Installation of Aluminium Work

METHOD STATEMENT
1. DESIGN PROCEDURE
A. Purpose: To establish the criteria for design.
Scope: Applicable to all products
Responsibilities: Designer/CAD-Operators
Technical Manager: Ensure the design criteria are met
Procedures:
In the design process, the following should be taken into consideration:
1. Strength and Stiffness of the system :
 Able to resist the maximum wind-pressure
 Able to withstand accidental pressure and impact
 Maximum deflection shall be controlled
 Performed sectional properties and detailed structural calculation
 Water Tightness
 Prevent water-infiltration (in accordance to specification)
 Air Tightness
 Avoid excessive air leakage
 Noise S(in accordance to specification)
 Thermal insulation (in accordance to specification)
 Durability and Maintenance
 Safety
 Material Selection
 Selected to complement the performance and aesthetic requirements
 material must uphold integrity of the system
2. Safety in installation
Design shall take into consideration, the form of the building, site restrictions and accessibility, to
determine the type and method of safe installation. Documentation shall be done on the Design
B. Purpose: To outline the development of design as specified in the contract, and subsequently
development of appropriate design drawings.
Scope: Applicable to work contracted to PBM.
Responsibilities:
Designer
 Interpret design requirement
 Develop design concept
 Arrange for prototype testing
 Evaluate prototype test results
 Attend meetings with architects
 Provide design calculation
Assistant Designer
 interpret design concept into drawings
 assist designer in designing
Draughtsman
 Assist Assistant Designer in drawing
Technical Manager / Designer

 Coordinate with production and project manager regarding design feasibility
 Validate design concept
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Premier Aluminium Systems Page 1
Design procedure (contin’)
Procedures:
Design Process
 The designer shall review design concepts from architectural drawing and specification to clarify any
ambiguous and/or conflicting requirements with the architects.
 The designer shall then interpret all requirements into the design concept.
 The Assistant Designer shall interpret the design concept and produce shop-drawings with the
assistance of the Draughtsman.
 The Assistant Designer shall check the drawings and the designer counter-check that drawings are
correct before submitting to the Technical Manager for design validation.
 The Technical Manager shall validate the design.
 Discuss design with the production regarding to feasibility and manufacturing methods.
 Submit design to the architect for verification and approval.
 The design shall include
- Structural strength and stiffness – elevations and specific detailing
- Air and water tightness - endurance and test-reports
 Use test results for evaluation to further refine of design and cost effectiveness.
Purpose: This procedure establishes control of design and can lead to changes in the drawings
Scope: Applicable to design and drawings

Responsibilities: Designer
 Update design revision
 Inform affected personnel and authorities of any design changes
Assistant Designer and Draughtsman

 Update drawing revision log
Procedures:
 Design changes may spring from :
 changes in client’s requirements
 (ii) New legislation from government bodies relating to safety, environmental matters and the like all
changes shall be documented and subjected to considerations in the same systematic way as the
original
 In addition to aspects of quality, effects of each proposed change on cost and schedule shall also be
considered
 All instructed changes by the client shall be authorized by the Technical Manager
 When changes in design could affect the activities of others, e.g. production department, they shall be
informed.
 All design changes shall be updated in detail in the Drawing Revision.
 The designer shall instruct the Assistant Designer and/or Draughtsman shall update amendments in the
drawing revision log
 All revised design drawings and design calculations shall be verified by the Technical Manager
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2. FABRICATION
2.1 INTRODUCTION
QUALITY ASSURANCE PLAN:

The Quality Assurance Plan outlines a system of necessary procedures and applicable standards for
the quality inspectors/controllers to carry out daily inspections ranging from goods receiving at the
unloading dock to the assembly line at the factory floor. It is to be fully complied with, with no exception,
by all departments to ensure that the end-product will conform to our in-house requirements as well as
the contract specification.
Update and modification:

To suit specific materials and procedures as required by the project, the Q/A Plan may be modified by
the committee formed by the Project Manager, Factory Manager and the Quality Manager.
Execution:
To ensure that the quality assurance plan will be carried out efficiently, a quality inspection team will be
nominated to execute the daily inspection and record/report their findings. They are working directly
under the supervision of the quality control manager who should maintain the strict compliance of the
quality requirements.
Design stage:
The Chief Designer is responsible to ensure the correctness and accuracy of the design shop drawings
and fabrication drawings. Fabrication drawings should be precise and specific for various members and
parts. Drawings will be crosschecked for feasibility and workability before release for production.
Material procurement stage:

The Purchasing Department is responsible to ensure that all material procured comply strictly with the
specification. All suppliers will be examined for their capability, their quality plan and sources of raw
materials to ensure timely deliveries and good quality of the items supplied. All procured items should
accompany with mill certificates, proof of origin, product warranty, etc. for review and record. All
suppliers should provide samples for testing and inspection before bulk production.
Material delivery stage:

All material received will go through our in-house inspection or tested by independent laboratories, if
necessary, to ensure that the quality meets the specification requirements. The inspection or testing will
be carried out on random samples from each batch of material received. Any items that fail the
inspection or the independent testing will cause the entire batch being rejected. The Q/C Inspectors are
responsible to maintain an inspection log for record and reference purposes.
Production stage:
All produced parts and completed panels will go through our in-house inspection procedure to ensure
that the quality meets the specification requirements. Inspection procedures will include random
inspections on sample lots and on-line inspection so as to screen out non-complied parts and hardware
before they are installed onto the completed curtain wall panels. The Q/C Inspectors are responsible to
maintain an inspection log for record and reference purposes.
Aluminium extrusion
Objective
The procedure described in this section is to establish an inspection routine of all incoming extrusions.
This will help to streamline the goods receiving process and inspection is being carried out concurrently
to assure that materials received comply with our purchase order requirements.
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Fabrication (contin’)
Person in charge
The Q/C Inspector is responsible of the inspection during unloading. All discrepancies and observations
are to be reported to the purchasing department, factory manager and project manager for subsequent
action. The Quality Manager and the Q/C Inspector are responsible of updating and maintaining of this
process.
Procedure
After extrusions are off-loaded at the unloading dock, material handlers will open all bundles for
verification on the following:
 Verify numbers of Extrusions and compliance with order bills
 Verify qualities of materials received (see work-preparation)
 Measure all profile dimensions (Width-Depth and Length)
 Spot check quality of finish with special attention to bundles having notable damages to the
packaging
 Check colour, layer-thickness and layer-condition
 The findings are then checked against the supplier’s Packing Lists and our Purchase Order. Each
bundle is marked with receiving dates and records are entered into our inventory record. A tag is
attached to each bundle noted with extrusion number, finish, length and quantity. The extrusions
are then stored and ready to be released for production.
Reporting and Recording

The Q/C Inspector should report all discrepancies and observations by filling out a report. It will be sent
to the purchasing department, the project manager and the factory manager for follow up and future
reference.
2.2 Gasket
Person in charge
The Q/C Inspector is responsible of the inspection during unloading. All discrepancies and observations
action. The Quality Manager and the Q/C Inspector are responsible of updating and maintaining of this
process.
Procedure
 After approval of curtain wall system, the design department will release the gasket profile. This in
accordance with the detail drawing of the project.
 Drawings to the extruder for die drawing preparation.
 Upon receipt of the extruder’s die drawings, the design department will conduct a thorough checking
of all dimensions to ensure that all dimensions are correctly indicated a tolerances conform to the
manufactures requirements.
 Discrepancies will be marked on the die drawings and returned to the extruder for necessary
revisions. All revised die drawings will go through the same routine to eliminate all discrepancies.
 Measure all dimension, radius, angle, etc. and mark the readings onto the gasket die drawings.
 Fit gasket into Aluminium extrusions and note the tightness/looseness of fit
 Fitting mating Aluminium extrusions with the gasket inserted and notes the tightness/looseness of fit.
 Label the sample with gasket number, inspection date and signed by the inspector before shelving up
for future reference.
 Any rejection of profile samples will require a re-run from the extruder and re-submit samples for
inspection and approval.

 The Q/C Inspector should report all discrepancies and observations by filling out a report.
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2.3 HARDWARE
Objective
The procedure described in this section is to establish an inspection routine of all incoming hardware.
This will help to streamline the goods receiving process and inspection is being carried out concurrently
to assure that materials received comply with our purchase order requirements.
Person in charge
The Q/C inspector is responsible of the inspection during unloading. All discrepancies and observations
action.
The Quality Manager and the Q/C Inspector are responsible of updating and maintaining of this
process.
Fabrication (Cont)
Procedure
 After hardware is off-loaded at the unloading dock, they are sent to the inventory division for
verification of quantity, size, finish and type of material. Quantities of small items are checked by
weight.
 Special attention is given to packages having notable damages to the packaging
 The findings are then checked against the supplier’s Packing Lists and our Purchase Order. Each
package is marked with receiving dates and records are entered into our inventory record. A tag is
attached to each package noted with type of material, finish and quantity. The hardware is then
stored and ready to be released for production.

