Table of Contents
Purpose
This Method Statement of Metal Door defines the installation process, quality control, and safety requirements, as well as the equipment to be used to perform the tasks according to the project specifications.
Scope
Its scope specified in the method statement can be used for the installation of metal frames and doors.
References
Standards-Steel Door Institute 117 (SDI 117)
Project Specifications
Project HSE Plan
Metal Doors and Frames – Approved Material Submittal
Tools and Equipment
Drill machine
Concrete drill bits
Level
Flathead plastic hammer
Flathead screwdriver
Star head screwdriver
Measuring tape
Ladder
Boom Loader/Crane
Methodology-Method Statement of Metal Door Installation
Site storage and handling of material
Information prior to storage on-site:
Door frames and leaves are manufactured and powder coated according to the color that is approved by the project.
They are not required to be repainted or require additional coatings or touch-ups at the site unless they are damaged after the delivery of the materials.
Thus, extreme care has to be taken to preserve the color and evenness of the coating at every stage of the life cycle of the materials.
The materials are put inside a truck or container in a manner that door leaves are securely wrapped with stretch wraps, and then laid out on a pallet.
The door frames are wrapped in bubble wrap, and then put in order and arranged freely.
The unloading of the steel doors and frames from the truck may be done either by manually unloading or by using forklifts.
Make sure that the storage area is set up prior to the arrival of the materials, in order that the material can be moved into the storage space without having to be temporarily stored in exposed areas, as the latter could cause serious damage to the material.
Additional care to be taken during storage:
As well as the previous considerations, the following precautions need to be observed when keeping the materials on the construction site.
If a grouping of the materials is done, not more than 5 door leaves (or) frames that are welded/assembled will be stored in a group.
Frames used to create multi-opening frames must be stored in no more than three groups as a group larger than that could cause severe harm to the frame at the bottom.
All welded (or) assembled frames must be stored in a proper place and laid down.
In storage, the door leaves and frames are to be kept from getting direct deposits of sand and dust to prevent the formation of scratch marks on the surface coat.
Furthermore, if materials are to be cleaned/wiped they should only be cleaned with a soft, damp cloth that is thoroughly rinsed to get rid of the dust that has eventually accumulated on them.
After which the materials shall be kept in dry-free and moisture-free air.
Installation procedure at the site
Select the required door and frame from the site storage.
All the materials needed for the installation will be taken and delivered to the installation site along with the delivery note.
The vehicle should be driven within the access zone designated after having obtained the necessary permission from security.
Vehicles are to be parked within the designated unloading area. Then the storage or stacking area must be properly covered. The area facilities for storage/stacking will be provided.
The unloading of the materials should be completed with the aid of a boom-loader truck or forklift.
Materials Inspection Request (MIR) to be made immediately following the delivery of the material, and prior to beginning the installation.
Transfer of material to the door’s designated location
Based on the opening number, the installation team will segregate the frames, and doors at the specified site.
The installation crew will move the material to the location via designated pedestrian access or egress. The crossing must be at only the specific crossing point.
The frame and door leaf shifting can be performed by two (2) installers in each specified area.
The transfer of each material will be in accordance with safety rules and safety programs.
Frame Installation
Frames to be installed will be carried out in accordance with the manufacturer’s specifications and SDI standards. Grouting within the frame isn’t necessary.
The following steps must be followed:
For Concrete Wall Masonry Wall & Dry Wall Partition
The proper placement should be observed. Finish the floor with level markings and threshold, if applicable should be confirmed before frame assembly.
It is important to get MEP clearance for wiring inside or conduits for card access systems or another MEP device if any.
After the measurement of the site, the opening should be verified in accordance with the approved shop drawing.
Make sure that all door frames are on the same wall or in the same space at the same height.
Ladders are not required for frames that are fixed above the floor’s finish level of 2.2m. However, if a greater than 2.2m mobile scaffold is needed.
The frame installation tolerance – the distance between the door frame and wall should be verified.
In the event that the frame’s in the knockdown stage, which includes three components (header, strike jamb, and the hinge jamb) the frame’s header and strike jamb are put together on the floor using the corners clip and by connecting with the M5 screws. The assembly should match the approved mockup.
The frame that is assembled will be placed inside the door opening.
The header’s level and strike jamb must be level prior to fixing the expansion-type anchor bolt.
A hinge jamb should be put inside the head slot and the alignment will be verified prior to fixing the expansion-type anchor bolt.
A proper alignment of openings must be achieved.
Keep the frame in the opening and make sure that each anchor bolt is tightened.
Install the rubber gasket.
The proper protection of the door frame must be put in place to avoid any damage.
Proper protection for the frame and ironmongery of the door should be put in place when the leaf has not been put in place in the meantime.
Threshold (if there is one) is possible to be added after the frame has been installed or door.
Door Installation
The installation of doors is to be performed following the manufacturer’s specifications and SDI standards. But, based on the style, dimensions, and weight of the door, the following steps are described according to the following specifications:
For doors up to a height of 2.2m and below:
Doors that are fixed above the floor’s finish, the floor up to 2.2m, and ladders will not be required. However, in the event that they extend beyond 2.2m small ladders are needed.
Two installers will be enough to support the weight (50 kilograms) of the door during its installation.
