Method Statement for Wall Panel Installation

The purpose of this procedure is to define how the wall panel installation and fabrication at a construction site shall be carried out under the controlled conditions.

Scope of work under this method statement covers the detailed procedure to be followed for fabrication, supply and installation of wall panels as per approved shop drawings and schedule of finishes for the project.

This procedure shall be read in conjunction with contract specifications and manufacturer installation requirements where applicable.

Other References

• Project specifications
• Contract drawings
• Approved shop drawings
• Material Submittal Approved
• Project Quality Plan

DEFINITIONS & ABBREVIATIONS

• Contractor:
• PM: Project Manager
• CM: Construction Manager
• PE:  Project Engineer
• QCE: Quality Control Engineer
• SE: Site Engineer
• SF: Site Foreman
• QA / QC:  Quality Assurance and quality Control
• PPE: Personal Protective Equipment
• HSE: Health, Safety and Environment

Roles and Responsibilities

Project Manager is responsible for overall project execution, quality and safety. He shall adopt a leading role with respect to contractor’s quality and safety procedures.

The PM is responsible for the overall implementation of this method statement.

Project Manager shall ensure that the key personnel are well aware of the specifications, method statement, ITP and risk assessment etc..

Construction Manager / Project Engineer shall arrange all materials, equipment, safety related items & manpower & direct the Site Engineers & Foremen to resort appropriate action for the smooth execution of the wall panel installation works.

Safety Engineer shall be responsible for ensuring the safe working environment & conditions. Hse shall coordinate with Site Engineer to identify potential hazards before works and advise methods of safe working from new developments or changes in working conditions.

Surveyor shall be responsible for setting out for levels, layout, and lines & establish top levels. Ensuring setting out books are properly maintained and filed when completed. To coordinate with the consultant surveyor in determining coordinates, levels, and limits.

QA/QC Engineer shall be responsible for ensuring that execution of wall panel installation works are complying with approved method statement; specifications, approved shop drawings.

Site Engineer shall ensure that all works are carried out according to approved shop drawings. He shall direct the surveyor for the setting out lines & levels in concurrence from the Construction Manager/Senior Civil Engineer.

Site Engineer shall ensure that all materials delivered to site are complying with approved samples and shall assign temporary storage locations at construction site according to different installation / fixing locations. The fixing location of each individual stone panel shall be defined by level number  and related identification marking to ensure compliance to the approved shop drawing and traceability.

Site Foreman shall ensure that all the materials are reached at the site as per the check list. SF responsible for the execution of the job under his control. SF shall report to the Site Engineer every end of the day to submit the report of work progress at site. The Site foreman shall be carrying all the times the drawing and Method of Statement to execute job properly. Site Foreman is also responsible to finish the job within the time frame given by the Site Engineer. The Site foreman is responsible and reports to the Site Engineer for any inconvenience at site for execution of wall panel installation work. Site Foreman is also responsible to inspect and ensure that the materials reaching at site are as per the inspection check lists.

MEP Coordinator / Engineer shall be responsible for proper execution of MEP works involved before, during and after the civil works.

Necessary Materials, Tools & Equipment

Below is the list of necessary tools and equipment for the installation of wall panels:

• Wood Cutter Machine
• Hilti
• Clamp
• Drilling Machine
• Tighter
• Screw Driver Set
• Measuring Tape
• Planer
• Compressor
• Silicon Gun
• Chisel
• Extension Cable  

The capacity / size of the above equipment shall be judged in accordance with site conditions, requirements, and availability at the time of execution.

Power Tools Health and Safety Requirements

• Before operations, check all power connections.
• Wear gloves, goggles, Mask for  protection.
• Do not operate any tool/machine when it is wet.
• Hold machine firmly, especially when starting.
• Check drill bit against bending or loose fixation.
• Before operation, check all power connections.
• Wear gloves and eye protection.
• Do not operate grinder when it is wet.
• Keep protection cover all the time.
• Do not operate if switch is damaged.
• Hold machine firmly, especially when starting.
• Check cutting disc against breakage or loose fixation.

