Installation Method Statement for ITC One Colombo One Façade

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: MS-INST-01
METHOD STATEMENT
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SITE INSTALLATION WORK EFFECTIVE DATE: 25-06-2017
MERO ASIA PACIFIC PTE LTD
MERO ASIA PACIFIC ENGINEERING PVT LTD
METHOD STATEMENT
FOR INSTALLATION OF SEMI-UNITIZED PANELS
ITC ONE COLOMBO ONE
DESIGN, SUPPLY INSTALLATION AND TESTING OF FAÇADE

SYSTEM FOR PODIUM, SKYLIGHT HOTEL AND RESIDENTIAL
TOWER
Important Notes
This information contain herein is the
Property of MERO ASIA PACIFIC ENGINEERING PVT LTD
REV 0
Prepared By
QA / QC Manager
_______________ __________________ _______________
(Signature) (Designation) (Date)
Reviewed By
_______________ __________________ _______________

(Signature) (Designation) (Date)
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Table of Contents
A. Revision record. ............................................................................................................................. 3
1. Purpose ........................................................................................................................................... 4
2. Scope of works............................................................................................................................ 5
3. Codes and standards ................................................................................................................ 5
3.1 Technical specification ......................................................................................................... 5
3.2 International standards/reference documents ............................................................ 6
4. Terms and conditions .............................................................................................................. 8
5. Roles and Responsibilities ..................................................................................................... 8
5.1 Project Director ....................................................................................................................... 8
5.2 Project Manager ..................................................................................................................... 8
5.3 Execution engineer .............................................................................................................. 10
5.4 Quality Control Manager/Engineer ................................................................................. 8
5.5 Other Departments: ............................................................................................................ 12
6. Access/Egress ............................................................................................................................. 13
7. Lighting ........................................................................................................................................ 13
8. Plant and Equipment & Safety .......................................................................................... 11
9. Materials ...................................................................................................................................... 18
10. Method of work ..................................................................................................................... 20
10.1 Preparation .......................................................................................................................... 14
10.2 Work Details ........................................................................................................................ 24
10.3 Inspection and Test........................................................................................................... 28
11. Risk and Controls .................................................................................................................. 31
11.1 Where new risk have been identified, the basic steps ......................................... 22
11.2Control measures ................................................................................................................ 23
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12. Technical Information ......................................................................................................... 34

13. Emergency arrangements ................................................................................................. 34
13.1 General .................................................................................................................................. 34
13.2 Fire precautions .................................................................................................................. 34
13.3 Communication .................................................................................................................. 35
14. Training ...................................................................................................................................... 36
15. Supervision ............................................................................................................................... 36
16. Working Hours ....................................................................................................................... 37
17. House keeping ........................................................................................................................ 37
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A REVISION RECORD
Version, Date of re Description Of Changes

Page, Para-
graph No.
submission
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1. Purpose
 The purpose of this Method Statement is to provide the personnel associated with
the works referred with appropriate work methodology and test procedures, so
that the Quality requirements as defined can be accomplished when planning and
executing the works described herein. This Method Statement outlines the work
sequence intended for the Installation of Curtainwall panels for ITC One Co-
lombo One project Tender submission.
2. Scope of Works
 This Method Statement is applied for the Installation of Curtainwall panels un-
der Design, Supply, Installation, Testing and commissioning of Façade works
carried out in ITC One Colombo One Project in Colombo, Sri Lanka.
3. Codes and standards

3.1 Technical specification
 The following standards are applicable to the design of the works covered by the
Technical specification. This is not an exclusive list and additional standards shall
be referenced where required to meet the contract/technical specification intent.

All standards and regulations referenced herein shall be the current revision of the
standards unless specified otherwise.
 India Local Codes and Standards
 NPQS
 BS or BS EN
 Other standards such as ASTM (US), AS (Australia) and DIN (German).

 As per technical specification : chapter 2, relevant codes and standards
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3.2 International standards/reference documents
3.2.1. Indian Standards
IS-875 : part 1 Dead loads
IS-875 : part 2 Imposed loads
IS-875 : part 3 Wind loads
Code of practise for design loads (other than earth-
IS-875 : part 4 quake) for building and Structures-Special Loads and

Combination
IS : 1893 Criteria for earthquake and Structures
Earthquake resistant design and construction of

IS :4326
building
Code of Practice for use of Aluminium Alloys in

IS : 8147
Structures
3.2.2. British standards
BS EN 755:2008 Parts 1,2 & Aluminium and Aluminium Alloys - Extruded
3 Rod/Bar, Tube and Profiles
BS 4255: part 1 – 1986

Gaskets
ASTM C 864, DIN 783-1
BS EN ISO 1461 : 2009 Hot dip galvanising

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BS EN 10210 pts1&2:2006 Hot finished steel hollow sections
BS 3692, BS EN ISO 898

Mechanical properties of fasteners / Carbon & Alloy
Parts 1/5&6-2000
Steels
1:2009/5:1999/6:1996
BS EN ISO 3506 parts 1 & 2

Stainless steel fasteners
: 2009
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4. Terms and conditions
 Terms and condition will be as per the specification/contract documents i.e.: MFI-
107 ITC One Colombo One, Sri Lanka, Façade Specification dated 19th April 2017.
 5. Roles and Responsibilities
5.1 Project Director
 The Project Director (Project Control Unit) key responsibility is to monitor and en-
sure the entire project progress. The responsibilities include endeavour for strate-
gic goal and troubleshoot the methods and sequences of the fabrication, assem-
bling, glazing and installation works.
 The project director shall take the responsibilities for all Communicating require-
ments, change in specifications to all affected departments and resolving prob-
lems that arise at interfaces of groups throughout the whole project.
5.2 Project Manager
 The Project Manager acts as the authorized person for the project, reporting to
the Senior Project Manager and Managing Director.
 Responsible within the project specification/contract, in term of design, procure-

ment, manufacture, quality, delivery, safety, schedule, overhead until project com-
pletion/handover, maintain and operate the project in term of facilitating the eco-
nomic and efficient manner including cooperation and control of the Subcontrac-
tors and Suppliers. His duties include the effective provision and management of
all resources to ensure the followings:
 Key project management responsibilities include creating clear and attaina-

ble project objectives and building the project requirements.
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 Addendum to any Method Statement and Risk Assessment, including any
change of working method or sequence.

