1. Doc. Title
Method Statement of Aluminum
Door & Window Work TOA-TOYO JOINT VENTURE
Doc. No CM – MS – BW - 025 Rev. No. 0 Date May, 2012
Construction of Port Facilities and Buildings for Cai Mep International Container Terminal
CAI MEP INTERNATIONAL CONTAINER TERMINAL
METHOD STATEMENT OF
ALUMINUM DOOR & WINDOW WORK
Page 1

2. Doc. Title
Method Statement of Aluminum
Door & Window Work TOA-TOYO JOINT VENTURE
Doc. No CM – MS – BW - 025 Rev. No. 0 Date May, 2012
Construction of Port Facilities and Buildings for Cai Mep International Container Terminal
CONTENT
1. Purpose Page 3
2. Scope of Work Page 3
3. Reference Technical Specification Page 3
4. Shop Drawing Page 3
5. Work Procedure Page 4
6. Quality Control Page 7
7. Safety Control Page 7
Page 2
Appendix 1

3. Doc. Title
Method Statement of Aluminum
Door & Window Work TOA-TOYO JOINT VENTURE
Doc. No CM – MS – BW - 025 Rev. No. 0 Date May, 2012
Construction of Port Facilities and Buildings for Cai Mep International Container Terminal
1. PURPOSE
The Purpose of this Method Statement is to describe the process of Aluminum door and
window works in compliance with all the required specifications, standards, and proper
construction procedures for the building finishing works of the project.
2. SCOPE OF WORK
The scope of works are including the fabrication, delivery and complete installation of
Aluminum doors and windows, including glazing and finishing hardware for the buildings.
3. REFERENCE TECHNICAL SPECIFICATION
• Refer to Division 03: Doors and Windows -– Part 4A – Volume 2 of Technical
Specification.
• Refer to Part 1 : General Requirements, Part 4A, Division 1 and Part 4B, Division 5 –
Volume 2 of Technical Specification.
4. SHOP DRAWING
Shop drawings shall be submitted to the Engineer by separated document for review and
approval before carrying out the works.
Page 3

4. Doc. Title
Method Statement of Aluminum
Door & Window Work TOA-TOYO JOINT VENTURE
Doc. No CM – MS – BW - 025 Rev. No. 0 Date May, 2012
Construction of Port Facilities and Buildings for Cai Mep International Container Terminal
Page 4
5. WORK PROCEDURE
5.1. General Flow Chart
Preparation Work
Approval of Materials
& Shop Drawings
Fabrication
Fabrication Inspection
Transportation of
Materials
Marking
Confirm Opening
Size
Installation
Glazing & Sealing
Water tightness
Test
Protection &
Cleaning

5. Doc. Title
Method Statement of Aluminum
Door & Window Work TOA-TOYO JOINT VENTURE
Doc. No CM – MS – BW - 025 Rev. No. 0 Date May, 2012
Construction of Port Facilities and Buildings for Cai Mep International Container Terminal
5.2. Detail Procedure
5.2.1. Approval of Materials & Shop Drawings
The proposal of each materials shall be submitted to the Engineer for approval.
The Shop drawing for Aluminum Doors & Windows shall be submitted to the Engineer for
approval.
5.2.2. Fabrication
5.2.2.1. Fabrication in Factory
High quality windows can be effectively achieved by fabricating and assembling as many
components as possible in the factory. This helps to minimize site assembly where quality
control is more difficult.
The use of mechanical tools, including jigs and computerized machines are useful in
achieving the required fabrication tolerances.
Figure 1.1: Use of cutting and drilling machines
Computerised drilling machine
Máy khoan nhiều đầu
Assembly of the window main frame and sash inner frame using a crimping machine
produces strong and quality joints. Sealant should be applied to the joining edges prior to
assembly for enhanced water tightness performance (Figures1.2).
Figure 1.2: Assembling of window frame (Crimping method)
Page 5