The Q/C Inspector should report all discrepancies and observations by filling out a report.
2.4 Panel assembly

Objective
The purpose of this procedure is to establish a sequence of steps by which panel assembly is carried
out and on line checking is performed to assure curtain wall panels are manufactured in accordance
with the assembly drawings and tolerances are complied with.
Person in charge
It will be the Assembly Supervisor’s responsibility to instruct workers on how to prepare and assemble
the curtain wall panels. He shall also check installation on a daily basis.
Procedure
 The team leader of the production unit is responsible to check the material received against the
 material list and their specification to ensure that types and quantities are correct.
 Check if protective tape is properly applied. If necessary, peel off and re-apply tape.
 Upon completion of a panel, crosscheck the diagonal measurement to ensure its size and
 squareness.
 Check that all screw heads are caulked and sealant properly tooled.

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2.5 SEALANT APPLICATION TEST PROCEDURE
Objective
The purpose of this procedure is to establish a uniform method of applying structural sealants.
Person in charge
It will be the responsibility of Assembly Supervisor to instruct people on how to apply sealant in the
method as outlined below.
Fabrication (Cont)
Procedure
 Clean surfaces before applying sealant as listed below:
Anodized - Use Isopropyl Alcohol
Painted - Use Isopropyl Alcohol
Chromate - Use Isopropyl Alcohol
Mill - Use Isopropyl Alcohol
Glass - Use Isopropyl Alcohol or Glass Cleaner, when needed
 Pour the solvent onto a clean, soft, absorbent, lint-free cloth. Rub the surface to remove surface
contaminants.
 Dry with a clean, dry cloth or towel.
 Prime surfaces when required and allow drying.
 Mask area, if necessary.
 Use silicone sealants that are structurally approved by manufacturer.
 Apply sealant to fill area in a continuous bead without air pockets or voids.
SEALANT MUST BE TOOLED.

• Remove excessive sealant and masking tape, if used.
• Store units in appropriate position and area for required curing time.

2.6 ONLINE INSPECTION

Objective
The purpose of this procedure is to maintain sufficient inspection during manufacturing to assure our
customer those quality products will meet end item requirement of contracts.
Person in charge
It will be the responsibility of the Quality Control Department to establish and maintain adequate
inspection stations as deemed necessary to assure all drawing requirements are met.
Procedure
• In order to assure that production processes are producing parts that conform to drawings, sample
lot shall be inspected periodically during production. The Q.A. Inspector will perform roving
inspections periodically throughout the day at all workstations. Each characteristic they check will be
recorded on Roving Inspection report along with indication as to accepted or rejected parts.
• When a rejection occurs, an In-House Rejection Notice is made up and issued.

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2.7 FINAL INSPECTION
Objective
The purpose of this procedure is to substantiate the quality of the end item and to assure the customer
that all drawing and contractual requirements have been met.
Person in charge
It will be the responsibility of the specific assembler and his/her supervisor to conduct all final inspection
and tests to assure that drawing and customer contractual requirements have been met. The Q.A.
Inspector will conduct periodic audits
Procedure
• To assure our customers that our assembled products will meet contract requirement, we will have
Quality Control conduct periodic audit (at 10% of product). The characteristic to be inspected will be
determined at the beginning of each job.
• When a rejection occurs, an In-House rejection Notice is made up and issued.

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2.8 HANDLING REJECTED MATERIAL
Objective
The purpose of this procedure is to establish a sequence of steps by which rejected parts and hardware
are handled.
Person in charge
It will be the responsibility of the Q/C inspectors, specific assembler and his/her supervisor to conduct
various inspections and determine whether parts are rejected and give specific directions as to re-work
or re-produce.
Procedure
• All parts and hardware that are rejected and directed to be re-worked shall be 100% inspected after
re-work to ensure full compliance will specification requirement. Any items that fail the inspection
shall be rejected and new parts shall be produced to replace the rejected quantity of the items.
• Rejected material shall be removed from the factory immediately and kept in specific storage to
avoid using the wrong parts.