 To ensure the Quality Manual, Safety Plans and Procedures are provided and
fully implemented.
 To ensure provision of sufficient resources including of staff, worker, plant
and materials to achieve the targets aspire by the management.

 The full execution of all prescribed work in accordance with the MERO’s sub-
contract.
 Monitor Project Programme and in accordance with Contract/Technical
specification Conditions.
 Preparation and Submission of all routine and specific samples submission
in accordance with the requirements of the project specification.

 To ensure that all necessary approval and documents are available and as
necessary prior to the commencement of works.

 Certification of all purchase orders or Sub-contracts prior to signing off by
the Senior Project Manager and Managing Director.
 Tabulate weekly site progress report in order to convey the actual site con-
dition to the management for review.

 Preparation and submit monthly progress payment application and varia-
tion claims in accordance with project circumstance

 That the responsibilities for all staff as assigned by the Senior Project Man-
ager or Managing Director, are understood and to achieve the project tar-
get.
 Maintain and continuation of good relations with the client and the repre-
sentatives.
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5.3 Execution engineer
 The Execution Engineer reports to the Project Manager and manages relating to
the entire site activities associated with the site, to monitor and to ensure the pro-
ject program within the prescribed time table allowed, to be responsible for the
installation sequence, quality, safety and conformance within the project specifi-
cation, daily report to Project Manager which is including of all project supervisors
and subcontractors responsibilities.
 Project Engineer is to liaise with the Main Contractor and project team approach-
ing the execution of effective works. The duties include the followings:
 Develop, implement and monitor installation program, including the devel-
opment of quality standards in accordance with project specifications.

 To closely monitor all site installation activities and resolve problems en-
countered on site and report accordingly to Project Manager.

 In charge of performance management of the architectural and engineering
vendor.
 The Project Engineer is inter-discipline coordination and overseeing the
quality control of engineering work done on site.

 To monitor and report daily work done by the workers or sub-contractors
and to ensure that the delivery of installations and goods are of good in-
stallation requirement as specified within the contractual schedule.
 Report and submit weekly progress reports to Project Manager, of work

done and daily manpower allocation.
 Ensure project is completed according to project plans.

 Attend project coordination meetings in relative to Main contractor and
sub-contractor.
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 Responsible for all site workers in the assigned project in particular relating
to safety regulations and of the statutory regulations.

 Monitor site safety daily tool box meeting and other related safety issues.
 To maintain and record in order to provide complete checklist of all site

equipment and facilities and proper storage.
5.4 Quality Control Manager/Engineer
 Coordinate the document controls of technical submittals, drawings, etc. with the
Project Team and to ensure that the QA/QC validation has been done, to ensure
their issue, amendments and recall of controlled documents.
 Coordinate all inspections; monitor the required tests and record inspec-
tions and tests made per the Contract Plan and Contract/Technical Specifi-
cations.
 Liaise with the Client's representatives for the conduct of day-to-day quality
related project activities.
 Coordinate with the Project Manager regarding work performance and hold
authority to stop work in any area where discrepancies remain uncorrected
and/or cancel the stop work order upon satisfactory correction of noted de-
ficiencies.
 Provide technical support to the Project Manager and guidance to site staff
in submission of materials for approval, request for inspection, shop draw-
ings, As-built drawings, O & M manual.

 Assist QA/QC Manager in conducting internal quality audits.
 Ensure that Non-Conformance Report (NCR) are raised once the activities
deviated from the Contract/Technical Specifications or normal construction
industry practices.
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 Coordinate with the project staff to compile and maintain pertinent records
of inspection and testing until end of the contract and all pertinent records
for retention on completion of the project.
 Attend Monthly Project Review Meetings (PRM) and alert the project team
of any potential problems.
5.5 Other Departments:
5.5.1. Safety Manager
 The Safety manager is responsible for the development, implementation, and ad-
ministration of this procedure. This involves:
 Conducting workplace risk assessments to determine the presence of haz-

ards.
 Conducting periodic workplace reassessments as requested by supervisors.

 Maintaining records on risk assessments.
 Providing training and technical assistance to supervisors on the proper use,

care, and cleaning of approved PPE.
 Providing guidance to the supervisor for the selection and purchase of ap-
proved PPE.
 Periodically re-evaluating the suitability of previously selected PPE.

 Reviewing, updating, and evaluating the overall effectiveness of this proce-
dure
5.5.2. Foreman/ Site Supervisor:
 Compliance to safety Rules& regulations and any other relevant legislation.
 Promote safe conduct of work at the site.

