Quality Assurance

Responsibilities of Key Personnel

1.1 Project Manager

• To act as the main contract for the main contractor/client/consultant.
• To ensure the progress of project to the agreed program.
• To co-ordinate the designing team dedicated to this project.
• To develop technical details and timely submission of drawings for approval.
• To make decision for day to day project activities of engineers, design, procurements, manufacturing, delivery and site installation.
• To liaise and control the activities for the Site Supervisor.
• To coordinate the office based personnel such as planning engineers, design staff and appropriated fabrication managers.
• Identify and satisfy training needs of personnel reporting to him.
• Ensure the effective implementation of the quality system in the area of his control.
• Ensure that quality policy and objectives are understood and implemented.
• Take corrective a preventive action as required for non-conformative in the area of his control.

1.2 Project Engineer

• Reports to the Project Manager in respect of the work progress and relevant information to ensure that work is carried our according to the client requirement.
• Supervision and follow-up of the day to day site work.
• Ensure that materials received at site conform to the specified requirements.
• Implement the corrective and preventive actions taken by Project Manager.
• Identify training needs of personnel reporting to him.

Quality Policy & Objectives

Our quality policy is:
To satisfy our Customers requirements by providing them quality products.

Our quality policy is:

1. To provide qualified / experienced personnel in the different stages of the work.
2. To execute the work as the agreed programme.

To achieve our objectives we are committed to the quality system requirements and contract specification requirements by ensuring that quality is the responsibility of every employee.

1.3 Project Supervisor

• To supervise day to day progress of work.
• To supervise quality of erection subcontractors.
• To ensure the program of the installation is in accordance with agreed program.
• To interface with the factory as far as deliveries of material is concerned.
• To ensure the compliance with the contractors security plan, in particular, access for personnel and materials.
• To accept instruction from the contractor and offer responses along with erection monitoring, quality control and material flow.
• To implement corrective & preventive action taken by Project Manager.

1.4 Site Technician

• To implement the actual work under the supervision of the Project Manager/Project Engineer & Project Supervisor.

2.0 Organization

• 2.1 An experienced Project Engineer & Supervisor will be appointed to manage the contract and control the production of design, manufacturing drawings and all technical, production and site installation matters.
• 2.2 The project Manager will be based mainly in our office but during the design phase, he will be able to attend scheduled meetings.
• 2.3 A team of experienced designers/draftsman will assist the Project Engineer.
• 2.4 Site Supervisors will be appointed to supervise the site installation and assist the Project Engineer for this purpose.
• 2.5 The Project Engineer and Supervisor will be responsible for day to day project activities and supervise the efforts of all other component of the project team

3.0 Sequence of Works

• Finalize all relevant technical information, specification sample submission and design with main contractor / consultant.
• Design development and approval.
• Construction drawings.
• Fabrication drawings.
• Procurement
• Site survey & measure area where our work is to be installed.
• Fabrication
• QA/QC all units to be sent to site.
• Fabrication
• Transport to site
• Installation and quality control on site
• Cleaning
• Inspection & final hand-over

4.0 Documentations/ Project Information

• Consultants plans, elevations and sections of the building.
• Definitive specifications.
• All other information which are relevant to the general design.
• Interfaces with other trades.
• Any other information that may be relevant to our sub-trade.

5.0 Design Resources

5.1 Design Method Statement

To achieve the best possible results in terms of costs, time and quality, the design phase will be carefully coordinated in order to define all the details and conditions required by the consultant for approval of workshop drawings. This phase is essential for procurement of the long lead-in time products. This will also contribute significantly to a well-planned fabrication phase.

5.2 design phase/approach

• Schedule of complete and definitive information about our planned submissions for the Contractor / Consultant.
• Submission of concept drawing with preliminary indication of details.
• Issue of pre-order for procurement.
• Submission of complete set of workshop drawings for approval.
• Approval of all details by the consultant
• Finalize procurement
• Site set up (definition of storage areas, scaffolding, work sequence, electricity, water, access and site hand over requirements.