6. Doc. Title
Method Statement of Aluminum
Door & Window Work TOA-TOYO JOINT VENTURE
Doc. No CM – MS – BW - 025 Rev. No. 0 Date May, 2012
Construction of Port Facilities and Buildings for Cai Mep International Container Terminal
Crimping machine for mitre joint Application of sealant on mitre end
Joining of frame components Securing of frame
5.2.2.2 Protection
All exposed parts of the aluminium frame/sections must be protected with suitable
protective tapes (Figure 3.1). The tapes used should not leave stains on the surface of the
frames nor damage the frame finishes during removal. Corrugated cardboard may be used
beneath the protective tape to give additional protection to the frame.
Figure 3.1: Protection of frames
For slender frame sections, styrofoam strips can be inserted to maintain the rigidity and
prevent deformation of the frames during delivery, storage and handling. In addition, corners
of frames should be protected to prevent damages during delivery and storage. All glazing
should also be protected with suitable materials.
Figure 3.2: Protection of frames for delivery
Page 6

7. Doc. Title
Method Statement of Aluminum
Door & Window Work TOA-TOYO JOINT VENTURE
Doc. No CM – MS – BW - 025 Rev. No. 0 Date May, 2012
Construction of Port Facilities and Buildings for Cai Mep International Container Terminal
5.2.2.3 Labeling
All fabricated frames, window sashes and glass panels should be properly labelled for ease
of identification (Figure 4.1). The frames should be arranged in batches for delivery to site
(Figure 4.2). Suppliers should plan the delivery of windows in accordance with the
installation schedule to minimize storage and handling on site.
Figure 4.1: Labelling of frames, sashes and glass panels
Label on frames Label on sash/glass panels
Figure 4.2: Completed frames arranged in batches for delivery to site
Page 7
5.2.3. Fabrication Inspection
Before delivery, frames and leaves need to be inspected to make sure material verification
as per submitted approved sample, correct dimension, good aluminum Surface Condition,
ect. with inspection checklist as per attached in attachment No.1 – Fabrication Inspection
Checklist.
5.2.4 Delivery, Storage And Handling
• Delivery
Before delivery, windows and theirs various components should be fully protected to ensure
the components remain in good condition until they are ready for installation.

8. Doc. Title
Method Statement of Aluminum
Door & Window Work TOA-TOYO JOINT VENTURE
Doc. No CM – MS – BW - 025 Rev. No. 0 Date May, 2012
Construction of Port Facilities and Buildings for Cai Mep International Container Terminal
All materials for delivery should be verified against the quantity and batch number stated in
the delivery order. All required accessories, including friction stays, handles, locking devices,
fixing, etc. should be delivered together with the main components. Materials could be
packed in either steel pallets or skids.
Upon delivery on site, the materials should be checked for damages during transportation
and that the delivered materials are in compliance with the specifications. Any damaged or
incorrect materials should be returned to the factory.
Figure 1: Packing for delivery
• Storage
Delivery of materials should be carefully planned according to the installation schedule so
that only the required quantity of materials are stored on site, where the possibility of
damages is higher. Just-in-time (JIT) inventory management system is effective in
minimizing unnecessary handling, storage and damages to the materials.
Proper site storage is important in preventing damages to the window components. A
suitable storage location should be:
Sheltered from weathering and fallen objects; and
Located for ease of material handling and distribution.
Components should be placed on timber bases to avoid direct contact with the floor. Glass
panels should be stored in pallets with individual glass panel separated from one another by
protective sheets to avoid scratches and other damages. The glass panels should also be
protected from exposure to water which may result in “ rainbow” effect and jeopardize the
visual properties of the glass.
In addition, the various components should be arranged according to the installation
sequence to facilitate ease of retrieval, i.e. to minimise searching and unnecessary shifting
of material which may lead to damages.
Page 8
• Handling

9. Doc. Title
Method Statement of Aluminum
Door & Window Work TOA-TOYO JOINT VENTURE
Doc. No CM – MS – BW - 025 Rev. No. 0 Date May, 2012
Construction of Port Facilities and Buildings for Cai Mep International Container Terminal
Large window units and components which cannot be delivered via staircases should be
hoisted in pallets to each floor before distributing to the different areas for installation. In
cases where window frames need to be hoisted without the pallet, the frame should be
handled only at the designed strong points.
Large pieces of glass panel should be handled with care using suction cups as shown in
Figure 3.1
Figure 3.1: Proper handling of glass using suction cups.
• Transportation of Material
The each type of materials shall be transported to the site by truck and dump truck
5.2.5 Preparation Work
a) Proper dimensional control and setting out of the wall opening are critical in ensuring
the quality of window installation. Precast facades provide superior dimensional
control than the cast in-situ RC walls and brickwalls and require less preparatory
works.
b) The use of cement grout to fill up large gaps should be avoided as this may lead to
cracks in the grout which would lead to water seepage through the building envelope.
Page 9
5.2.6 Marking
Reference line (R.L) should be set up at appropriate location to facilitate proper alignment
of the wall openings and installation of the window frames.
5.2.7 Confirm Opening Size
Close dimensional control on wall opening should be exercised to ensure the gap
between the wall and window frame is within the range of 7-25mm wide.
5.2.8 Installation
Window installation involves the fixing of window frame at an earlier construction stage and
subsequent installation of the window sashes. This is a highly workmanship dependent
process. Only trained and approved contractors can carry out installation and retrofitting of
windows.

