

 Required Flashings and smoke seal / Fire stops works will be carried out with sealing the
floors.
 Each installed panel shall be checked for quality and its alignment.
 After the completion of Panel Installation, Cleaning activities shall be carried out and will
be handed over to Client.

C. Field Quality Control

 Almech has Initiated and is practicing in achieving the ISO Quality Standard for below
mentioned activities & Procedure.
 Bracket Fixing:
o Position of Bracket
o Fasteners Fixed
o Shims used for Packing & Alignment
 Panel Installation:
o Position & Plumb alignment of Panels.
o Position of Panel
o Gasket Fixing
 Besides practicing above mentioned activities & procedures for the entire Project, the
handy checklist shall be prepared and practiced for the day-to-day proceedings at the
site.

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D. Cleaning

 At the end of each workday, remove unused materials, debris and containers from the
project site/location.
 Clean aluminum surfaces promptly after installation. Exercise care to avoid damage to
protective coatings and finishes. Remove excess glazing and sealant compounds, dirt
and other substances. Lubricate hardware and other moving parts.

E. Protection

 Protect the Work so it will not deteriorate or be damaged. Remove protection at time
of Substantial Completion. (Not recommended more than three months of supply).

 Initiate and maintain protection and other precautions required through the
remainder of the construction period, to ensure that, except for normal weathering,
window units will be free of damage or deterioration at the time of substantial
completion.

II.
1. Examination

Site Verification Conditions: Examine and correct conditions of area to receive the Work
prior to installation. Comply with the following requirements.

 Masonry surfaces shall be visibly dry and free of excess mortar, sand and other
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construction debris.
 Metal surfaces shall be dry, clean, free of grease, oil dirt, rust and corrosion, and welding
slag, without sharp edges or offsets at joints.

2. Installation
 UCW is installed as per approved drawings in line, level and Pumb.
 At beginning of the fenestration, the brackets installation will be carried out from
outside / inside by cradle or without cradle or scaffolding. Ensure all Scaffolding have Scaff
tag before commencing the work.
 A test run for the cradle will be carried out at the landing level prior to each use.
Competent trained operatives will fix the brackets at set outpoints, standing inside the
cradle. Shims will be used if required to adjust the brackets to the correct level.
 Only the required Aluminum frames will be shifted from the store area to the point of
installation. Landing platform shall be arranged at the edge of the building which shall be
used to accept the components for distribution on to the floors. 2-3 Nos. of operative
inside the cradle will carry on the installation with the help of 2 Nos. of operative from
the floor inside the building.
 The operatives will check the level Vertical & horizontal with the help of plumb & spirit
level, so that after installation the installed components are in line with the corresponding
false ceiling or finish floor level.
 Once the proper alignment is achieved the operative will tighten all the bolts. The same
procedure shall be carried to install the adjacent ladder type assembly. Before installing
the adjacent assembly, the connection between the 2-components or ladders, shall be
carried on site by fixation of the transoms, from bottom to top.
 Ensure that the joint between the mullion & transom or approved system design is well
fit.
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3. Field Quality Control

 QA & QC of each windows shall be completed in accordance as per the technical
requirement set as per contract.
4. Adjusting
 Adjust operating toggle and hardware to provide a tight fit at contact points and at
weather-stripping, for smooth operation and a weather tight closure.

5. Cleaning
 At the end of each workday, remove unused materials, debris and containers from the
project site.
 Clean aluminum surfaces promptly after installation. Exercise care to avoid damage to
protective coatings and finishes. Remove excess glazing and sealant compounds, dirt and
other substances. Lubricate hardware and other moving parts.
6. Protection
 Protect the Work so it will not deteriorate or be damaged. Remove protection at time of
Substantial Completion. (Not recommended more than three months of supply).

 Initiate and maintain protection and other precautions required through the remainder
of the construction period, to ensure that, except for normal weathering, window units
will be free of damage or deterioration at the time of substantial completion.

II. GLASS RAILING

Purpose
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 The Glass Rail System utilizes an aluminum extruded base shoe to anchor and support
structural glass balustrades or as per system approved drawing which support a variety of
top rails and handrails to construct guards and dividers.
 Aluminum components are designed in accordance with the Aluminum Design Manual.
 Cap/top rail or grab rail shall be installed on appropriately sized glass installed in a
matching base shoe properly mounted to the supporting structure. This report is in
support of the approval of the system.