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 Rectify unsafe condition and correct unsafe practices.
 Check that contractors comply with the safety procedures and practices.
 Attend safety inspection and patrols and monitor corrective action.
5.5.3. Workers
 It is the responsibility of the workers to understand and adhere to the procedures of

this plan and to follow the instructions of the engineer/supervisor. It is also the re-
sponsibility of the employee to bring to management's attention any unsafe or haz-
ardous conditions or acts that may cause injury to either themselves or any other
workers
6. Access/Egress
 Adequate and proper means of access & egress shall be used. Stairways & ramps
shall be used for means of access/egress. Suitable directions shall be provided.
 The pathway of the access/egress should be free from obstructions. Adequate

hand railings & illumination should be provided.
 The location shall be directed with an understandable language.
 The means of access/egress shall be controlled. Only the part allotted by L&T
should be used for access/egress (i.e. provision of various gate entry & ramps).
 In the event of certain access entry is changed other entry points shall be used as
per the L&T instructions.
7. Lighting
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 Before launching this project, The HSE Manager and Electrical Engineer shall plan
Electrical Work System that includes all types of planning for electrical safety ac-
tivities such as;
 Electrical Wiring and Apparatus

 Disconnect and Over Current Protection
 Temporary Wiring and Facility

 Lighting at the work areas
 Lockout and Tag-out Procedures.

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 L&T/MERO shall provide sufficient ELCBs (maintain sensitivity 30 mA) / RCCBs for
all the equipment (including portable equipment), electrical switchboards, distri-

bution panels etc. to prevent electrical shocks to the employees.
 All electrical work, installation, and wire capacities shall be in accordance with the
pertinent provisions of the Indian Electricity Act 2003 and Rules 1956, Indian
Standards, ANSI or equivalent in-country standards.
 Each cord/lead, and any tools or equipment connected by cords/leads and a plug
shall be visually inspected for external evidence of defects, by the intended user,
before beginning of work. Sufficient sockets will be provided for computers and
other equipment’s to avoid use of multiple sockets. Such defects include plug
damage, deformed or missing pins, exposed cores and breaks in cable or other
insulation. Damaged or defective tools and equipment shall not be used until re-
paired, inspected, tested and certified safe for use.
 Equipment grounding conductors shall be tested for continuity and shall be elec-
trically continuous. Each receptacle, attachment cap, and plug and receptacle of
cord sets shall be tested for correct attachment of the equipment grounding con-
ductor.
 Contact with energized electrical parts is the principal hazard to be guarded when
dealing with electrically powered equipment. Consequently, all energized parts
must be guarded in such a way as to prevent workers from accidentally making

contact. Guarding of energized parts shall be accomplished in a number of ways,
including the following:
 Locating the equipment in a protected, enclosed environment that limits
access. This enclosed environment shall be a designated room, vault, cabi-

net, or some other enclosure that limits access
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 Locating the equipment in an area enclosed by permanent barriers, such as
partitions or screens that can effectively limit access.

 Locating the equipment on an elevated platform, balcony, or gallery that
can effectively limit access

 Elevating the equipment 2.5m or more above the floor
 A proper warning signs shall be posted around electrical equipment.

 Moreover, electrical conductors shall not be connected to a power source,
without approval from a designated representative.

 Refer MFI-107 ITC One Colombo One, Sri Lanka, Façade Specification dated 19th
April 2017- Electrical Safety & Energy Isolation.
 Electrical Checklist shall be complied – MFI-107 ITC One Colombo One, Sri
Lanka, Façade Specification dated 19th April 2017.
 Following requirements in the table are comply:
Sr.
Classification Item Minimum Requirements Remarks
No.
1 Material Conduit FRLS PVC casing
FRLS PVC conduit
2 Material Wire FRLS HV wire
LTG – 2.5 sq.mm
Socket – 2.5 sq.mm
A/C - 4 sq.mm
3 Material DB All of MCB should be connected to
30mA sensitivity RCCB
4 Circuit LTG Circuit Each circuit cannot be over 6A
Fan switch should be connected to
LTG switch.
(In case of usage of 10A MCB)
5 Circuit Socket Cir- Each circuit cannot have more than
cuit 6 no’s of socket.
Copy machine pot heater should
be connected to separate MCB.(In
case of usage of 20A MCB)
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6 Circuit AC Circuit Each A/C should be connected to 1 ton, 2

separate MCB recommended with ton
25A considering starting current.
Socket for A/C should be used with
minimum 25A. and 25A Deep
switch.
7 Earthling All equip- All of equipment and device includ-
ment ing lighting, socket, A/C should be
provided with earthling wire as
same size of conductors.
8. Plant and Equipment
 Equipment’s used in Quality control are:
 Total station
 PMC 46 laser machine
 Torque wrench
 DFT Gauges
 Vernier Calliper
 Spirit level
 Plumb
 Glass holder
 Measuring tape
 Thermal Chalks
 Welding machine
 Drill machine
 Grinding Machine
 ACP grooving/cutting machine

 MPI/NDT inspection machines
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9. Materials
 Below List of Materials to be used for the installation of Curtain Wall panels& ACP
Cladding
 MS Plates, MS Angle, MS hollow sections, (TATA, Apollo, Jindal) – Fabricated
steel with hot dip galvanizing (DFT – Avg : 70 micron FOR Internal Use and
100 micron for External use as per technical specification)
 Anchor fasteners (HILTI, Wurth) - Fixing of secondary steel on RCC

slabs/beam/columns
 Welding electrode (Royal Arc, Esab, Adoni) - Welding of secondary steel

 SS fasteners (APL) – Fastening of secondary support steel to aluminium/run-
ners
 Aluminium extrusions/sections (Bhoruka, Hindalco & SAPA) – anodised,
powder and PVDF coated from Ajit coaters, MJ coaters and SAPA.
 EPDM setting block/Gaskets (Avigiri, Osaka) – as per approved shop draw-
ings
 Glass panels (Laminated DGU) - As per approved drawing
 Silicone sealants (Dow corning) – weather sealant – 789 / 991
 Backer rod as per approved shop drawing