10. Doc. Title
Method Statement of Aluminum
Door & Window Work TOA-TOYO JOINT VENTURE
Doc. No CM – MS – BW - 025 Rev. No. 0 Date May, 2012
Construction of Port Facilities and Buildings for Cai Mep International Container Terminal
• Installation of frame on brickwall/ concrete wall
Before installation of the window frame, the following checks should be carried out:
- Wall opening should be checked for any physical defects. Any defects should be rectified
before installation proceeds.
- Window frames should be checked for any damages. Defective frames should be repaired
or replaced prior installation.
Timber V-shaped wedges are commonly used to temporarily hold the window frame in position
within the wall opening as shown in Figure 2.1 The window frame is then checked for plumb,
levellness and alignment.
Figure 2.1: Use of V-shaped timber wedges for positioning of frame
Figure 2.2: Checking the plumb, levellness and alignment of window frame
Check plumb of frame Check alignment of frame
Page 10
Strap
V-shaped timber
wedge
V-shape timber
wedge
Strap
Level peg
Plaster
finished
level peg

11. Doc. Title
Method Statement of Aluminum
Door & Window Work TOA-TOYO JOINT VENTURE
Doc. No CM – MS – BW - 025 Rev. No. 0 Date May, 2012
Construction of Port Facilities and Buildings for Cai Mep International Container Terminal
Page 11
Check alignment of frame
Check positioning of the frame
with reference to wall
After confirming the position of the frame, the galvanised straps are ramsetted to the wall.
When ramsetting the straps, the plumb line should be maintained to ensure proper alignment
of the frame.
The levellness and squareness of the installed frame can be checked by carrying out a
diagonal dimensional check as shown in Figure 2.3.
Figure 2.3: Fixing of window frame
Ramset the straps to the wall after confirming Check diagonal dimensions after
installation
• Installation of Finish Hardware
All hardware shall be installed in strict accordance with the manufacturer’s directions.
All work shall be installed plumb and true and secured with proper fastenings so as to
make all work rigid and firm.
After installation, all finishing hardware shall operate and function smoothly and efficiently
in strict accord with their respective expected operating performance.
All works which are to receive hardware shall be inspected and any defect must first be
rectified before installing finishing hardware.
After has been properly fitted, all exposed items such as knobs, plates, pulls, locks, etc.
shall be removed until final coat of finish has been applied, and then hardware installed.
5.2.9 Glazing & Sealing
For better quality, glazing work should, as far as possible, be carried out by skilled installers
in the factory. The gasket used should be of a continuous length, with splices made at
appropriate locations for good fitting around the corners of the glass panel (Figure 2.1).

12. Doc. Title
Method Statement of Aluminum
Door & Window Work TOA-TOYO JOINT VENTURE
Doc. No CM – MS – BW - 025 Rev. No. 0 Date May, 2012
Construction of Port Facilities and Buildings for Cai Mep International Container Terminal
Figure2.1: Installation of gasket
Splicing of gasket to fit around corner of glass
When assembling frames, ensure that gasket fits properly to the glazing and the frames are
properly aligned.
The gaps between the window frame and wall must be properly sealed to prevent water
seepage at these locations. Depending on the size of the gap, waterproof sealant can be
used.
• Application of sealant
Sealant could be used to seal the gap between wall and window frame if the gap size is
between 7-10mm.
Before the application of sealant, clean the aluminium window frame with white spirit using a
clean rag. The frame and wall surfaces around the gap should be protected with masking
tape to prevent the sealant from staining these surfaces and to obtain a neat sealant joint.
Backer rod should be used to achieve better compactness of the applied sealant. To obtain
a complete seal, apply sealant by pushing the bead forward into the joint cavity.
The joint should have continuous caulking to ensure that all areas are filled. Remove the
excess sealant and
tool the joint to achieve a smooth surface.
Page 12
Mitre joint
Mitre joint
Glass
Splicing off part of the
gasket
(create a mitre joint)
Gasket in fitted position