6.0 Design Development

• 6.1 Design development drawings will be produced based on tender specifications and consultant’s requirements after the preliminary discussion to define the principles of the construction.
• 6.2 The Design is executed on CAD to improve quality control and easy reviewing in short time after the consultant’s remarks for modification.
• 6.3 The design development will be carried out in close liaison with consultant.
• 6.4 Design drawings will be approved prior to the preparation of construction drawings.
• 6.5 All drawings and information will be submitted for formal approval to the consultant
• 6.6 The design development drawings approval is required in due time to allow the procurement of main components or non standard elements, in particular the aluminium sections and individual non standard extrusions dies, if any, which may require long delivery periods.
• 6.7 The working drawings will be submitted in accordance with the conditions of the contract and fabrication of components will not commence until formally returned by the consultant with either “Approved” or Approved with Comments” marked on the working drawings. The stamp “Approved” shall mean fabrication, manufacture or construction may proceed in accordance with the submitted drawings. The stamp “Approved with comment” shall mean fabrication, manufacture or construction may proceed in accordance with the drawings submitted subject to Emiral Aluminium Co. taking necessary action based on the consultant comments and all annotations added to the returned drawings. The stamp “Not Approved” shall mean that no work will be fabricated, manufactured or constructed.

7.0 Construction Drawings

• 7.1 The Construction drawings will be performed in accordance with the approved design drawings.
• 7.2 The construction drawings will contain elevations plans and sections showing grids level, overall dimensions, materials, fixing location and details to the primary structure Interface details with other trades will be indicated is so required.
• 7.3 Structural design calculations, thermal insulation, acoustic performance and other technical reports will be submitted as part of the design construction process if required.
• 7.4 Drawings will be submitted to the consultant via the Main Contractor.
• 7.5 Drawings will be submitted in an agreed sequence and priority to suit the contract program, together with a period for return from the consultant

In case of remarks of requirement of modification or substantial change

• 7.6 By the consultant, the drawing/s will be reviewed and up dated and resubmitted for final approval.
• 7.7 In case of minor remarks, the drawings should be approved on condition that the comments clearly marked on the drawings will assumed.
• 7.8 Drawings will be approved duly signed and confirmed in writing.
• 7.9 Construction drawings indicating all components will be prepared, submitted and approved prior to commencement of manufacture.

8.0 Workshop Drawings

• 8.1 Workshop drawings are produced for internal use in accordance with the requirement of design, the construction and the contract program.
• 8.2 The workshop drawings will indicate the requirements for profiles, cutting sizes, preparation, working details, finishes, assembly of components, fabrication of elements, and detail for procurement of materials.
• 8.3 The workshop drawings will also indicate the information for the glass supplier such as glass types, thickness combination, colour and cutting sizes.

9.0 installation drawings

• 9.1 Installation drawings will; be produced for site use in accordance with the requirements of design, manufacturing drawings and contract program.
• 9.2 The installation drawing should indicate all construction details and element marks in order to allow the identification of same elements and to follow the installation sequence
• 9.3 The installation drawings should also define the correct location of every element together with the interface with adjacent components.

10.0 Procurements

• 10.1 Procurement of materials undertaken by the Procurement Department, based on requisitions prepared by the design and under the supervision of the project manager in compliance with the contract specification and program.
• 10.2 Suppliers are selected on the basis of their compliance to the specification of the design proposed products, quality and quality assurance procedures, experience, logistics, delivery time, reliability and commercial terms.
• 10.3 Goods are obtain from approves suppliers as defined in the Company Quality Manual. Standard goods are obtain using the Company’s specification for supply; prescribed goods are obtained in compliance with the contract specification.
• 10.4 All procurements is controlled in accordance with the procedures defined in the Company Quality Manual. Progress and delivery as per the required program monitored by the Procurement Department.
• 10.5 Emiral Aluminium personnel direct in the Suppliers and Sub- contracting follow their quality control procedures and will periodically audit their process during visits to their factories / offices.
• 10.6 Suppliers are responsible for the movements of all their materials with adequate packing to prevent damages.
• 10.7 Certificate of conformity are obtained from Suppliers for goods received whenever possible.
• 10.8 Limited samples for approval are issued whenever required in accordance with Contract Specifications.
• 10.9 Aluminium sections are produced from Technal Exports, manufacturer France, with expertise and capacity to make new dies when required. The extruders acceptable to us must offer material suitable to the design specification and according to the delivery program.
• 10.10 Glass is to be procured from the most suitable recognized glass manufacturer whose products corresponds and fully complies with the requirements of the Contracts Specification such as color, heat gain, light transmission, energy absorption, “U” Value, reflection, shading co-efficient and sound insulation.