 PVC Bi-Metallic separator as per approved shop drawing
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10. Method of work:
Construction and
Pre-Construction Major Management Points
Inspection Flow
 All material receipt at site visual inspected &approved materials to be ac-

Receipt of cepted and used.
Material  Testing of material shall be carried out as per approved ITP.
 MIR shall be done and approved
 Storage and handling of material shall be carried out as per approved draw-
ing &Logistic Plan.
 Check for erection of scaffold as per approved HSE plan
 Check for Standard Clearance form is obtained from L&T
Pre-con-  Check for Shifting of Fabricated steels, Curtain wall panels and ACP Panels
struction &accessories to the desired location of installation as per Logistic Plan at-
tached.
 All the material shall be brought to the location of execution as per ap-
proved shop drawing.
 Check for Pull out Test as per approved ITP & supplier recommendation be-
. fore installing of Dead load and Wind Load steel bracket.
 Check for installation of Dead load and Wind Load brackets at locations as
per approved shop drawing with packer plates for alignment.
 Check for alignment for installed Dead load and Wind Load Brackets
During In-
 Check for Anchor bolt tightness with required Torque value as per manufac-
stallation
turer’s recommendation
 Check for Installation of Aluminium mullion in to Dead Load and Wind load
brackets as per approved shop drawing.
 Check for alignment of installed aluminium mullion as per approved shop
drawing.
 Check for the tightening of SS Fasteners (Nut & Bolts) with required Torque
value as per manufacturer’s recommendation.
 Check for Installation of Aluminium Transom in between installed mullion as
per approved shop drawing.
 Check for alignment of installed aluminium Transom as per approved shop
drawing.
 Check for the tightening of SS Fasteners
 Check for welding of Washers as per approved shop drawing and ITP. if ap-
15. plicable
 Check for installation of gaskets on installed mullion and transom as per
16.
17. approved shop drawing.
 Check for installation of Glass panels as per approved shop drawing.
18.
 Check for installation of fixing bone & tightening of all screw (for concealed:
19.
20. grade A2-70, for visible/external: grade A4-70) manually.
 Check for
21.
22.
23.
24.
25. (Continued)
26.
27.
28. GFC DWG
2
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 Check for fixing of 'T' brackets to receive wooden Fins wherever applicable
as per approved drawing.
 Check for the wooden Fin fixing with suitable ss fasteners wherever appli-
cable as per approved drawing.
 Check for fixing the pressure plate along with gasket in to the external ver-
During In-
tical grove of the installed panels wherever applicable. as per drawing.
stallation
 Check for the fixing of capping into the pressure plate wherever applicable
 Check for application of weather sealant with backer rod wherever applica-
ble as per approved shop drawing.
 Check for fixing of bracket for Fin Glass in position as per approved drawing.
 Check for installation of Fin Glass in to the bracket as per approved drawing.
 Check for tightening of Fasteners to secure Fin Glass in position.
 Preparation of inspection documents, joint inspection & sign off.
 Steel :
 Check for Survey of installed steel frame as per tolerance limit +/- 8mm.
 Check for touch up of damaged HDG painting on steels with cold galvanizing
paint.
 Glass panels :
 Check for any damaged of curtain wall panels & ACP Cladding and proceed
for rectification works if any, as per approved QCP
 Check for finished sealant works. (shall have neat finish)Check for survey of
installed elements as per clause number 7.5 of Façade technical specification
 Check for field water test as per Façade Technical specification MFI-107 ITC
One Colombo One, Sri Lanka, Façade Specification dated 19th April 2017,
Protection of glass shall be carried out with signage’s
 Final Cleaning of Curtain wall panels & ACP Cladding, Prior to handing over
29.
30.
31.
32.
33.
 Preparation of inspection documents , joint inspection & sign off.
34.
35.
36.
37.
38.
39.
40.
41.
Post In- 42. GFC DWG
stallation 2
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10.1 Preparation
10.1.1 Approvals
 Approval of Materials, shop drawings and other applicable documents shall be

approved prior to start of work
10.1.2 Quality points
 Person in charge of the work shall ensure that works are executed as per the
approved specification and approved methodology.

 Person in charge of the work shall ensure that, Quality procedures shall be
followed during work execution.

 Elastomeric paint damages due to drilling of holes for bracket fixing shall be
touched up as per approved method statement provided by manufac-

turer/applicator.
 Only qualified personnel shall be engaged for weld visual inspection.

 NDT examinations such as DPT & MPT shall be carried out as per approved
ITP.
 Hot dip galvanised paint damages due to installation and material handling
on secondary steel shall be touched up

 Check for fillet welding as per approved shop drawing and ITP.
 Alignment of installed secondary steel (runner and brackets) shall be

checked
 Alignment of curtain wall panels shall be checked and ensured as per ap-
proved shop drawing.
 Alignment of ACP shall be checked and ensured as per approved shop draw-
ing
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 Sealant application shall be done with proper tools in straight line; excess
sealant should be cut off.

 Experienced supervisors, tradesmen and Labour shall be allocated to exe-
cute the works.

