Method Statement Template for Installation Metal / Steel Door.
PURPOSE.
This document defines the methodology, sequence, control
measures, safety and quality control
requirements, and equipment intended to be used in performing the works
as established in the project
specifications and relevant referenced documents.
SCOPE.
The scope of work described in this method statement is
applicable for installation of Metal Door and
Frame.
REFERENCE.
- Project Specifications
- Project Quality Plan
- Project HSE Plan
- Steel Door Institute 117
Materials and their approval.
Metal Doors & Frames - Approved Material Technical
Submittal.
Equipment.
- Drill Machine (110 volts or 220 volts as per site requirement) 6.3.2 Concrete Drill bits
- Level
- Flat Head Screwdriver
- Star Head Screwdriver
- Flat Head / Plastic Hammer
- Measuring Tape
CONSTRUCTION SEQUENCE (METHODOLOGY):
Storage of Material at site.
Information Prior To Site Storage - Door Leaves and Frames are fabricated and Factory Powder Coated to the main contractor Approved Color and does not require any further coating/touch-ups at the site, unless being damaged at/after the receipt of materials (Repair works procedure). Hence, utmost care is to be taken in retaining the color and the evenness of coating, at all the stages throughout the lifecycle of the materials.
The Materials are arranged in a Container/Truck in such a way that Door Leaves are wrapped with a Stretch-Wrap and are stacked on a Pallet and Door Frames are wrapped with Bubble Wraps and are arranged individually and freely. Unloading of material from the truck can be done by either manual unloading or using forklift.
Let the Area of Storage be ready before the receipt of the material so that the materials can be shifted to the Storage Area without being stationed in temporary exposed areas since the latter may attract serious damages to the materials.
Additional Care required during Storage - In-addition to the above, the following cares are to be taken while storing the materials on the Construction Site.
When grouping of materials are done, not more than 5 Door Leaves (or) Welded/Assembled Frames are to be stored in a group. Frames that are used for multi-opening frames, shall be stored in not more than groups of three, since a group of more may cause serious damage to the bottom most frame.
All Welded (or) Assembled frames shall be stored as shown in
below picture:
During Storage apart from the other natural elements, the Door Leaves are to be prevented from getting direct deposit of dusts and sand, to avoid the formation of scratches on the topcoat.
Additionally, in-case the materials are to be wiped, the materials should only be wiped with damp soft cloth [which is to be rinsed well to remove the dirt deposited on it time to time] followed by extensive exposure to dust-free and moisture-free air.
Site Installation Procedure:
Pick the required door & Frame from Site Store.
All materials use for installation will be collected and
delivery at site with the delivery note.
Vehicle should travel in designated access area after obtaining necessary permission from the security and it should be fixed with evolving flashlight on it. Vehicle to be parked in the designated parking/unloading and storage area, it should be covered properly. Storage facilities will be provided.
Unloading of the material should be with the help of
forklift/boom loader truck.
MIR to be raised immediately after material delivery and
before starting the installation.
Shifting of Material to the designated door location.
As per the opening number, installer team will segregate the
doors and frame to the designated location. Installation team will shift the
materials to the site through earmarked pedestrian access/egress. The crossing
shall be in only designated crossing point.
Frame and door leaf shifting can be done by two (2)
technicians in every designated area.
Shifting of each material will be according to safety
regulation and safety plan.
Frame Installation.
Installation of frames to be carried out strictly adhering
to manufacturer’s recommendations & SDI standard. Grouting inside the
frames are not required. Following steps should be done:
Concrete Wall and Masonry Wall.
Proper setting out (finish floor level markings and
threshold, if any) shall be verified prior frame installation.
Ensure getting MEP clearance for inside wiring/conduits for
card access system or any other MEP system, if any.
After Site measurement, the opening should be verified as
per the approved shop drawing.
Ensure all door frames located in same area/wall in same
level.
All frames that fix above the floor finishing level up to
2.2m ladder is not required, but if the more than 2.2m mobile tower/scaffold is
required.
Tolerance for frame installation and gap between door frame
and wall shall be verified.
If frame is in knockdown condition which has 3 parts
(header, strike jamb and hinge jamb), Frame header and strike jamb will be
assembled on the floor by connecting the corner clip and using M5 screw (to be
same as approved Mockup).
Assembled part of frame will be inserted on the opening.
Header level and strike jamb shall be plumb prior fixing the
expansion type anchor bolt.
Hinge jamb will be inserted to the header slot and alignment
shall be check prior fixing the expansion type anchor bolt.
Proper alignment of the opening should be done.
Keeping the frame in
the opening and tightening each anchor bolts.
Installation of rubber gasket.
Proper protection on door frame shall be applied after
completion if the leaf is not yet installed at the same time.
Dry Wall Partition.
Proper setting out (finish floor level markings and
threshold, if any) shall be verified prior frame installation.
Ensure getting MEP clearance for inside wiring/conduits for
card access system or any other MEP system, if any.
Opening should be verified as per the approved shop drawing.
Ensure all door frames located in same area/wall in same
level.
All frames that fix above the floor finishing level up to 2.2m
ladder is not required, but if the more than 2.2m mobile tower/scaffold is
required.
Tolerance for frame installation and gap between door frame
and wall shall be verified (as per project specs.).
If frame is in knockdown condition which has 3 parts (header,
strike jamb and hinge jamb), Frame header and strike jamb will be assembled on
the floor by connecting the corner clip.
Assembled part of frame will be inserted on the opening.
Header level and strike jamb shall be plumb prior fixing the
self-tapping screw to ensure proper alignment for fixing frame jambs (as per
approved mockup).
Hinge jamb will be inserted to the header slot and alignment
shall be check prior fixing the self-tapping screw.