Installation:
 As the structure progresses and the worksite is cleared of obstructions, we will check the
client’s grid points relative to each column & floor level. This is done to ensure accuracy of
setting-out during the project.
 All clear floors are required prior to starting of our works. This is to enable a thorough
check of the plumb line of the Structure grid executed by the Main contractor.
 Grid lines are established by the client and should be easily definable. These reference
lines should be enough to reference the building line around the totally perimeter of the
building.
 Railing Aluminum U channel to be fixed properly with the help of Anchor fasteners.
 The distance between anchors should be as per specification only.
 Setting block to be fixed at the bottom for resting the glass and spacing of packers should
be as per drawings only
 After that railing glass to rest on packing with the support of another flat setting block.
 The gap between Glass and U channel to fill with gaskets or sealant as per specification
only.
 The top of the glass Railing U channel or any approved section has to fix for better
alignment and aesthetical purpose.
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 Proper quality check must be done at the time of installation.

 Installation check list to made after complete installation.
 Before hand over entire installation work shall be inspected and a snag list shall
be prepared for the same. Along with clearance of snag list handover shall be done
to client.

III. PERFORATED ALUMINUM SHEET.

Purpose:
 It is used commonly in DG & outer face areas for air circulation purpose.

Installation Process:
 Ensure all the openings are as per the approved shop drawings.
 Check whether size of louver panel is as per the requirement.
 Check whether the size of the Aluminum sheet and perforation is as per specification and
approved drawing.
 Check whether coating on the Aluminum sheet / frame is as per approved shade.
 Check for the uniformity of spacing between the Aluminum perforation as per design /
frames.
 Install the outer frame of the louver using the specified anchor fastener. Following inner
frame to be installed onto the outer frame and maintain the uniform spacing between the
screws or as per approved shop drawing.
 Check whether the Aluminum sheet is properly fixed to the panel.

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 After the installation of Aluminum sheet, sealant to be applied with proper tooling
throughout the periphery both inside and outside or as per approved drawing. (Color of
the sealant is recommended by Arch / Client / Consultant Approved shop drawing)

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6. METHODOLOGY – PRODUCTION - FACTORY

6.1. MS FOR INSPECTION OF DELIVERY OF PROFILES

When the Aluminum material reaches to the factory from the supplier the Quality
team in the factory inspects the following.

 Checking the profiles as per the approved make and size

 Checking the profiles as per the approved shop drawing.
 Checking the profiles for any scratch marks.
 Checking the profiles for any bend / twist / angularity etc.
 Collecting the MTC & cross checking with the packing list.

Then the material is been sent to the coating plant. The required coating
(Anodizing / PVDF or Powder coating) is done on the profiles as per the approved
sample as submitted by the client for the shade / type approval. When the
coating process completes, the material is been sent to the fabrication
department.

6.2. INSPECTION FOR THE COATING ON PROFILES

The Quality team inspects the following after receiving material from the coating plant.

 Correctness of the coating shade/color/finish as per approved sample.

 Checking if any Visual Damages seen on profile/coatings
 Checking for Micron thickness using Elcometer as per project requirement
 Collecting the MTC & cross checking with the packing list.

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6.3 PANEL FABRICATION PROCESS

When the QA / QC department certifies the profiles for the coating, the same are
being taken for the fabrication as per the fabrication drawings received by the design
department. All the profiles including Mullion (Both Male & Female), Transom,
Gutter, Sill, Outer frame, Dead load Support etc. are being cut (Degree wherever
applicable) as per the panel size. These cut to size sections are joined with the help of
self-tapping screws as per the fabrication drawing. These fabricated panels are being
checked by the QA / QC department for any visual damage, bow error, diagonal
etc. In case of these issues the panel is rectified there itself. Now the panels are
ready for glazing and are sent to the glazing line.