 QA/QC activity is as per the construction Methodology
 Alignment of curtain wall panel as per approved drawing

 Experienced supervisors, tradesmen and Labour shall be allocated to exe-
cute the works

 Erection tolerance as per approved drawing/ s per ITP
 QA/QC activity is as per the construction Methodology

Installation Tolerance:
Installation tolerance for Steel:
 Plumb: +/- 8mm for 3 meters
 Level for horizontal: +/- 6mm for 6 meters

 Joint thickness: Do not vary joint thickness more than 3mm or 2 of nominal joint
width, whichever is less. Variation in plane between adjacent units: Do not exceed
3.0mm, difference between planes of adjacent units.
Installation tolerance for glass (curtain wall):
Installation tolerance shall be as per.
Line +/- 2 mm in any structural bay width
+/- 2 mm in any one structural bay

Level
+/- 2 mm in any one structural height

Plumb
+/- 2 mm in any one storey height or structural bay width

plane
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+/- 2 mm in alignment in any direction between any two

Intersection adjoining panels, at 4 way intersection of panels
10.2 Work Details:
 This Method Statement is applied for the Installation of Semi-unitized Curtain

wall panels, Wooden Fin, Fin Glass & ACP Cladding works under Design, Supply,
Installation, Testing and commissioning of Facade & Associated works carried out
in ITC One Colombo One project, Colombo, Sri Lanka
10.2.1. Delivery, Storage, Handling and clearance:
 The scaffolding shall be erected as per safety standards (HSE plan)
 Scaffold’s tag displaced on scaffolding for “safe for use” and “unsafe for use”
 All scaffolds are to have appropriate ladders or stairway access.
 Supervisor shall inspect the scaffolds weekly, and checklist for inspection
kept for records.
 Deliver manufactured units and component parts to project site in accord-

ance with manufacturer’s instructions, in its original, unopened packaging
with labels intact, properly protected from nature and construction activi-
ties.
 Shifting of Fabricated steel, Curtain wall panels, ACP sheets and their acces-
sories shall be shifted to desired location as per Logistic Plan attached with
this Method statement.

 MEP clearance shall be accorded prior to proceeding of activity
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10.2.2 Site Survey & Setting out
 Ensure all the working platform and equipment to carry out survey works
 Check for Survey benchmarks as provided by L&T during clearance and the
same shall be used as reference for setting out and layout of curtain wall
work
 Based on survey report MERO will prepare As Built dimension and will cir-
culate to Fabrication and installation works.
 Any major deviation which can’t be rectified, the shop drawing will be re-
vised accordingly after approval of Main Contractor/Client and Consultants
 The revised shop drawing incorporating the entire as built dimension will be
issued for Fabrication and installation works.
10.2.3 Fixing of Dead Load and Wind Load Bracket
 Drilling shall be carried out on the Walls and RCC structure i.e.: beam, slab
etc. as per marked location to a embedment depth as per manufacturers
recommendation
 Selection of anchor fasteners as per approved shop drawings and hammer
it on the masonry wall

 Conduct pull out test of the anchor fastener as per the approved ITP.
 Installation of Dead load or wind load brackets shall be carried as per ap-
proved shop drawing

 The brackets are then aligned to the setting out marks and checked for ver-
ticality and if necessary shims (shim plates) are placed below the brackets to
create vertical plumb and to be fixed firm in position.
 Variation in the plumb will be restricted within the specified tolerances.

 The bolts shall be tightened and checked with the help of torque wrench
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.
 Check for torque value as per Manufacturers recommendation.
 Once the bracket is in its final position, the anchor bolts are tightened.
 Damaged galvanised Paint on steel brackets or plates shall be touched up
on site only by cold galvanising spray.
10.2.5 Installation of Aluminium Extrusions:
 Install the aluminium Mullion in to the dead load and wind load brackets
and secure properly as per approved drawing.

 Align all the Mullions to ensure module reference as per approved drawing.
 Install the Aluminium Transom in to the 'C' channel of the Mullion.

 Align the Transom and secure it with Mullion.
 Check for the Fasteners tightness.

 All the fixing & fastening in placed and secured prior to process glass instal-
lation.
10.2.6 Installation of Semi-Unitized Curtain wall Panels:
 Check for fixing of gaskets on aluminium extrusions installed on transom

and mullion as per approved shop drawing
 Installation of glass panels shall be carried out according to the tag numbers
given in Fabrication drawing.
 Secure curtain wall panel with fixing bone screwed to the Mullion or Tran-
som accordingly as per approved shop drawing.
 Before fixing cleaning of all the joints by cloths and blower shall be ensured
to remove the dirt/dust.
 Check for survey report of alignment of Curtain wall panels which shall be
within the tolerance limits
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 Once the alignment is ensured as per drawing, application of sealant will be
started with well skilled workmanship.

 Check for application of weather sealant with backer rod as per approved
shop drawing.
10.2.7 Fixing of GMS T-Section with Wood works:
 Fix the 'T' brackets in position to receive wooden section as per approved
drawing.
 Fix the wooden T section with suitable SS fasteners as per approved drawing.
 Align the wooden fins and ensure tightness of Fasteners.
10.2.8 Fixing of External Glass Fin Works
 Drilling shall be carried out on the RCC structure i.e.: beam, slab etc. as
per marked location to a embedment depth as per manufacturers rec-

ommendation
 Selection of anchor fasteners as per approved shop drawings and ham-

mer it on the masonry wall
 Conduct pull out test of the anchor fastener as per the approved ITP.
 Fix the bracket for Fin Glass in position as per approved drawing.
 Install the Fin Glass in to the bracket as per approved drawing.
 Tighten the Fasteners to secure Fin Glass in position.
10.2.9 Fixing of External Vertical Capping in Semi-unitized Curtain wall panel
 Fix the pressure plate along with gasket in to the external vertical grove
of the installed panels wherever applicable as per drawing.

 Fix the capping by pressing into the pressure plate wherever applicable
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METHOD STATEMENT
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 Check for application of weather sealant with backer rod wherever appli-
cable as per approved shop drawing.
10.2.10 Post installation of Curtain wall Panels & ACP Cladding works
 Check for survey report of alignment of Curtain wall Panels as per tolerance
limit
 Check for finishing of applied weather sealant with backer rod as per ap-
proved shop drawing
 Preparation of handing over document and handing over

 Check for no gaps between any of the aluminium joints
10.3 Inspection and Test Plan
 The following inspection & Test procedures will be adopted to ensure that the work
executed complies with the project requirements and relevant standards.
 10.3.1 Major Quality Management points
 Materials checked against delivery docket upon receipt and for signs of any
damage caused in transit.
 Structural substrates checked for accuracy prior to and during bracket in-
stallation.
 Brackets checked for position and torque setting – check confirmed using
colour spray painted fixings.