Proper alignment of the opening should be done
Keeping the frame in the opening and tightening each
self-tapping screw.
Installation of rubber gasket.
Proper protection on door frame and ironmongery shall be
applied after completion if the leaf is not yet installed at the same time.
Threshold (if any) can be installed after installation of
either frame or door.
Door Installation.
Installation of doors to be carried out strictly adhering to
manufacturer’s recommendations & SDI standard. However as per the design,
size and weight of the door following steps are explained with regards to same
parameters:
For Doors up to height 2.2m and below:
All doors that fix above the floor finishing level up to
2.2m ladder is not required, but if the more than 2.2m small ladder is
required.
Two technician is sufficient to carry the weight (50 kg) of
the door during installation.
Hang the leaves with only 8 screws on the hinges.
Door height up to 2.2m, 3 hinges is sufficient per door leaf
as per SDI standard.
Door height more than 2.2m, 4 number of hinges will be
define as per SDI standard.
Once the weight of the door is on hinges, tighten the hinges
in the order of top and bottom together and then the center one.
Apply all 8 screws and tighten them until flush with the
hinge. The door leaves to hang on the respective frames with proposed number of
hinges.
Ensure SDI and industry tolerances between the frame and the
door are maintained.
Install other hardware e.g., locks, closers, etc., as per
their respective manufacturer’s instructions, SDI standards & as per
project specs.
WIR to be raised for all stages as per ITP.
For Doors height 2.2m and above (sic. 3.5m) – weighing nearly 100Kg:
All doors that fix above the floor finishing level above
2.2m, a scaffold/tower is required.
Four technicians with the assistance of the boom loader are
required to carry the weight (100 kg) of the door during installation and
others properly aligning the door to the opening.
Door height more than 2.2m, 4 or more number of hinges must
be provided as per SDI standard and approved shop drawing.
Once the weight of the door is on hinges, tighten the hinges
in the order of top and bottom together and then the center one.
Apply all 8 screws and tighten them until flush with the
hinge. The door leaves to hang on the respective frames with proposed number of
hinges (preferably 5 to 6 hinges)
Ensure SDI and industry tolerances between the frame and the
door are maintained.
Install other hardware e.g., locks, closers, etc., as per
their respective manufacturer’s instructions and SDI standards.
WIR to be raised for all stages as per ITP.
For Grill Doors – weighing nearly 150Kg:
A grill door installation is slightly different from
standard steel doors owing to its design, space, and weight.
Following artilleries with likes of cranes/boom loaders –
All lifting with supporting belts shall have 3rd party cert, medium to heavy
duty forklifts shall be employed for installation.
Six technicians are required to support the weight (150
kg) with help of the lifting equipment
for the alignment of the door during installation with one contractor operator
operating the boom loader and two people balancing the door via belt / chain. Proper PPE will be
followed. The door is a finished product so the operator and technician should
make sure to avoid any damage.
Grill Doors are hung with 4 to 5 industrial hinges provided
as per design and weight of the door.
Once the hinges are fixed properly, crane can be detached on
the door (weight of the door).
Ensure industry tolerances between the frame and the door
are maintained. Install other hardware e.g., a drop, industrial hinges, tower
bolt, etc., as per their respective manufacturer’s standards.
WIR to be raised for all stages as per ITP.
Protection for installed doors shall be provided against
material shifting and ongoing site activity.
As per the approved shop drawing, installer will collect
ironmongery and install it to the door with proper fixing and proper protection
shall be provided to avoid damages.
Vision Panel Installation (if any).
There are two parts for vision panel, male and female part
(vision lite frame).
Prior fixing the male and female part, glazing tape to be
sticked to the vision frame beading.
Male part will be inserted to the door cutout from inside
room area.
Vision glass to be fixed on its proper location.
Female part to be inserted and align properly and to be
screwed from the male part.
Louver Installation (if any).
Self-attaching (25mm) head screws will be used to fasten the
auxiliary frame to the louver core thru the cutout in the door. Corridor side
of the frame is free of fasteners for added security.
Final Alignment.
After installation, Installation Team will check the proper
door swinging and locking.
Fire Rated Sealant application.
Ensure that all surfaces are clean, dry, sound and frost
free. Clean all joints thoroughly to ensure that adhesion of the silicone to
substrate is not impaired.
It may be necessary to mask adjacent areas to prevent
contamination and to ensure a neat sealant line. Masking tapes should be
immediately removed after tooling and finishing.
Install backing materials as required and fill cavity with
acrylic.
Joint should be tooled within 5 minutes of application to
ensure a good contact between the acrylic and substrate. Tooling of the sealant
also gives a smooth and professional finish.
Dispose of spent cartridges in accordance with local
regulations.
Repair works (paint touch-up).
Shall be done as per project specification Below procedure
to be followed:
Sand the damaged area: Use sandpaper to remove any existing
rust or paint from the damaged area. The area should be sanded until it is
smooth to the touch and no lip is felt between the metal and the paint.
Fill the damaged area: Use a putty knife to fill the damaged
area with BONDO putty filler.
Smooth out the putty so it blends evenly with the surrounding
parts of the door.
Sand the patch: With the patch nice and dry, use a very
fine-grit sandpaper to lightly sand the patch smooth. Wipe away the resulting
fine dust with a cloth before applying the paint.
Paint the patch (with same approved color): When painting
the patch, you can use either the brush-on approach or a spray-on approach.
Apply a very light coat of spray paint, allow it to fully dry and then apply
another very light coat. Continue applying light coats until the patch is no
longer noticeable and the door looks finished. Applying several very light
coats of spray paint reduces messy paint runs and provides a nice even finish
on the surface of door.