6.4 PANEL GLAZING PROCESS

While fabrication is under progress in the fabrication department, the glazing plant
checks for the availability of the glass (Both Single and DGU as per the requirement
of project) as per the panel type and dimensions as per the drawing.
The glass is properly cleaned for Sealant application. Once again, the assembled panel
is checked for diagonal. Later Double-sided tape is applied on the sections. After
application of the spacer tape glass Spandrel and Vision) is pressed on the panel
maintaining uniform groove with the help of PVC separators. Masking tape is
applied on the aluminum sections to prevent excess silicone while tooling on the
inapplicable areas. Now this assembly is ready for silicone application
.
The two-part glazing pump is adjusted properly as per the required specification of
sealant base and the catalyst. The primer is applied on the sealant area before
glazing. Approved structural silicone is applied to glaze the glass with the help of
silicone gun. The silicone is properly tooled, and the masking tape is removed, and
the panel is kept for curing. After curing of the structural silicone, weather silicone
is applied with silicone gun. Again, the panel is kept for curing.

Later the glass is cleaned properly with glass powder and is covered with the plastic.
The G. I. sheet is properly cut to form a tray. At the spandrel glass, tissue paper and
glass wool are pressed to cover entire area and then the G. I. Tray is fixed on the
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mullion and the transom with the help of aluminum clits and screws. The panel is now
ready for dispatch.

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UNIQUE IDENTIFICATION NUMBER

The complete Methodology of the Project is based on the concept that there shall
be a limited stock of Materials at site. Considering this there shall be a Unique
Identification Number for each Part of Façade before shipment to site. This shall also
be mapped on the Drawings for tracking installation and review later.

Each Panel / Window etc. shall have this unique number marked on it along with the
name of the Fabricator. This shall facilitate review later. However, the exact details
of Fabrication cannot be documented and maintained due to big variety of the
façade parts.

As a function of the installation planning, the individual panels shall have a

detailed
installation location. This together with the date the panel is installed shall be
recorded on elevation drawings in the ALMECH site offices to produce full
traceability from the manufacturing stage through to installation.

For each of the key stages of factory operations, a method statement shall set out
the procedure to be followed. This, together with QA/QC sheets and factory
inspection and check sheets shall be completed to confirm the standards have been
achieved and tasks complete

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TOOLS & INSTRUMENTS TO CHECK FOR THE SAME

1. Vernier caliper 2. Measurement tape 3. Coating thickness meter (Elcometer)

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7. METHODOLOGY – SITE ACTIVITIES

7.1. METHOD STATEMENT FOR THE CONCEALED WORKS

Aim:
 To ensure all the materials are involved in production which is hidden / concealed.
 To achieve a quality project experience throughout the project.
Purpose:
 To achieve effective project progress by ensuring the low rejections
 To effectively reduce last minute rejections.
Description:
 Especially Unitized panels are subjective to have conceal works such as filling with
insulations, flashings etc.
 Since Concealed works are subjective to hide materials, concealed reports shall be
objective to be marked and based on the process of production to report the client
as such all the requirements are fulfilled as per the project requirement.
 Concealed work reports are generally prepared by the Production engineers.
 Repetitive reports as per the frequency (for every batch) shall be marked and
subjective to the client’s approvals.
 Concealed work reports are based on periodic photo snaps addressing the dates too.

Result:
 To ensure the concealed activities are generally met during the production of panel

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8. WORK METHOD STATEMENT FOR SMOKE SEAL APPLICATION AT SITE:

Aim:
Smoke Seal Is installed in order to protect and avoid smoke ingress in consecutive floors in
case of fire in the building
Purpose:
The purpose of smoke seal is to stop the spread of fire and smoke damage once a fire was
started.
Description:
 In the event of fire in a building, physical barriers are needed to stop the flames and smoke
from spreading to higher floors through the gap between the floor plates and the curtain
wall. For this purpose, smoke seals are used.
 While a smoke seal is installed from the edge of the slab to the curtain wall at the beam
level.

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9. METHOD STATEMENT FOR QUALITY CHECK – INSULATIONS ( Quality )

Aim:
 To check the insulation material in the glazed panel
Purpose:
 To reduce the heat transfer in the building
 Checkpoints for Insulation Quality Check:
Glass wool insulation
 Check the thickness (50 mm) and density -48kg/m3 of received Glass wool from
suppliers
 Check the Density of Glass wool as per required specifications.
 Check the length and width of the received material as per WIFA PO & specifications.
 Check for any damages for the received material.
 Check whether the supplier provided Material test certificate with the material.
 Check for technical data sheet for quality analysis.