SECURITY – HEALTH AND SAFETY CHECKLIST AT PLACE OF WORK:

• Housekeeping – Keep place of work clean and tidy.
• Do not dump the tool here and there, keep all the tools/equipment in a designated area. Keep all the tools and Equipment in a wooden box after the completion of their duty. Put the tag on each tool box with the Name tag of respective operator/worker.
• Protect the floor with corrugated sheet in order to avoid the floor damage.
• Wear the Hand glove for using Disc cutter or Wood Cutter Machine.
• Provide the First Aid Box at the site.
• Provide sufficient drinking water at site.
• Provide safe access with suitable lighting and protection.
• Ensure goggles, gloves and masks are worn when dipping marble in sealer.
• Ensure safety boots are worn all the times.
• Ensure safety helmets, goggles, gloves and belts are provided and used if required.
• De-nail and stack timbers in proper areas.
• Prohibit horseplay on scaffolds.
• Make sure that power connections are safe, never tamper with electrics and get help from an electrician if needed.
• No power tools to be used without proper plug.
• Never remove Safety Guard on machines. They are there for proper protection.
• Ensure Fire Extinguisher on site and make sure that site operatives are aware of its location and usage.

Wall Panel Fabrication / Installation Procedure

Before commencement of work make sure manufacturer instructions are available for reference. Check the materials/sizes are in compliance with approved shop drawings, cross check the measurement at Site.

In case of any major variation at the site it must be reported to the project engineer and it should be approved by the PE.

If any changes or rectifications are required at the site it must be brought in to notice of Project Engineer and approval must be taken.

Site engineer will report to quality control engineer about the variations/changes and QCE will handover details to the production department after his approval.

Production manager will also cross check the drawings on his side for any kind of variations before ordering the start of cutting process.

The foreman will prepare the cutting sizes according to the drawing for his subordinates, meanwhile all the approved controlled samples should be handed over to QCE.

Production manger will be conducting routine inspections to make sure that production is being done under the control of foreman in compliance with drawings and approved samples.

Make sure that all materials are available in good quality and quantity for execution of the production processes.

Check all the wall panel materials avoid using any material having scratches, cracks or moisture.

Prepare MDF panel as per sizes required through the Circular Saw Machine for the carcass. Run through the base cutter machine.

Prepare the beach wood lipping all around by 10mm thick. The lipping joining to the MDF panel is done using clamp with industrial glue, and keep dry for at least two hours to obtain strong enough joint.

Prepare the MDF bracket male and female to hang the panels at the wall.

Prepare temporary installation at the factory to make sure that panels are proper as per the sizes provided in the drawing.

Check and find out any potential difficulties which might come during installation of wall panel at site, suggest suitable solutions to avoid any inconvenience during installation at site.

Prepare for veneer pressing. Cut out the sheet by using veneer guillotine machine. Once ready send for pressing to the hot pressing machine at the temperature of between 70-120°C. All the veneer should be kept in isolated Air conditioned area.

Painting the Wall Panels

Check that all goods have been manufactured in compliance with final approved shop drawing. If any discrepancy is found send the material back to the concerned section for the rectification.

Send the wall panels for polishing after the approval of QAQC.

Clean veneer panel and remove the Glue of Joint.

Check for any cracks on veneer, Grains are in proper direction.

Make first sanding and apply the pate for the filling. Remove the over filled pate. The surface should be smooth plain.

The application of primer will take in to place as the first processing of painting. After the first coat primer on one side keep to dry for three to four hours.

After drying one side other side of the panel shall be applied with primer and kept to dry again for three to four hours.

Once dried from both sides, look for any damage or cracks, apply pate, fill the gaps and cracks, and go for second sanding.

Again apply the primer as mentioned above.

Check again and make sure there is no crack or gaps any more. If any apply the same pate and make the surface finish even.

The final coat shall take place with the requirements of percentage of glossy or mate according to specified in the drawing.

Keep it to dry about three to four hours.

QA / QC CHECKS

After the completion of painting the QA/QA will inspect the materials for the quality control before dispatch to the packaging.

The QA/QC will enter the data into checklist which shall be signed and stamped for the packing purpose.

In case of any rectification requirements on painting the materials are sent back to the painting section with comments provide by the QA/QC.