2.9 TOLERANCE
Objective
The purpose of this procedure is to define acceptable fabrication (manufacturing) tolerances. This
procedure applies to all fabricated parts or assemblies that are produced by our factory or purchased. In
the event of any conflict between this procedure and the drawing or other specifications called out on
the drawing, the drawing and other specifications will take precedence.
Person in charge
It will be the responsibility of Production Supervisors and Q.A. Inspector to maintain and update this
procedure.
Procedure
Control of Measuring Tapes
It will be the responsibility of Quality Control to verify the accuracy of each tape received, against
calibrated 2-mitre straight edge. Tapes that are within 0.5mm for accuracy will be accepted and a
calibration sticker will be applied, then tape will be given to Tool Crib for issuing. Tapes that do not meet
this criterion will not be issued for production use. When a replacement tape insert is put on, it must be
re-calibrated following the above procedure before using.
TOLERANCE
The following list of operations has been complied with applicable tolerances, are as follows:
OPERATION TOLERANCE
Saw Length + 0/ -1mm
Shear Size + 0/ -1mm
Squareness of Sheared Sheet ± 3mm (on diagonal measurements)
Hole Size ± 0.3mm
Hole Location ± 0.5mm
Mill Cuts ± 1mm
Bend Size ± 1mm
Angularity (Bending Sheet Metal) ± 1°
Radius Size (I.D.) 1 Times Metal Thickness
Coping Size ± 1mm
Coping Location ± 1mm
Welded Parts Location ± 1mm
Stud Weld Location ± 1mm
Straightness ± 1mm per meter
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Handling Rejected materials (Cont)
VISUAL WORKMANSHIP ON EXPOSED AREA:

 Scratches
 Chatter Marks
 Dents
 Corrosion Marks
 Die (Tooling) Marks
 Clamp Marks
 Hole Distortion - Holes located near bends in formed metal parts which are elongated due to bend
operation will be acceptable providing the hole will accept the correct size bolt, screw, etc.
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3. PACKING
3.1 Stick System

Packing profiles with same specification, to avoid burr on the end of profile nicking the surface.
Before packing, as avoiding nick, we should clear up Aluminium waste of profile’s cavity and surface.
Using protection adhesive tape, and then using crafts during packing and moving, avoid nick on the
decorative surface. NOT PERMIT PACKING in different specification, dimension and type.
Notice to give clear indication of product’s item, symbol, specification, quantity and project’s name.
Assemble two panels together, place them face to face, and separated them by foamed polystyrene
board.
4. TRANSPORTATION
4.1 Packing
The packing will be in strong plastic tape, well protected against tough handling, moisture, rain, and
corrosion with special adhere for easy removing after installation.
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5. CONSTRUCTION PROCESS CHART :
SIGN CONTRACT
CONTRACT PARTICULAR
BUILD GENERAL PLAN
DRAWING DESIGN
DRAWING CONFORM
PURCHASING ALUMINIUM
PROFILES AND ACCESSORIES
ACCEPTATION OF PROFILES AND

CONTROLLED BY
QUALITY CONTROLLER
FABRICATION SET UP SCAFFOLDINGS

AND/OR CRADLES
PACKING & DELIVERY
MEASURING & SET LINE
UNITS ACCEPTATION AFTER
QUALITY-CONTROL ON SITE BRACKET & SUB-FRAME
INSTALLATION
CURTAIN-WALL & CLADDING

INSTALLATION
GLAZING AND WEATHER-SEALANT
REMOVE PROTECTIVE TAPE FROM

PROFILES AND CLADDING-PANELS
DISMANTLING OF SCAFFOLDINGS
AND/OR CRADLES
CHECK & ACCEPT ON SITE
HANDING-OVER ON SITE
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1. ANALYSIS OF CONTRACT COMMITMENTS
As overall requirement of quality, standards and schedule commitments are made known to Site staff. The Site
staff are encouraged to propose plans on how they would assist to comply with such contract requirements. Site
staff members are encouraged to question on requirements that are not mentioned in order to achieve clarity of
objectives in their course of work.
2. REVIEW OF SHOP-DRAWINGS
Responsible staff are encouraged to analyse shop drawings to determine its clarity. Issues pertaining to
clarification of details, hardware required installation methods, workability and even requests for alternative
design changes are encouraged.
3. ANALYSIS OF MATERIAL DELIVERY REQUIREMENT

Responsible staff having analysed scheduled requirements participate in resource bargaining with
management to determine the various milestones in which parts and various materials shall be ready for
installations as part of adhering to contract obligations.
4. ANALYSIS OF SPECIAL TOOL OR EQUIPMENT REQUIREMENTS