11.0 Fabrications

• 11.1 Fabrication takes place at the Emiral Aluminium Factory (Dubai). The sequence of main activities is the following:
• 11.2 Receipt of the material and checking for quality as well as compliance with specification.
• 11.3 The aluminium – extruded profiles are delivered by the extruders to the Company’s factory where they checked for compliance with our Quality plan procedures.
• 11.4 The Aluminium extruded profiles are then delivered to the finisher’s premises for the finish treatment, either anodizing or painting, in stock length bars.
• 11.5 The aluminium profiles are returned from the finisher’s premises to the Company’s factory where they are once again Quality inspected.
• 11.6 Extruded profiles are arranged for cutting, drilling and machine preparation for fotting of accessories and assembling.
• 11.7 All exposed surface of the aluminium profiles then have a low tack protective tape fitted.
• 11.8 Standard accessories are usually supplied from the factory storage and through procurement of elements specifically developed in accordance to project needs.
• 11.9 Glass is delivered by producers, properly packed for transportation to our glass factory in Dubai. The glass units are then cut, arranged for cleaning, dimension controlled, then are insulated bonded if required. An outside supplier does heat treatment of glass required.
• 11.10 Special glass such as soft coated, heat mirror or similar types are usually delivered to our factory completely insulated and numbered in accordance with our project requirements. This glass is checked prior to delivery to site.
• 11.11 All glass components are clearly identified with a label in accordance with the quality procedures and to facilitate the installation on site.
• 11.2 All in house fabrication is stringently controlled in accordance with the procedures defined in the Quality plan and in the Company Quality Manual.

12.0 Transport & Site Delivery

• 12.1 All curtain wall, window, door and similar components are packed in an appropriate way, suitable for loading and transportation by lorry and for unloading storage. The flow of fabrication will be monitored to follow the contract program and/or to be adjusted as determined by changes in site program.
• 12.2 The Composition of every shipment is recorded by the specific packing list documentation, to allow the Site Manager the control of quality and type of received units.
• 12.3 Transport of factory made units is by means of vehicles of suitable size and shape.
• 12.4 Access to the site is arranged to suit the main contractor requirements.
• 12.5 The deliveries are monitored and booked to the site in advance as agreed with the site supervisor’s site requirements.
• 12.6 The material storage areas are located in a suitable storage area in our factories. It will be suitable to store curtain walling, window and door components till the end of the installation phase. Site storage area (at ground level or at agreed floor slabs) will be used as temporary storage areas during installation.
• 12.7 Our Site supervisors generally arrange site storage in a low traffic area or an area where installation is to proceed immediately.

13.0 Off Loading, Handling & Distribution

• 13.1 In storage area, materials shall be removed directly from vehicles by crane facilities available on site. During the off loading and distribution, operation site co-ordination and off loading is monitored by our site supervisors.
• 13.2 Materials, assembled units, elements of framing an all components shall be lifted and handled in a way that will prevent damage or distortion. If however a part is damaged the contractor will be advised and it will be replaced.
• 13.3 Materials, assembled units, elements of framing and all components will be stored as per:
  • Number and type of window / door elements.
  • Curtain wall aluminium substructure components, mullions, transoms and any related accessories.
  • Factory made glazed units and any related accessories.
  • Factory made panels units and any related accessories.
  • Factory made aluminium rain screen panels and any related accessories
  • Flashing, coping closure panels with related accessories.
• 13.4 Inspection will be undertaken in line with the agreed quality procedures of elements and components prior to their use. All damages and non conformities in general will be recorded and remedial procedures and actions agreed prior to incorporation in the works.