Smoke seal or Rockwool Insulation:

 Check the thickness (100 mm) and density -100 kg/m3 of received smoke seal from
suppliers.
 Check the Density of smoke seal as per required specifications.
 Check the length and width of the received material as per WIFA PO& specifications.
 Check for any damages for the received material.
 Check whether the supplier provided Material test certificate with the material.
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 Check for technical data sheet for quality analysis.

9.1. METHOD STATEMENT FOR PULL OUT TEST AT SITE

Aim:
 Pull out test will be carried out by Hilti representatives in presence of client members,
contractor’s members
 Check the load capacity of specified anchors at the desired location where bracketing will
be done for installation of unitized system at site.

Scope:
 Outlines the test regimes (number of tests, test load, assessment of results) which need to
be satisfied to achieve the appropriate objectives.
 These are summarized below. This GN gives the details of how tests should be carried out:
equipment, how loads are applied, how movement may be monitored, reaction spacing’s,
etc.
 Some elements of the recommendations repeated here to provide a single reference.
 This Guidance Note covers the procedures for applying Ultimate, Preliminary or Proof Loads
in concrete and masonry materials.
 Tests in the tensile direction are covered in the main body of the document.
 Tests in shear are not usually needed as shear performance is generally limited by the
material strength of either the structure or the anchor
Tests to validate the quality of installation – Proof tests:

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 The minimum number of fixings to be proof tested should always be at least 2.5% and at
least 3 of the total number of anchors installed on a job.
 The minimum of 3 applies in any discrete area where different anchors may have been used,
the base material is different, the condition of the base material has been affected by
weather conditions e.g. on a different elevation or where anchors have been installed by
different installation teams.
Acceptance criteria
 Anchors can be said to have satisfied a proof test if the required load is held without
movement or any damage or deformation occurring to either the fixing or the base material.
 Any anchor suffering movement or damage should be recorded as a failure.
Failures during Proof Testing

 If the correct selection and installation procedures have been carried out as recommended
by respectively and the manufacturer then no failures should be encountered.
 Failures indicate that one or other of these processes may not have been carried out
correctly so must be treated seriously.
 If, in any discreet area, 1 failure is encountered then the reason for failure should be
investigated, the number of anchors tested in that area should be doubled to 5% and at
least 6.
 If more than one fails then 100% of the anchors should be tested, the reasons for failure
determined and the specification reconsidered.
 Reasons for failure should be communicated to those responsible for specification of the
fixing and for its installation as they may prompt either the improvement of the installation
method or a revised fixing specification.

Replacing failed fixings

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 Failed fixings will usually need to be replaced.

 This should be carried out by a competent installer observing all installation procedures as
set out and in manufacturer’s installation instructions.
 The specification of replacement fixings should be confirmed with the specifier before
replacement is carried out in case a revised specification is deemed necessary.
 Depending on the nature of the failure it may, under certain circumstances, be possible to
install new fixings in the original holes – specialist advice, including from the anchor
manufacturer, should be sought before pursuing this option.
 If replacement anchors are not permitted to be located in the same holes, then the location
of new holes should be determined by the specifier.
Procedure for tests
 The following is a general procedure which covers preliminary tests, test to failure and poof
tests.
 Any deviations from this procedure should be noted in the test report.
Safety:
 All testing operations must be carried out with due regard for the safety of the tester and all
bystanders.
 Ensure that the anchors to be tested are as specified on the job or by the client and that the
test objective is known, including proof load levels (if appropriate).
 In the case of tests into new construction - Ensure that the base material is at least the
strength assumed by the specifier in the design of the fixing
 Ensure the positioning of anchors to be tested is as required.
 Ensure the fixing is or has been installed as per the manufacturer’s instructions.
 Assemble the test rig– check that reaction spacing’s meet the recommendations of in
relation to the test objective.
 Connect the test meter or hydraulic load cell to the fixing,
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 If movement is to be monitored in detail (not usually required for proof tests)