The leaves can be hung with just 8 screws to secure the hinges.
Door heights as high as 2.2m – 3 hinges are enough for a door leaf according to SDI standards.
Door heights greater than 2.2m – 4 hinges will be determined as per SDI standards.
When the entire door’s weight is placed on the hinges, close the hinges by putting them in order from top and bottom and then the middle hinge.
Use all eight screws and make sure they are tight until they are flush with the hinge. The door’s hinges will be hung on the frames in accordance with the number of hinges.
Make sure that SDI and industry tolerances of the frame and the door are ensured.
Install additional hardware e.g. locks or closers according to the manufacturer’s instructions for each, SDI standard & project specifications.
Work Inspection Request (WIR) must be made at all stages in accordance with the Inspection and Test Plan (ITP).
For doors of height 2.2m and above with a weight of more than 100kg:
For any door that is fixed over the floor’s finishing line over 2.2m, a scaffold or a tower is required.
Four technicians assisted by the loader boom are needed to lift all the load (100 kilograms) that the door needs during its installation.
Door height greater than 2.2m – 4 hinges should be supplied as per SDI standards and approved shop drawings.
When the door’s weight is placed on the hinges, close the hinges to the point of the top and bottom and then the middle one.
Use all eight screws and make sure they are tight until they are flush with the hinge. The door’s leaf is to be hung on the frames that are attached to them with the number of hinges (preferably 5-6 hinges)
Make sure that SDI and Industry tolerances of the frame and the frame are ensured.
Install additional hardware e.g. locks or closers. according to the manufacturer’s instructions and SDI specifications.
The Work Inspection request (WIR) must be made at all stages in accordance with the Inspection and Test Plan (ITP).
For Grill Doors – 150kg weight:
The grill door installation is somewhat different from regular steel doors because of its shape, design, and weight.
Using equipment similar to boom loaders and cranes – All lifting that is supported by belts must be certified by a third party. A medium to heavy-duty forklift is required for the installation.
Six technicians will be required to help support this load (150 kg) using the lifting equipment used to align the door during the installation.
There is one operator from the contractor who is operating on the boom loader and two individuals balancing the door using a chain or belt. Proper PPE must be used.
This door will be a final product and the technicians should ensure that there is no damage during the installation.
Grill doors are fixed with the use of 4 to 5 hinges, as per the load and design of the door.
After the hinges have been fixed in a proper position, the crane will be disengaged and removed from the door.
Check that the allowed tolerances between the frame and the door are implemented.
Install the additional hardware e.g. dropping or industrial hinges, tower bolts, etc. in accordance with the manufacturer’s specifications.
Work Inspection Demand (WIR) must be made for each stage as per the Inspection and Test Plan (ITP).
The doors that are installed should be protected against material shifting and site activity.
Ironmongery Installation
In accordance with the approved shop drawings, the installer should fix the ironmongery properly way.
Adequate protection must be installed to prevent damage.
Vision Panel Installation (if there is one):
There are two components for the vision panel: both male and female pieces (vision light frame).
Before attaching both the male and female components, the glazing tape should be fixed to the beading of the vision frame.
The male component is to be placed into the door cutout from the inside of the room.
The visibility glass must be fixed to the correct spot.
The female component must be accurately positioned and set. It is to be installed onto the male component.
Louver Installation (if any)
Self-attaching (25mm) head screws can be used to attach the auxiliary frame onto the louver core through the door’s cutout. The side that runs along the corridor part of the frame is completely free of fasteners to provide additional security.
Final Alignment
After the installation, the proper door’s swinging and locking mechanism should be checked.
Application of Fire-Rated Sealant
Make sure that the surfaces are dry, clean, and free of frost. Clean the joints thoroughly to ensure that the adhesion between the sealant and the surface isn’t compromised.
It could be necessary to mask areas adjacent to protect against contamination and to create a clean sealant line. Masking tapes must be removed following the tooling and finishing.
Install the backing material as needed and complete the cavity with acrylic.
Joints must be tipped within 5 minutes after application to ensure that there is a good bond between the acrylic and substrate. The process of tooling the sealant can also give an even and smooth appearance.
Used cartridges shall be disposed of according to local rules.
Repair work (paint touch-up)
It is to be done in accordance with the specifications of the project.
Below are the guidelines to be followed:
- Sand the area that is damaged using sandpaper. This will remove any paint or rust from the affected area. The damaged area should be sanded until the surface is smooth and soft and there is no visible lip in between the steel and the paint.
- Fill in the damaged area. Make use of a putty blade to fill the region with putty filler.
- Smooth the putty out so that it blends in with the rest of the door.
- The patch should be sanded: Once you have the patch looking nice and dried, make use of fine-grit sandpaper to gently smooth the patch. Remove the fine dust using a cloth prior to applying the paint.
- The patch should be painted with the identical approved color. If you are applying the paint to your patch, apply either the brush-on method or a spray-on method.
- Apply a thin coating of paint, and let it dry completely, before applying a second thin coat. Continue to apply thin coats until the spot disappears and the door appears to be completed.
- Applying several light coatings of the spray paint will reduce the chance of messy paint drips and give a nice, clean finish on the exterior that the door.