Resource bargaining is encouraged of the Responsible staff to consider its special tools or equipment is
necessary for their course of works. Special equipments may come in the form of cradles, movable platforms,
cranes, hydraulic jacks, winches cherry pickers, etc.
It is highly recommended that preparations to either lease or purchase such items should be done at an early
stage, as its availability require long lead times.
(2) Purpose: To ensure good quality products by determining readiness of installation and proper
positioning of installations.
Scope: Applicable to all installations prior to actual works.
Responsibilities: Site staff
Perform pre-installation site survey
Procedure:
Responsible staff is imparted the concept that products when installed and appropriate times would reduce
possibility of damage by other trades and that proper positioning of installations eliminates rectifications, which
may affect product quality. Responsible staff is encouraged to visit the site on a regular basis as stipulated below,
before actual installations in order to determine the progress of other works (related to our installations) that
may hinder our capability of adhering to our committed schedules for installations.
The recommended guidelines would be as follow:

 Between 2 to 1 month before targeted installation period - visits to site every 2 weeks.
 Between 1 month to 2 weeks before targeted installation period - visits to site at least once a week.
In the event that progress of other trades is expected to delay our schedule of installations, the Site staffs is
encouraged to seek the assistance of the Main-Contractor.
The Analogy goes the same that a rushed work in order to meet deadlines causes poor quality as well.
Responsible staff in preparation for installations shall ensure that survey points and bench works are adequately
provided by the main contractor’s surveyors. This is to ensure proper positioning of products when referencing
from the given points. Site staff is also encouraged to check structural openings or space available in order to
ensure that free space is available for intended installation.
Responsible staffs are encouraged by management to take photographs of given points and document them via
written correspondence to Main Contractor so that they can help to counter verify to ensure quality installations.
(3) Purpose: To ensure communication and feedback between management and Site staff, in order that
management may offer assistance of strategy and resources to achieve customer's
requirements.
Scope: Include site problems and actions taken to address them, attained achievements,
resource allocations, progress of works, stage completion and site activities.
Responsibilities: Responsible staff to make periodic informal reports to management regarding the
progress of each project.
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Analysis of contract commitments (contin)
Procedure:
Progress Reporting constitutes two forms, which may be simultaneously practised to achieve the above
purpose,
 Weekly informal discussion between management and staff.
 Written Progress Report.
1. DAILY INFORMAL DISCUSSIONS

Staff interacts with the management on a weekly basis to discuss the overall progress of works on site..
2. WRITTEN PROGRESS REPORT

Reference being made to projects and name of staff: a formal weekly-report is submitted to the management.
It is expected that the following topics should constitute the progress reporting activity:
(a) Site problems with action taken to address them.
(b) Attained achievements.
(c) Resource allocations e.g. labour, etc.
(d) Progress of works.
(e) Stage of completion.
(f) Other site activities e.g. bad weather, etc
(4) Purpose: To document all agreed matters of discussion with representatives of organisations
pertaining to scope of works.
Scope: All meetings concerning discussion with Clients, Architects, Main Contractors and
Consultants
Procedure:
 Site-staff must follow up with representatives of organisations (pertaining to scope of works), after every
meeting on the issuance of minutes of meetings. Such minutes must reflect critical points of agreement,
as certain quality issues or schedule implications tend to reflect at a later stage. The guidelines are as
follows:
 In the event that minutes are not received within a week from meeting, written confirmations are to be
issued after consultation with the management.
• In the event that minutes are only to be issued after one week from meeting as promised, the same action as
in item 1 above is also to be taken, e.g. fortnightly meetings, etc.
• In the event that the intention of issuance of minutes is unlikely, similar written confirmations are necessary.
(5) Purpose: To ensure quality installations of products in conformance to specifications

Scope: This covers from pre-installation to post installation procedures.
Responsibilities:
Site Staff
Ensure correct quantity and quality of products to be installed are available on site.
supervise installation
• Ensure follow up checks on completed installation.
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SYSTEM INFORMATION
R52 (Reyno 52)
WINDOWS, DOORS, PARTITIONS, SHOP-FRONTS
Reyno R52 is manufactured in Saudi Arabia, under Alcoa supervision and technology for the Middle-Eastern
market. Top quality hardware from (Germany, Belgium, Holland and Italy)
Profile depth of 52 mm with a maximum glass fitting of 42mm
RT50F/RT50SG (REYNOTHERM) A THERMAL-BREAK SYSTEM