 Put in place displacement measuring equipment, e.g. dial gauge on remote mounted stand.
 With load at zero record reading of dial gauge.
 Apply the load slowly and progressively and record the load at first movement and at the
manufacturer’s recommended resistance if known.
 Increase the load in increments to give at least 10 readings up to the expected failure load.
 For each increment allow both load and displacement to substantially stabilize then record
load and displacement
 When the maximum load is reached record the load and, if possible, displacement.
 Record the condition of the fixing and base material, e.g. cracks o If failure has occurred
record the mode of failure and the size of any material cone that may have detached from
the base material.
 If failure has not taken place release the load and record the residual displacement. •
Detach the movement monitoring and test equipment. Make good any damage to the base
material if possible.
 If movement is not to be recorded in detail
 Apply the load slowly and progressively and record the load at first movement
 Increase the load steadily at a rate to reach the required proof load in 30 seconds or, if
testing to ultimate load, the maximum load in between 60 and 90 seconds.
 When the proof or maximum load is reached record the load and, if possible, any
displacement, by estimation if necessary.
 If failure has occurred record the mode of failure (see below) and the size of any material
cone that may have detached from the base material.
 Detach the test equipment and make good any damage to the base material if possible.
 Complete the test report.

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9.2. METHOD FOR FAÇADE PROTECTION:

Aim:
To protect the façade system from the Scratches and unwanted damages.
Procedure:
 Protection tape will be provided at powder coating area of aluminum profiles used in
unitized panel, Sliding Window, convectional glazing etc..by supplier first.
 Secondly when material received in Baggy factory material will be checked for any kind of
scratches and damages, rejected material will be segregated from ok lot and return to
vendor during quality inspection of material.
 After cutting and fabrication and glazing work all item in panel will be well protected by
protection tape including Glass, Aluminum coated profiles for avoiding scratch and damage
to final aesthetic appearance of product.
 Panel will be transferred to site with proper packing and transportation technique.
 At site material will be stacked in a proper manner and at place provided by client
 During of installation of facade system, the protective film should not be removed.
 After the installation of facade system, the interior work has been started that time may
occur damages to the system only the protective film control from scratches.
 If any damages occur by other vendor inform to the client
 After the installation, the system will be handed over to Client

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1.1. METHOD STATEMENT FOR SITE CLEANING

Aim:
 A clean building presents a more hospitable front - & therefore a more attractive real
estate prospect - to the public.
 The company undertakes facade cleaning contracts for high performance buildings
having glass facade or UCW.

PROPOSE CLEANING METHODS: -

Water cleaning method
 Water soaking: - A slow steady stream of water is used to loosen dirt & wash it away, a
very effective method as dirt becomes swollen & soft. Hand scrubbing with brush or
rinsing with 400 psi water spray may follow the water soaking.
 Pressure washing: - Pressurize water, measure in pounds per square inch, blasts
contaminants away from the facade. The procedure is effective on stone, masonry &
concrete for the removal of light to moderate atmospheric & organic staining.
Chemical cleaning method.
 Chemical products work by dissolving the stains, allowing them to be rinsed away.
 Four categories of chemical agent: -
 Acidic cleaners, alkaline cleaners, organic solvent, nonsuiting detergent. The procedure
is effective to conquer tough facade stains.
 Abrasive cleaning

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 Design to completely remove the outer portion of substrate on which the stain sits,
rather than merely dissolving & washing away stain. Effective for stone, masonry &
concrete.
SPIDERMAN SERVICE: -
It is very low on capital cost & on the cleaning cost; besides it is safe & operative friendly.
Components of the system: -
 Nylon Ropes: - The ropes which are parachute guide, are capable of withstanding one
ton of load
 Ascending & Descending system (Spiderman kit): -We use kits imported from UK /
France.
Key features are: -
 Portable & light weight.
 One-man operation.
 Fail safe capability.
 One is to two pulley ratios.

METHOD AND CHECKLIST FOR VENT/OPENABLE FIXING AND QUALITY CHECK

Aim:
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For the purpose of ventilation and safety ways fix the openable window.
Checkpoint:
 Openable window is fixed in Aluminum profile system with help of stay hinges and screws,
side striker and handle accessories provided for closing and opening function of Openable
window.
 Gasket provided at periphery of window profile section in order prevents water ingress
through Openable system or as per approved drawing.
 Beep holes/drainage holes will be provided in outer frame section for overflow water
drainage.
 Silicon will also be applied between joints of Main Panel frame and Openable outer frame.
Glass will be fixed on system frame of Openable window as per approved drawings and
specifications

1.2. METHOD STATEMENT FOR SCRAP REMOVAL:

Aim:
Removal of unwanted materials from the site.