13. Doc. Title
Method Statement of Aluminum
Door & Window Work TOA-TOYO JOINT VENTURE
Doc. No CM – MS – BW - 025 Rev. No. 0 Date May, 2012
Construction of Port Facilities and Buildings for Cai Mep International Container Terminal
Figure 2.4: Application of sealant
Protection of the frame with masking tape Protection of the wall with masking
tape
Application of sealant
• Installation of window glazing
It is recommended that glazing work for inner glass panels be carried out in the factory,
where higher work quality can be achieved. Where this is not possible, glazing work must be
carried out on site with proper handling and good workmanship. For fixed glass panels,
glazing is usually done on site.
This section will discuss the good practices to be adopted when carrying out glazing works
on site.
For glazing work in the factory, refer to Chapter 6 on Fabrication.
- Preparatory works before glazing
The protective tapes should only be removed when glazing works is to be carried out. The
following verification works should be carried out prior to glazing work:
Page 13

14. Doc. Title
Method Statement of Aluminum
Door & Window Work TOA-TOYO JOINT VENTURE
Doc. No CM – MS – BW - 025 Rev. No. 0 Date May, 2012
Construction of Port Facilities and Buildings for Cai Mep International Container Terminal
ƒ Inner frame and associated hardware should be checked for defects. Damaged frames or
hardware should be replaced.
• Inner frame should be cleaned and free from dust and debris.
• Weep holes in the inner frames should be cleared of blockage to allow discharge of
Page 14
incidental water.
5.2.10 .Water Tightness Test
Water seepage through windows is one of the major problems.
Laboratory tests are not able to detect water seepage problems caused by poor workmanship
during installation of the window system. Field watertightness test should, hence, be carried
out to verify the watertightness performance of the installed windows.
The following parameters are used in field watertightness test:
Water intensity 300mm/hr
1 litre/min/m of joint
Wind Pressure 240 Pa = 35 psi
Nozzle inclination 900 to wall
Distance of nozzle from wall 300mm
Sample 1 sample = 2m length of joint
Spray duration 10mins
No sign of seepage should be detected throughout the test.
Figure2.10: Conduct field watertightness test
Portable pump with hoses Lightweight nozzles

15. Doc. Title
Method Statement of Aluminum
Door & Window Work TOA-TOYO JOINT VENTURE
Doc. No CM – MS – BW - 025 Rev. No. 0 Date May, 2012
Construction of Port Facilities and Buildings for Cai Mep International Container Terminal
Page 15
(viewed from outside the building)
Figure 2.11: Detection of water seepage
Seepage through gasket Seepage through joint in frame
5.2.11 Protection and Cleaning
Protection should be provided to all vulnerable surfaces such as the frames, glass panels,
handles, etc. Protection of the windows starts in the factory and should remain intact throughout
the construction process until the windows are scheduled for final cleaning and handling over.
Material used for temporary protection must be compatible with the protected surfaces and should
not stain the finishes of these surfaces. It is important that the life span of the protective tapes be
considered to ensure that the quality of the tapes is maintained throughout the construction
process.
Figure 1.1: Protection of components for delivery and storage

16. Doc. Title
Method Statement of Aluminum
Door & Window Work TOA-TOYO JOINT VENTURE
Doc. No CM – MS – BW - 025 Rev. No. 0 Date May, 2012
Construction of Port Facilities and Buildings for Cai Mep International Container Terminal
Figure 1.2: Protection of frame throughout construction process
Protective tape on window frame
Page 16
Box-up protection for bottom frame
of full height window
Protection at access-prone location
Figure 1.3: Protection of window after installation
Protection of glass panel Protection of accessories
It is good practice to adopt a multi-layer protection system, such that different layers of protective
tape can be removed as installation progress on site (Figure 1.4).
Figure 1.4: Multi-layer protection system
Two separate layers of protection on frame Removal of protective layer 1 for glass
panel installation
Glass panel
Layer 2 remains infact
Glass panel
Layer 3 protection to protect
l & df
Layer 2 remains infact
Window frame
Window frame