 External weathering elements checked for adherence to design details..
 Curtain wall Panels checked for line/level.

 Curtain wall Panels checked for damage.
 External finish checked for line/level.
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 Check for any damage on of curtain wall panels as per the acceptance crite-
ria defined and proceed for rectification works as per approved methodol-
ogy
 Cleaning of curtain wall panels after completion of installation works

 Check bolt & Nuts tightness as per requirements
 Preparation of handing over document and handing over
 10.3.2 Maintenance of records

 The quality control Job cards will be completed during each phase of inspection and will be held on site and
register of Job cards will be up-dated as work progresses.
S.no. Procedure/Document/Forms Periodicity
1 Method Statement Prior to commencement of activity
Once as per Review & Comments Prior to commencement of ac-

2 Inspection Test Plan
tivity
3 Material Inspection Report Every Incoming Materials
4 Job Cards All materials
5 Material Submittals All materials
6 QCP Once and updated as per project requirements
For the documents to be shared for information and as per Docu-

7 Document Transmittals
ment distribution matrix
8 Drawing Register For Every Submission of drawing as per DCI
9 Material Test Certificates All materials
10 Third Party Certificates As mentioned in ITP and immediate on occurrence
As mentioned in Calibration log. (weekly as per document distri-

11 Calibration Certificates bution matrix)
Refer Annexure - 06
Structural steel
12.1 Fit up inspection Report Prior to start of welding

12
12.2 Weld visual report After completion of welding
12.3 NDT tests for welding Before blasting/surface finishing (as per ITP)
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12.4 Surface finishing/Blasting report Before Painting
12.5 Painting inspection report After painting completion
13 Training report As per training plan (Monthly)
14 Audit Report As per Audit schedule
15 Factory visit report/Evaluation report After every factory visit and before every material submittal
16 Monthly Quality report Once in a month
17 Bench marking file with lessons learnt After every bench marking of activity
18 Internal NCR log Once in a month (NCR to be informed upon occurrence
19 Suppliers Evaluation report Once in a month
20 Workmen competency/evaluation report Initially and Once in 3 months
21 Staff competency/Evaluation report Initially and Once in 3 months
22 Approved shop drawings As per DCI
 10.3.3 Inspection and test standard (as per specification)

 As per project Façade Technical specification MFI-107 ITC One Colombo One, Sri Lanka, Façade Specification
dated 19th April 2017
Description Standards Requirement
Façade Test requirements for Glass or Curtain wall panels
Cl. 4.3.32- thickness of technical

Minimum thickness if glass lites 6 mm
specifications
Roller waves on glasses ASTM C1651 Less than
Maximum Bow ASTM C1048 0.10%
All thickness 0.075
mm depth max be-
Roller waves ASTM C1048
tween peaks and
troughs
Edge dip ASTM C1048 0.25 mm maximum
Horizontal/ parallel to
Roller wave marks ASTM C1048
the sill
Residual surface compressive strength in 35 N/sq.mm to 50
ASTM C1048
glass(normal) N/sq.mm
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Residual surface compressive strength in

45 N/sq.mm to 50
glass(point supported glass using heat ASTM C1048
N/sq.mm
strengthened glass)
If used as laminated glass, length and width
Length 6.4 mm
tolerances- for thickness between 6.4 mm ASTM C1172-09
Width -3.2 mm
to 12.7 mm
If used as laminated glass, length and width
Length 7.9 mm
tolerances- for thickness between 6.4 mm ASTM C1172-09
Width -3.2 mm
to 12.7 mm
Façade Test requirements for Aluminium Composite Panels
BS EN 13501-1 Minimum Class B

Fire rating
NFPA 285 Minimum Pass Criteria
Thickness Cl. 4..4.3-technical specifications Minimum 4 mm
0.5 mm panels on
both sides sandwich-
Sandwich system of panels Cl. 4.4.3-technical specifications
ing a solid core of fire
retardant material
Minimum bond strength ASTM D1781-2004 178 N/sq.mm
Allowable bending strength 79 N/sq.mm
2.36 x 10^-5
Coefficient of expansion ASTM E228-11
mm/mm/oC
Tensile yield stress ASTM D638-10 44 N/sq.mm
 10.3.4 Job cards and Evaluation
 The following Job cards and Evaluation will be adopted to ensure that the work executed complies with the
project requirements and relevant standards.
 11. Risk and Controls

 When identifying health and safety risks, the following shall be considered;
 Physical injuries (e.g. cuts, fractures, bruises, loss of body parts etc.)
 Ill-health (headaches, breathlessness, deafness, limb disorders, diseases, etc.)
 Property damage.
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 The Project Manager will compile Standard Work Method (SWM) Index of all the trades that are to be per-
formed on site. The SWM index for the site is also appended here for reference.
 The various trades will be checked for availability against master list of Standard Work Method Index compiled
by the HQ EHS Department, to see if risk assessment had been performed earlier on the trades.
 Where such trades have been ‘risk assessed’, the Safety Manager /Safety Supervisor will extract the relevant
Risk Assessment data and conduct a review of the risks assessments to verify if changes are required, in terms
of varying work method of similar trades, or new hazards/risks due to differing worksite conditions.
 Where there are no changes to the risk assessment done, the SWM will be adopted for the site, and the safety
precautions followed.
11.1 Where new risks have been identified, the basic steps should be followed:
 a) Before commencement of work on site, all subcontractors are required to submit a standard Safe Work
Method Statement (SWMS) of the specific trade.
 b) A Risk Assessment Team will be formed comprising the MERO Engineers/Supervisors/Foreman, workers,
site safety department and subcontractor’s representatives (if any).
 c) As a guide, the SWM shall be developed along the following guidelines:
 The trade is first divided into its various Work Phases or Job Steps.
 For each phase or steps, the impacts/risks/hazards encountered are listed down.
 For each impacts/risks/hazards encountered, a safe work procedure is recommended.
11.2 Control Measures:

 The basic principle of controlling risk in the work place is to either remove the risk or to control its possible
impact. The following hierarchical process to be followed when implemented control.
 Eliminate - eliminate the risk by removing the hazards.
 Substitute - substitute the process etc., with one that is less risky.
 Source - control the risk at source.
 Procedure - devise safe system of work.
 Training - provide adequate instruction and training.

 Supervision - ensure adequate supervision.
 PPE - provide suitable personal protective equipment.

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 Appropriate checklists will be prepared by each contractor and used as a guide for site safety inspec-
tion.
 Site safety meeting and safety patrol reports will be addressed to chairman safety committee with
appropriate carbon copies given to the contractor. The report will be in the form of check lists.
 Non-compliance of safety matters shall be corrected within a time frame depending on the degree
of danger it possess: however it shall be not later than seven days or otherwise decided by chairman
safety committee.
 ‘Stop work order ‘issued in such a condition that work cannot be so carried out with due regard to
workman safety.
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12. Technical Information

 As per the technical specification of Façade MFI-107 ITC One Colombo One, Sri Lanka, Façade Specification
dated 19th April 2017
 13. Emergency arrangements
13.1 General
 Any incident or injuries must be reported to any MERO Staff IMMEDIATELY. No claims will be accepted after
the workers leave the Site. In an event of a fire, any worker may shout “FIRE!” & evacuate to outside the Guard
House (Assembly Area). Firefighting, should be attempted only if there is no danger to life or limb & if he/she
is qualified.
 Every temporary building or structure designed for human occupancy shall be provided with exits sufficient
to permit the prompt escape of occupants in case of fire or other emergency.
 Two means of egress, as a minimum, shall be provided in every building or structure, section, or area where
the size, occupancy, and arrangement endangers occupants attempting to use a single means of egress which
is blocked by fire or smoke.
 Adequate “Emergency Exit” signs shall be installed to direct personnel to the correct exit.
 Field offices, staging areas, stockpile storage areas, and temporary buildings shall be placed in areas desig-
nated and approved by L&T on the Site drawings. Temporary movement or relocation of facilities shall be
made only with approval by L&T.
13.2 Fire precautions
 MERO shall regulate open fires, carrying matches, and welding permits when and where deemed necessary
in the interest of safety. MERO shall be responsible for and enforce requirements on its employees, the em-
ployees of all subcontractors and visitors, who shall comply with the regulations and restrictions as directed.
These open fires and similar regulations may vary during the progress of construction, or during testing or
initial operation of any portion of the plant. Smoking is not permitted at the Work Site.
 Within certain areas designated by Company as "DESIGNATED HOT WORK AREAS," Company shall issue a
"HOT WORK PERMIT" that shall authorize open flames, burning, and welding activities during regularly sched-
uled Work hours.
 Within certain areas designated as "RESTRICTIVE AREAS," Company shall issue a "HOT WORK PERMIT" daily
that shall authorize open flames, burning, and welding activities during regularly scheduled Work hours.
 "DESIGNATED HOT WORK AREAS" shall be reclassified as "RESTRICTED AREAS" whenever designated by
Company and upon completion. For “RESTRICTED AREAS,” a trained person, referred to as a “fire watch,” shall
be assigned and equipped with personal protective equipment provided by MERO.
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 The fire watch shall be maintained during lunchtime and other breaks and shall continue for 30 minutes after
welding operations have been completed. This individual shall keep the area clear of unauthorized personnel
during welding operations.
 The construction site is always inherent to fire hazards.
 All construction employees shall be aware of this situation and shall abide with the following rules:
 Smoking is allowed only in designated smoking shelters (outside plant area)

 Lighters, matches and other sources of ignition shall not be brought inside the plant
 MERO employees may attempt to extinguish any fire with available fire extinguisher in the site if it is
safe for them to do so or they were trained on proper use.

 Accumulation of flammable materials (both construction materials, scraps and trash) is to be avoided:
such materials shall be disposed of (stacked in dedicated areas or disposed outside the construction
site).
13.3 Communication
 Project publications and general communication notices on site will be printed or presented in both English
and local language(s). In order to guarantee an easy verbal communication on site, an adequate number of
bilingual (English-local language) staff will be employed in the work area. This will facilitate the communica-
tion between the workforce and all other parties involved.
 All HSE training and education for the local workforce, including training material and booklets, will
be translated in local language. The minutes of meeting if necessary will be produced bilingual (Eng-
lish-Local language).
 MERO HSE Dept. shall post HSE posters, signs, and notices in prominent locations at the site to inform
the potential hazards and maintain safety awareness.

 HSE bulletins shall be issued to notify particular HSE issues and progress in achieving objectives,
targets, and performances to employees.
 Safety Flash and Safety Alert shall be issued to notify the serious incidents; lesson learned and control
measure to avoid recurrences.
 All available catalogues, publications and information regarding HSE will be made available at Project
site office and circulated.

 Motivational HSE program will be organized periodically to award incentives to workers performed
best practices in HSE to encourage the moral of workforce.