CURTAIN-WALLS, PYRAMIDS, SKYLIGHTS, DOMES, SHOP-FRONTS
A comprehensive thermally broken curtain walling system, consist of 50 mm wide mullions and transoms, glazed
with EPDM gaskets from edge to edge of the panes, combined with butyl tape to provide a double reliable
weather protection, suitable for all types of facades.
Reynotherm RT50F & RT50SG are manufactured in Saudi Arabia, under Alcoa supervision and technology for
the Middle-Eastern market. Top quality hardware from (Germany, Belgium, Holland, and Italy)
Profile width of 50 mm and depths up to 250 mm or more.
Conventional Glazed Curtain-walls (with aluminium pressure-plate and cover-caps outside)
Structural Glazed Curtain-walls, (without any aluminium profiles outside)
Project customized profiles and systems (Special designs per project)
Complicated Skylights - Glass-Roof, Domes etc. (mainly without the use of steel support structure)
COMPOSITE CLADDING
REYNOBOND PE (Polyethylene core) and REYNOBOND FR (Fire Resistant)
An aluminium composite material manufactured by Alcoa-Europe in France thickness from 2mm to 6mm with a
strippable, 70 micron thick, UV resistant plastic film capable of being easily removed after 3 months exposure to
the sun. The finish is a PVDF two-coating utilizing 70% Kynar resins and is factory-applied coil a continuous
process. The coil has a basic chromate conversion coat followed by a primer coat with a thickness of 5 microns
and 20 microns of topcoat containing 70% of Kynar resins.
All items are manufactured by PBM according to Alcoa guidelines and manufacturing methods and monitored by
a specialist-representative of Alcoa.
Company Profile
MANUFACTURING AND INSTALLATION
CURTAIN WALL ALCOA SYSTEM ALCOA RT50SG
INTRODUCTION:
Alcoa RT50F (Conventional Curtain-wall) and RT50SG (Structural Glazed Curtain-wall) are thermally broken
Curtain Wall systems that offers a wide range of possibilities with a selection of mullions and transoms to suit
most situations. Alcoa RT50F and RT50SG enable a wide range of different windows and doors configurations
to be inserted into the curtain-walls in combination with the Alcoa windows and doors systems R52. There is also
the possibility to use our embedded windows of the RT50SG.
MANUFACTURING:
1. GENERAL:
All aluminium profiles are fabricated here in the Gulf in accordance with Alcoa guidelines and manufacturing
methods. Fabricated glazed curtain wall system according to shop-drawings. Fabricate components that,
when assembled, will have accurately fitted joints with ends copped or mitred to produce hairline joints free
of burns or distortions. After fabrication, clearly mark components to identify their location on site and
according to shop-drawings.
2. FASTENER:
Prepare components to receive concealed fasteners, anchors and other connecting devices.
All connection between aluminium parts are stainless steel A304
All anchor-bolts and other fixing materials to fix into concrete are galvanized.
3. DRAINAGE:
This system is the so-called overlapping joint system where the transom covers 13mm over mullion. The
transom drains the leakage water and condensation after passing joints in a special dedicated gutter in the
mullions. This water runs down the mullions and is guided outside the system by special moulded EPDM
pieces.
4 METAL PROTECTION ON SITE:

Where aluminium will contact dissimilar metals, protect against galvanic action by painting the contact
surfaces with a primer or using sealant or special tape recommended by the manufacturer for this particular
purpose. Where aluminium will contact concrete or masonry, protect against corrosion by painting contact
surfaces with bituminous paint.
5. FRAME UNITS:
Factory assembled frame units according to shop-drawings to greatest extent possible. Rigidly secure
movements joints. Seal joints watertight, unless otherwise indicated. Assemble components to drain water
passing joints.
6. QUALITY CONTROL:
After receiving the profiles, the QC checks the profiles on;
Surface treatment, thickness, quality, damages, and/or scratches etc.
Dimension tolerance
Straightness, squareness and twisting of the profiles
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FABRICATION ALUMINIUM CURTAIN-WALLS
Before fabrication of the mullions and transoms, our Project Manager will do a survey and take all the necessary
measurement. The aluminium profiles are ordered in custom lengths according to the drawing and cutting lists.
The approved profiles will then be protected by special strippable, 70 micron thick, UV resistant plastic film
capable of being easily removed after 3 months exposure to the sun. Only now, these profiles are ready for
cutting. After cutting the profiles to specific lengths, milling and drilling from the cutting-list and according the
drawings, which are calculated from special designed computer programs, the brackets for the transoms are
fixed on centre-to-centre distance according measurements on site and approved shop drawing.
If possible, the so-called “ladders” (Two or more mullions connected with the transoms) will be assembled in the
factory. This will be every alternate vertical strip of the curtain wall. This method reduces the labour work at site
because since most of the fabrication is done by fabricators in the factory and is more efficient, faster, and more
practical. All the necessary precautions of water and air tightness sealing are better controllable in the factory.
Ladders can completely finished with EPDM sealing and inner gaskets and than taken to site. After fabrication of
all the units and other profiles they will be transported to the site and stored on the appropriate floors in special
area appointed by the main-contractor.
INSTALLATION:
Erection Tolerance:
Plumbing: 3 mm in 3 meter and 6mm in 12 meter.
Level: 3 mm in 6 meter and 6mm in 12 meter
- Alignment: Where surface abut in line, limit offset from true alignment to 1.5 mm; where a reveal or
protruding element separates aligned surfaces by less than 50 mm, limit offset to 13 mm.
- Location: Limit variation from plane or location shown on Shop-drawings to 3mm in 3.7 meter; 13mm
over total length.
DIMENSIONING AND INSTALLATION:

The dimensions measured on site, will be implemented in the drawings and estimation program to produce the
cutting lists. The Curtain Wall will be than fabricated in “ladder-segments” as mentioned before. The installation
of the ladder-segments shall start on the first available floor and successively proceed to all floors, following the
alignment and levelling of the first installed ladder-segments.
The steel brackets for the curtain-wall mullions will be distributed, fixed and alignment, according the approved
drawings on the concrete slabs. (See attached structural calculation for allowable windload and deflexion of the
mullions). The pre-fabricated ladders will be aligned vertically, horizontally and plumb whereas the transoms
shall be positioned to matching the height as shown and approved in de shop-drawings. The ladders to be
connected with pre-fabricated transoms and fixed with aluminium brackets. After completion of the aluminium
curtain-wall frame, the gaskets for glazing will be insert in the special channels in both mullions and transoms..
After completion of all installation works, the project manager and our supervisor will check the all installations,
e.g. fixing of the brackets, the mullions and transoms and the gaskets. Only after approval, we will proceed with
the installation of the glass and aluminium cladding panels. The gabs between the glasses will be sealed with
special weather sealant in this case SilPruf® from GE Bayer Silicones (See product information included
herewith). Finally the scaffolding, cradles and/or mast-climbers will be dismantled and replaced, while
simultaneously the protective film of the cladding will be removed.
Where aluminium will contact dissimilar metals, protect against galvanic action by painting the contact surfaces
by primer or using sealant or special tape recommended by the manufacturer for this particular purpose. Where
aluminium will contact concrete or masonry, protect against corrosion by painting contact surfaces with
bituminous paint.
WEATHER SEALS:
Wet sealant - The joints between the curtain-wall and the building shall be sealed with a compatible neutral cure
sealant such as SilPruf® from GE Bayer Silicones. A suitable polypropylene foam backer rod shall be fitted into
the joint before applying the sealant. Dry sealant - When a dry seal is required, an EPDM gasket shall be used,
which is mechanically retained to ensure it, does not loosen and fall out due to thermal movement.
Company Profile
WARRANTY:
To submit a written warranty executed by the fabricator agreeing to repair or replace components of glazed
-curtain wall system that fail in material and/or workmanship within the specified warranty period. Failures
include, but are not limited to, the following:
 Structural failures including, but not limited to, excessive deflections.
 Noise cause by thermal movements
 Adhesive or Cohesive sealant failures
 Deterioration of metals, metal finishes, and other materials beyond normal weathering within the
warranty period.
 Water leakage
 Glazing breakage cause by material failure, mechanical error and/or thermal tensions in the glasses
MATERIALS
Aluminium:
Alloy and Temper, recommended by the manufacturer, but not less than alloy and temper indicated hereafter, for
type of use and finish indicated, complying with the requirements of standards indicated below.
Sheet and Plate: BS EN 485, Part 1-4 and BS EN 515
Extruded round tubes and system sections: BS 1474 and BS EN 755 Part 1-8 or BS 1161, alloy and temper not
bless than 6063 T6
Aluminium Alloy Drawn Tubes: BS EN 515 and BS EN 754 Parts 1, 2, & 7.
Thickness:
Aluminium Alloys not less than 2.00 mm at any location for main supporting elements, vertical or horizontal, 1.6
mm thick movable parts, and 1.500 mm for caps.
FIXING COMPONENTS
Brackets and Reinforcements:
Provide manufacture’s standards high-strength steel galvanized brackets and reinforcements provided that
there should be a space between the steel and aluminium components of minimum 3 mm. This will be achieved
by using pvc shims..
FASTENERS AND ACCESSORIES:

Manufacturer’s standards, corrosion-resistance, no staining, no bleeding fasteners and accessories compatible
with adjacent materials. Finish exposed portions to match glazed aluminium curtain wall.
FABRICATION ALUMINIUM COMPOSITE PANELS

The aluminium composite panels are ordered in custom lengths but standard widths according to the drawing
and cutting lists. Since the Aluminium cladding-panels, are integrated in the curtain-walls the same way as glass,
these panels shall be cut according the width between the mullions and height to cover the spandrel area of
approx. 2500 mm. A horizontal gab of approx. 20mm will considered to divide the height respectively 1000 and
1500 mm. Upper panel: This panel will be executed with a return of 25 mm on four sides
Lower panel: This panel will be executed with a return of 25 mm on three sides; left, right and bottom while the
top will have a double return of respectively 25 mm x 25 mm.
An aluminium tube 25 x 25 mm will be fixed around the panels accept the horizontal gab, to accommodate the
same thickness as the glass. (see attached drawings).
After fabrication of all the panels, they will be transported to the site and stored on the appropriate floors in
special area appointed by the main-contractor.
Company Profile
WORK PREPARATION
1. Design and drawing

2. Cutting lists
3. Glass order
4. Gaskets
5. Accessories
6. Hardware
7. Silicon and backing rod
8. Fixing materials, screws, plugs and shims
ORDER OF WORK
Checking profiles:
On colour, shape, twisted, damaged or curved
Measuring paint layer thickness
Protective taping of profiles
Dimension of profiles
Dimension of glazing beads
MANUFACTURING OF ITEMS (Window)

WINDOW-FRAME:
1. Main profiles cut at exact length
2. Glazing bead, adapters, angles, flats etc. to cut with additional 1 cm extra and to cut precisely later
3. Profiles to pack per item, mark with sticker, and distribute per group per table
4. Drilling of fixing holes centre to centre ± 450mm
5. Punching of water outlet sleeve holes (35x5MM)
6. Fixing of transom brackets.
7. Provide corners with epoxy-glue
8. Slide in corner-cleats
9. Crimp frame on crimping machine
10. Clean frame from excessive glue and other waste materials
11. Fit hinges, takers for locks, cover caps for water outlets
12. Provide outer-gaskets
13. Cut glazing-beads and fit in frame (block glazing-beads with polystyrene to avoid losses)
14. Frame to move to assembly table for window sash
WINDOW-SASH:
1. All preparations are similar to the above-mentioned including water outlet holes
2. Punching of water-holes and sleeve-holes for window handle
3. Fixing hinges and handles
4. Provide outer-gaskets
5. Install glass (lift window approx 2mm on the locking side with PVC shims)
6. Install and align sash in window frame
7. Packing window and provide fixing materials (Screws, plugs, shims, silicon and backing rods)
Company Profile

Installation of Aluminium Work

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Installation of Aluminium Work

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METHOD STATEMENT

Technical Manager / Designer

Scope: Applicable to design and drawings

Assistant Designer and Draughtsman

QUALITY ASSURANCE PLAN:

Update and modification:

Material procurement stage:

Material delivery stage:

Reporting and Recording

Reporting and Recording

Reporting and Recording

2.4 Panel assembly

Reporting and Recording

SEALANT MUST BE TOOLED.

Reporting and Recording

2.6 ONLINE INSPECTION

Reporting and Recording

Reporting and Recording

Reporting and Recording

VISUAL WORKMANSHIP ON EXPOSED AREA:

3.1 Stick System

BUILD GENERAL PLAN

ACCEPTATION OF PROFILES AND

FABRICATION SET UP SCAFFOLDINGS

CURTAIN-WALL & CLADDING

GLAZING AND WEATHER-SEALANT

REMOVE PROTECTIVE TAPE FROM

CHECK & ACCEPT ON SITE

3. ANALYSIS OF MATERIAL DELIVERY REQUIREMENT

4. ANALYSIS OF SPECIAL TOOL OR EQUIPMENT REQUIREMENTS

The recommended guidelines would be as follow:

1. DAILY INFORMAL DISCUSSIONS

2. WRITTEN PROGRESS REPORT

(5) Purpose: To ensure quality installations of products in conformance to specifications

RT50F/RT50SG (REYNOTHERM) A THERMAL-BREAK SYSTEM

4 METAL PROTECTION ON SITE:

DIMENSIONING AND INSTALLATION:

FASTENERS AND ACCESSORIES:

FABRICATION ALUMINIUM COMPOSITE PANELS

1. Design and drawing

MANUFACTURING OF ITEMS (Window)

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