17. Doc. Title
Method Statement of Aluminum
Door & Window Work TOA-TOYO JOINT VENTURE
Doc. No CM – MS – BW - 025 Rev. No. 0 Date May, 2012
Construction of Port Facilities and Buildings for Cai Mep International Container Terminal
Installation of glass panel
Glass protective tape (layer 3) is been applied to protect the glass panel and exposed frame.
Layer 2 & 3 would be subsequently removed after the completion of all works.
6. QUALITY CONTROL
6.1. Inspection and Testing Plan
Before start Fabrication and Installation, Inspection and Testing Plan shall be established to
keep proper quality of the works in accordance with specification and standard. ITP shall be
submitted to the Engineer for approval.
Page 17
6.2. Fabrication and Installation Inspection
Before deliver the materials to the site, fabrication inspection shall be conducted and after
finished installation, installation inspection shall be conduct with witnessed by the Engineer.
Sampling and Testing
7. SAFETY CONTROL
7.1. Fundamental Policy
“Safety is the First Priority"
7.2. Key Activities
• Implementation of Safety & Health Education
• Prevention of Human Error and Machinery Accidents
7.3. Development and implementation of Activity
• Implementation of Safety & Health Education
• Pick up hazardous factors of each work activity and always reflect them at the safety
meetings.
7.4. Point out them every day at the meetings in order to let individual worker to renovate his safety
consciousness
• Prevention of Human Error and Machinery Accidents
• Be consistent with inspection at beginning of works, regular maintenance of working
platform, machinery tools designation of working area.
7.5. Others
• Safety signboards and barricades shall be installed around working area if necessary.
Security guard should observe all passengers around the site.

18. Doc. Title
Method Statement of Aluminum
Door & Window Work TOA-TOYO JOINT VENTURE
Doc. No CM – MS – BW - 025 Rev. No. 0 Date May, 2012
Construction of Port Facilities and Buildings for Cai Mep International Container Terminal
Appendix – 1
Inspection and Testing Plan
Page 18

19. Doc. Title
Method Statement of Aluminum
Door & Window Work TOA-TOYO JOINT VENTURE
Doc. No CM – MS – BW - 025 Rev. No. 0 Date May, 2012
Construction of Port Facilities and Buildings for Cai Mep International Container Terminal
ALUMINUM
CAI MEP-THI VAI INTERNATIONAL PORT CONSTRUCTION PROJECT
Package 1 : Construction of Port Facilities and Buildings for
FACTORY INSPECTION CHECKLIST
ITEMS TO BE CHECKED
1. Material verification as per submitted approved sample
2. Dimensional Check
3.Cutting joints Connection
4. Aluminum Surface Condition
5.Coated Paint/ Final Paint
6.Material Storage condition-Protection and Handling
7.Hardware and Accessories
Cai Mep International Container Terminal
Result of Inspection
Sub - Contractor TTJV Consultant (JPC/NK)
Page 19
Date :
No. :
Building Name : Location :
Inspected Item : ALUMINUM DOORS AND WINDOW Type: Aluminum Doors / Aluminum Window / Aluminum Louver
Shop Drawing No.:
Acceptable Rejected N/A Remark
8.Others
Notes / Comments :
Sign : Sign : Sign :
Name : Name : Name :
Date : Date : Date :

20. Doc. Title
Method Statement of Aluminum
Door & Window Work TOA-TOYO JOINT VENTURE
Doc. No CM – MS – BW - 025 Rev. No. 0 Date May, 2012
Construction of Port Facilities and Buildings for Cai Mep International Container Terminal
Page 20
Date :
No. :
Building Name : Location :
Inspected Item : DOOR WORK
Shop Drawing No.:
Acceptable Rejected N/A Remark
Sign :
CAI MEP-THI VAI INTERNATIONAL PORT CONSTRUCTION PROJECT
Package 1 : Construction of Port Facilities and Buildings for
Cai Mep International Container Terminal
FINISHING WORK CHECKLIST
Result of Inspection
ITEMS TO BE CHECKED
TYPE: Steel Door/ Wooden Door/ Aluminum Door/ Steel Shutter
Door Works :
1. Material verification,type,size free from damage
2. Material handling and and storage
3. Installation:Location and plumbness
4. Accessories/Hardware
5.Free from damage
6.Door wooden trim ( for wooden door )
7.Others
Notes / Comments :
Sub - Contractor TTJV Consultant (JPC/NK)
Sign : Sign :
Name : Name : Name :
Date : Date : Date :