The Points to be  checked by QA/QC

• Check with control sample and make sure the same specification and materials are used for painting.
• Check that the surfaces of the materials are smooth. No any kind of particle spread on the material. No rough on the surface.
• Check all the joint if any. No joint should be visible.
• Check all corners and lipping edges for not having any damage or crack.
• Check all materials are even in finishing, there should not be any differences in finishing.
• Segregate panel according to site installation number.
• Send for packing.

MATERIALS USED FOR SANDING

• Heavy Duty Machine
• Second Sealer Sanding
• Final Check up Sanding
• Pate blade
• N.C pate
• Primer
• Top coat

Protection of Wall Panels

All the materials are cleaned with pure soft cotton to remove all the dust if any.

Arrange the segregated materials by numbers provided in the check list.

Arrange all hardware and fitting/accessories for installation purposes.

Protect each corner with thermopore sheet in order to avoid any damage during transportation. All the panels shall be packed individually to avoid any damage.

Pack with polyurethane sheet to avoid any scratches, pack with corrugated sheet with industrial heavy duty masking Tape.

Mark the top and Bottom.

Check again if the packing is proper.

Now the panels are ready for loading and delivery.

Hand over the D.O and Inspection report to the delivery section.

Wall Panel Dispatch and Delivery Procedure

The Materials will be delivered once the area of installation/storage is ready. Storage site must be free from dampness. Check the delivery truck there should not be any particles are may damage the wall panels. Keep the protection all around the sides i.e. thermopore sheets.

Stack the material properly inside the vehicle.

Storage must be provided by main contractor. The separate storage should be provided for the joinery contractor. The storage must be clean, empty and free from dampness. Once the Material reaches to the site the Site Foreman inspects the dispatch form to make sure that the material received according to receipt.

Stack materials according to code number, and in order. Space should be provided between pallets or rows so that material handling is easy.

All the code numbers should visible to identify easily.

Pre-Installation Method of Wall Panel – Site Condition Checking and Setting Out

• Site engineer shall check site conditions to ensure readiness for the installation/fixing of wall panel at site.
• Main contractor shall sign off clearance to each area/section to proceed for the installation.
• Check that the area of installation is free from any kind of dampness, electrical work, fall ceiling, gypsum, marble, Stone work and painting.
• Ensure that electrical power available at site.
• Segregate the frames and doors according to location of installation.
• Make sure approved drawings, method of statement, ITP, checklist and risk assessment is available at the site.
• Make sure that all the materials including accessories and tools are available for wall panel installation.
• Provide the protection for the floor from any kind of damage during the installation works.

Method of Wall Panel Installation

• Mark the wall by numbers as provided on the panel.
• Make straight line to make sure for straightness of installation.
• Provide the hole on wall with Hilti machine.
• Provide the fishers for the hole in order to hold the screw tight and stiff.
• Hang the male part of the MDF support to wall.
• Hang the female part of the MDF support to the back of veneer panel.
• Hang temporary to see proportion of the panels.
• Follow the same procedure for all the panels.
• After completion of installation of all the panels check the alignment.
• Check if there is any unnecessary gap.
• Check the alignment of ceiling and floor is even.
• Check the gaps or grooves are equal between the panels.
• Mark the panels having any kind of problems.
• Remove and replace all faulty panels.
• Check the back panels for strong enough support.
• Make additional screws if required.
• Once temporary wall panel installation is found OK, hang panels permanently.

Cleanliness

Make sure that the site is cleaned after every duty hours.

Do not dump any dust / wastage at the working area, it should be cleaned adequately.

All waste should be disposed off to designated waste containers.

QA/QC  Checking

The Site Engineer co-ordinate with site foreman that all cabinets are installed as per the client requirement.

The following points to be taken care

Check for no scratches, damage panels

Check for all panels are aligned properly.

Check all the panels are even and straight.

Check for any gap between the panels.

Check the wall panel surface for cleanliness and remove deposition of any dust particles.

Make sure the availability of protection with polyurethane sheets or as applicable.

Attachments

• Inspection and Test Plan ITP
• Installation Inspection Checklist
• HSE Risk Assessment