 The mode of communication at site shall be communicated through walkie – talkie.
 All the Project HSE campaigns shall be organised and co-ordinated with L&T
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14. Training
 Only individuals with the appropriate experience, skills, and training will be authorized to perform works that
require personal fall-protection system. They shall be trained and instructed in the following areas:
 Recognition of the fall hazards in the work area.

 Avoidance of fall hazards using established work practices which have been made known to the em-
ployees.
 Recognition of unsafe practices or working conditions that could lead to a fall, such as windy condi-
tions.
 The function, use, and operation of safety monitoring systems, guardrail systems, and body belt/har-
ness systems, control zones and other protection to be used.
 The correct procedure for erecting, maintaining, disassembling and inspecting the system(s) to be
used.
 Knowledge of construction sequence or the erection plan.
 In addition to the above training, toolbox meeting & briefing shall be carried out prior to starting work in-
volving all members of the work group. The toolbox meeting will be conducted by the site supervisor in
charge of the specific work area and he shall remind all members of the work hazards and the safe work
procedures.
 The Safety officer/safety manager shall provide awareness training to all employees working on site. Topics
should include falling hazards, hazard identification, consequences of falling from height, PPE usage, safe
work procedures & etc.
15. Supervision
 Installation is carried out by experienced and competent fitters who have expertise in They are as-
sisted by unskilled labours. This work is in turn supervised by experienced Foremen.
 Site Engineer will be available for co-ordination with other sub-contractors and Main Contractor and
also to look into the technical aspects.
 He will ensure that the overall work conforms to the shop Drawing.
DOC NO.: MS-INST-01
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16. Working Hours

 Working hours for all the Staff and Workers shall be 10 hours / shift from morning 8 am to 6 pm with 1 hour
of break for Lunch from 1:00 pm to 2:00 pm.
17. House keeping

 The house keeping of the working area and office permission will be achieved by following Do's and Don'ts
by all the persons in the organisation:
Do's:
 Remove all protruding nails or bend them over.
 Keep all platforms and gangways free of debris so as to prevent tripping.

 Stack materials in a tidy manner on a firm and level base.
 Unload materials only at designated area.
 Stack materials 30 cm above ground to prevent water trapped underneath

 Turn over items e.g. formwork, tyres, containers, which can collect water.
Don'ts:
 Don’t accumulate debris as it causes accident
 Never obstruct platforms and gangways with materials or equipment.

 Don’t obstruct the designated exit / entry point by materials.
 Never stack materials near the edge of the building or lift opening or other service openings where
they are liable to fall off.
 Never stack materials near the edge of the building or lift opening or other service openings where
they are liable to fall off.

 Don’t allow stagnant/accumulation of water at site which may cause breeding of mosquito
 Don’t leave plastic canvas in open areas which may lead to collection of water
 Don’t leave the unwanted materials which can accumulate water.

 Cover areas of works e.g. IC, Scrapper drain, which may easily keep water with sand or spray pesticides
frequently.

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Installation Method Statement for ITC One Colombo One Façade

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DOC NO.

MERO ASIA PACIFIC ENGINEERING PVT LTD

ITC ONE COLOMBO ONE

DESIGN, SUPPLY INSTALLATION AND TESTING OF FAÇADE

_______________ __________________ _______________

12. Technical Information ......................................................................................................... 34

Version, Date of re Description Of Changes

3. Codes and standards

be referenced where required to meet the contract/technical specification intent.

standards unless specified otherwise.

 India Local Codes and Standards

 Other standards such as ASTM (US), AS (Australia) and DIN (German).

3.2 International standards/reference documents

3.2.1. Indian Standards

IS-875 : part 1 Dead loads

IS-875 : part 2 Imposed loads

IS-875 : part 3 Wind loads

Code of practise for design loads (other than earth-

IS-875 : part 4 quake) for building and Structures-Special Loads and

IS : 1893 Criteria for earthquake and Structures

Earthquake resistant design and construction of

Code of Practice for use of Aluminium Alloys in

3.2.2. British standards

BS EN 755:2008 Parts 1,2 & Aluminium and Aluminium Alloys - Extruded

3 Rod/Bar, Tube and Profiles

BS 4255: part 1 – 1986

BS EN ISO 1461 : 2009 Hot dip galvanising

BS EN 10210 pts1&2:2006 Hot finished steel hollow sections

BS 3692, BS EN ISO 898

BS EN ISO 3506 parts 1 & 2

4. Terms and conditions

 5. Roles and Responsibilities

5.1 Project Director

bling, glazing and installation works.

lems that arise at interfaces of groups throughout the whole project.

5.2 Project Manager

the Senior Project Manager and Managing Director.

 Responsible within the project specification/contract, in term of design, procure-

 Key project management responsibilities include creating clear and attaina-

 Addendum to any Method Statement and Risk Assessment, including any

change of working method or sequence.

and materials to achieve the targets aspire by the management.

in accordance with the requirements of the project specification.

necessary prior to the commencement of works.

dition to the management for review.

tion claims in accordance with project circumstance

5.3 Execution engineer

and subcontractors responsibilities.

 Develop, implement and monitor installation program, including the devel-

opment of quality standards in accordance with project specifications.

countered on site and report accordingly to Project Manager.

quality control of engineering work done on site.

 Report and submit weekly progress reports to Project Manager, of work

 Ensure project is completed according to project plans.

to safety regulations and of the statutory regulations.

 To maintain and record in order to provide complete checklist of all site

5.4 Quality Control Manager/Engineer

their issue, amendments and recall of controlled documents.

ings, As-built drawings, O & M manual.

5.5 Other Departments:

5.5.1. Safety Manager

 Conducting workplace risk assessments to determine the presence of haz-

_ ___