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Procedure:
 After finishing the fabrication work, the unwanted material stored in the different location
 In site also collect the unwanted materials to store in the desired locations.
 All the wastage or damage materials are stored in single location.
 The wastage materials are taken from the site and send back to the factory.
 The wastage materials are details informed to the client and got approval from the client.

1.3. METHOD STATEMENT FOR DEMOBILIZATION

 The materials are arranged for the desired location to fix the system.
 We have to the start the work
 Arrange the supporting machines to fix the system
 After finishing the work in the desired location dismantle the parts of the supporting system.
 Then dismantle parts shifted to the next location in the continuous process

1.1. METHOD STATEMENT FOR HOUSEKEEPING

Housekeeping is not just a push broom effect. Housekeeping means much more than that. It
means not only cleanliness, but also an orderly arrangement of operation tools, equipment
storage facilities and supplies. It is practical method of increasing production, reducing
accident and improving morale and public relation.

 It’s prime duty of site supervisor to maintain housekeeping on daily and alternate day
basis after the job is finished.
 Proper lay out of work area
 Area clearly marked and identified as aisles, storage space, receiving and delivery points.
 Arrange necessary items in good order so that they can be easily picked for use.
 Maintain high standard of housekeeping and workplace at all time

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1.1. PROCEDURE FOR HANDING OVER OF ATTIC STOCK.

 After the completion of project, the attic stock also handed over to the client
 Handed over 2% of All material to be handed over to the client
 In case of emergency, client used the attic stock material.
 All the attic materials are shifted to the desired location safely.
 Make the list of the Attic stock materials handed over to the client and got signature
from the client.

2. PROGRESS REPORTS AND REVIEW MEETINGS

2.1. WEEKLY PROGRESS REPORT AND HINDRANCE

 Main concept for the weekly progress report is to monitor the weekly target and
achieved progress.
 It contains the details of the material received last week.
 It contains the previous week’s productivity
 It displays the balance target
 As per the productivity the target must be varied.
 It displays the delay and what are the issues happen.
 We must control the issues to achieve the target within the time without any delays
 All reports are submitted to the client.

2.2. MONTHLY PROGRESS REPORT

 Main concept for the progress report to monitor the monthly target and achievement.
 It contains the previous month supply details.
 It contains the previous month productivity
 It displays the balance target
 As per the productivity we must plan for the target.
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 It displays the delay and the issues and concerns.

 We must control the issues to achieve the target within the time without any delays.
 All reports are submitted to the client.

2.3. DAILY PROGRESS REPORT

 Main concept for the Daily progress report is to monitor closely and control the targets
daily.
 It contains the details of the material received up to the previous day
 It displays the daily productivity and the balance targets
 As per the productivity the strategy needs to be changed
 It displays the day-to-day obstructions which are causing delays.
 We must control the issues to achieve the target within the time without any delay.

2.4. WEEKLY REVIEW MEETINGS

 In the weekly review meeting, the productivity of the previous week is discussed, and
the issues and concerns are discussed if the target was not achieved.
 In the weekly review meetings, the balance targets and the mitigation plan required to
achieve it are to be discussed.
 As per the discussion on weekly review meeting to execute the plan.
 The weekly review meeting minutes is sent to the Client.

11. RFIs

 If any clarification is required from client/PMC, request to be forwarded client and get the
instructions from the client and do as per client instructions.

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 Log of Engineering Instructions:

S. No Date Type of work Requesting information Client instructions Closing date Remarks

12. SEALANT:
There are four main types of sealant
 Clear Sealant
 Weather sealant
 Structural sealant
 Firestop sealant
12.1 CLEAR SEALANT
Clear sealant is used to control the water leakage location. Clear sealant is used in all the
periphery joints as well.
12.2 WEATHER SEALANT
Weather sealant is used in the external condition. Weather sealant is applied in the groove
location. It comes in various colors as per client requirement

12.3 STRUCTURAL SEALANT:

Structural sealant is mainly used to bonding the glass/ACP on the Aluminum frame.
Structural sealant curing time is quicker than weather sealant.

12.4 FIRESTOP SEALANT:

Fire stop sealant applied on the smoke seal. Firestop sealant is used to control the
spread of fire from one floor to another
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13.DOCUMENTATION
Attached in this quality plan there is a Flow chart which depicts the various stages
of Façade from Supply to Handover. Quality forms are attached which can be tracked
on the Flow Chart. The quality plan describes the QA/QC management systems for
the project.

This quality plan shall be used in conjunction with the company integrated
management system where appropriate.

Project controlled documents shall be utilized in line with the Client’s requirements.

13 QUALITY RECORD
The Factory Manager / Quality Manager shall be responsible for ensuring that quality
records are maintained and issued to relevant clients as required by the contract.

The quality manager shall ensure that quality records are retained for a period as
defined by the contract.

Quality Records or communication Documents shall be taken from Site if so desired

from time to time for Management Review in ALMECH Head Office.

14 TOOLBOX MEETINGS
The company has developed training procedures which apply to employees and
subcontractors.

Toolbox talks shall be provided to factory personnel to cover quality, fabrication &
glazing, health and safety and environmental topics, these shall include, and

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specialized training considered necessary i.e. Materials, non- standard installation

techniques/ sealing up procedure
Minutes for the Toolbox Talks may be Read upon request to the Project Management.

15 CONTROL OF MONITORING AND MEASURING DEVICES

The company shall ensure that the inspection measuring, and test equipment used
to demonstrate the conformance of a product to the specified requirements is
calibrated in accordance with procedure, which shall ensure that:

 Each item of equipment is uniquely identified and traceable by record to

internationally recognized standards

 The calibration interval is defined

 The method of calibration id defined

 The equipment’s are clearly identified as such and that any necessary measures
are implemented to ensure that unauthorized adjustment is not made.

 Should any item of equipment be found not to conform to the specified

requirement then the validity of previous results shall be assessed, and any
required action will be implemented.

16 INSPECTION AND TEST

The Inspection & Test Plan is attached separately.

ALMECH shall conduct internal inspection before asking Client / Consultant for
witness. Later ALMECH shall submit the Inspection Request for joint inspection of
Requested samples of material to establish the acceptability of the completed
products.

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 Project:

The inspection and test plan provide detailed requirement for inspection and testing
from receipt inspection which includes inspection of received goods and inspection
of customer provided interfaces etc. on site, in process inspections and final
handover to the Client.

17 SAMPLE BOARD SUBMISSION WITH LIST OF APPROVED MAKES

Aim: To Inform and get necessary approvals from Clients & Concultants as such any
deviations found shall be rectified immediately.

Purpose: To Ensure the list of materials covered in the project is subsequently aimed in
procuring the materials on required durations, as such the project shall be delivered on
stipulated time.

Advantages:
 Prototype is readily available for any technical verification.
 Alarms the vendor to facilitate required materials on required timelines.
 Helps in understanding the sequence of materials to procure.
 Helps in understanding the required materials to be used in project over production
and installation.
 Educate the vendor / client / consultant on referring to project during execution on any
deviations followed if any.

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18 VISUAL MOCKUP-METHOD STATEMENT

Aim:
Visual Mock-up (VMU) means undertaking mockup before commencement of the work.
It is used to identify any deficiency in the system.
It is used to identify and ensure the mode of erection of system.
Procedure:
 As per client approved location mock-up shall be performed in the site.
 The VMU panels are fabricated as per the approved drawing.
 VMU panels are fabricated on high priority with respective approved shop drawings,
list of approved materials makes (sample board) etc.
 Any VMU shall be executed with subject to Client’s requirement which depends on
various projects. Usual practice is to perform a Mock-up for 1 bay: 1 bay OR FLOOR
over vertical and horizontals or subjective to the defines as prescribed in the WO/ BOQ.
 Brackets shall be installed on prior reference after the receipt of approval on the mock-
up subjective
 Panels are installed on various modes of logistics with safety bound accessories and are
mechanically fixed to the brackets which suggest the timeframe required in achieving
the project.
 Various interim finishes required shall also be accompanied and by latest the Mock-up
shall be furnished to clients and consultants for further Project progress.
 VMU shall be technically verified on subject to various test performances which should
be imperative and accepted over the successions of technical parameters, aesthetics
and architectural requirements.
Result:

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 Project:
If any defect comes that must control during the erection of the panel and complete the
project within time and in quality.

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19 FACTORY/SITE INSPECTION APPEAL FORMAT

Aim:
To call the client for inspection of material, method, work done and whenever required
by client.

Description:
Whenever task is completed from our side to inform the client to inspect our work done
and prepare the document as per client requirement and got the approved from the
client.

LOG FORMAT for INSPECTION REQUEST:

Sl No Inspection Details Date of Inspection Remarks

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20 WORK PROGRESS FLOW CHART:

Shop drawing

Procurement

Material receipt at stores

Back to Vendor

If Certified Quality Reject

Inspection

Production

Proper Packing& Protection of Materials as

per client specifications

Dispatch as per site

Requirement

Site installation

Re-work
Quality check

Pass -OK
Snag list & Handing over

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21 DEBIT NOTE FORMAT FOR SITE DAMAGES BY OTHER AGENCY

WORKING AT ALMECH SITE

DEBIT NOTE

Ref No. ALM/2023 /--------- Date: …………

AAccounts Dept.

Please arrange to deduct the amount from the bill of the Site
Contractor/Agency due to Non-Returnable damage of Material.

NName of Contractor: …............................

Sl. No. Particular Qty. Unit Rate Amount Remark

Total

AAMOUNT:

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PPrepare by, Approved

22 FORMAT FOR CORRECTIVE ACTION & PREVENTIVE ACTION

Aim:
Corrective and preventive action is improvements to an organization's processes
taken to eliminate causes of non-conformities
Description:
Corrective action is a reaction to any of the cause/non-conformance mentioned above
and can be divided in two phases of action:
 Identification of root cause
 Taking necessary actions
The effectiveness of the corrective action taken must be verified periodically through a
systematic approach
Preventive action is prediction of problem and trying to avoid the issues through self-
initiated actions and analysis related with processes.
Implementation of corrective and preventive actions is the path towards improvement
and effectiveness of Quality Management Systems. Corrective actions are nothing, but
the action/s based on the problem identification

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 Project:

Format for Corrective Action

Last Update
CORRECTIVE ACTION PLAN LOG
On:
DOC.NO.: KAT/SITE NAME/QA/-------

Sl. No. NCR No Date of Issue Description Action plan Date of Status Remark
Reply

Format for Preventive Action

Last Update
PREVENTIVE ACTION PLAN LOG
On:
DOC.NO.: KAT/SITE NAME/QA/-------

Sl. No. NCR No Date of Issue Description Action plan Date of Status Remark
Reply

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 Project:

23 FORMAT FOR MICRON INSPECTION

Aim:

To Check the coating thickness for Aluminium and M.S materials

Description:

 The coating thickness is identified in microns

 Elcometer is used to check the coating thickness of the materials.

 The micron inspection for powder coating, PVDF and galvanizing finish.

POWDER COATING /PVDF- THICKNESS -CHECK FORMAT

DOC.NO.: KAT/SITE NAME/QA/-------

Sr. No. Material Date of inspection Micron Total Pass Reject

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 Project:

24 PROCEDURE FOR HANDING OVER:

PROCEDURE FOR HANDING OVER OF KEYS

 After the completion of the façade system fixing. The Doors and windows are
Handed Over
 After the door & window is fixed in the system, all the alignment works are finished
in the Doors & windows.
 All required accessories as per design are fixed on the doors & windows.
 The keys of the Doors are handed over to the Client
 Checklist to be prepared and signature to be obtained from Client after Final
inspection.

PROCEDURE FOR HANDING OVER:

 After the completion of the entire façade package handing over to the client.
 WIR is raised and given to Client for Inspection
 Client or Client appointed qualified 3rd party / Consultant to inspect the Façade
system to check the scope of work & the quality.

 After inspection, if any work to be redone or any other snag points are observed,
Client to provide a Snag – list containing all the points that needs to be attended
and rectified.

 All the snag points to be attended and necessary remedies to be taken to rectify
the issue.

 Once all the points in the Snag list are attended and rectified, WIR to be raised for
Final inspection.
 Prior to Handover, all scopes of work to be cleaned properly.
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 Project:

 Final completed WIR and other handover documents to be obtained from Client.

***************

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