14.0 Lay-out & Setting out

• 14.1 The site should be surveyed by Emiral. Any discrepancies will be reported to the main contractor in writing.
• 14.2 Control Lines, benchmarks and reveal data must be furnished by the main contractor to establish the curtain-wall/ window/ door location/ This is the first critical step the site supervisor / erector and contractor must agree upon.
• 14.3 A benchmark – locating the top of finished floor must be checked annealed agreed to.
• 14.4 A reliable plump bob must be used to maintain consistency in producing the control line on the other floors of the building in the case of curtain walling.
• 14.5 Window and door head levels must be given to us by the main contractor prior to installation.

15.0 Bracketing of Curtainwalls

• 15.1 Once the contractor agrees upon base floor control lines, the fixing of curtain walling brackets will be commenced after waterproofing painting is completed in the areas where brackets are to be installed.
• 15.2 The brackets will be plumbed in both directions. Should the Drop beam edge be out of alignment, leveling shims may be required to properly align the brackets. A stainless steel anchor fixing, if necessary, will be installed with the agreement of consultant/ contractor and to an approved design detail.
• 15.3 The bracket provides the fixing point with a tolerance (in or out) of 25mm from plan location. Ensure the anchor will fit existing drop beam prior to bolting the bracket and by checking dimension between a stacked control line and edge slab.
• 15.4 The bracket, bolts and maximum shim thickness allowed should never be altered other than with the written permission of Emiral Engineer.

16.0 Assembly & Installation of Curtain-walls

• 16.1 Like any other slab stick system, assembly and installation will be done together on site usually starting from bottom to top.
• 16.2 Intermediate brackets will be prefixed on the concrete / steel truss. Bottom and Top shoe bracket will be bolted to the mullions prior to assembly.
• 16.3 Bolt the 1st mullion to the bracket, then fix the 1st line of transom to the mullion by using cleats and screws. Cleats shall be pre screwed to the mullions prior to erection.
• 16.4 After that the 2nd mullion will follow which will be fixed to the above mentioned transom from one side and will be bolted to the bracket.
• 16.5 Next the 2nd line transom will be fixed to the 2nd mullion and 3rd mullion will follow and the sequence continually repeated.
• 16.6 The main fixing will always be to the mullion, which will in turn support the transom without visible screw or fixings.
• 16.7 zullions and transoms will always be checked for alignment in both directions by using plumb weights and or theodolite.
• 16.8 Prior to installing any glass the framework will be properly aligned and bolts tightened to the required torque. The expansion jointing will be checked to ensure that water channels are free of burr or holes.
• 16.9 Flashing will be installed as per approved/ agreed details during and after installation of the glass dependent upon our design.
• 16.10 Should the consultant require inspection before approval of our installation, the curtain wall should be stage inspected for framing after completion of 16.9 above.

17.0 Glass & Glazing

• 17.1 Specified glass will be ordered from approved shop drawing dimension.
• 17.2 Before arrival of the glass units on site, the internal gaskets, accessories, sealant, and thermal insulator should be fitted where required.
• 17.3 The glass units are installed in the frame on the glass carrying profile of the transom, mechanical fixings will be anchored to the mullions by means of spring steel. Stitch/pressure plates will be used to hold the glass in place. Proper sized foam backer tape will be inserted in the horizontal and vertical grooves and will be sealed with silicone if required however this area is sometimes covered by a EPDM gasket.
• 17.4 Should back pans be included in the design, the installation of these will depend upon the site conditions. Installation could be done prior to glazing or after glazing dependent upon the design.
• 17.5 Should the consultant require approval of our installation, the glazing should be stage inspected for glass installation after completion of 17.3 or 17.4

18.0 Protection

• 18.1 During installation work on site, protection will be provided during assembly and installation up to the time of practical completion. After completion the protection should be removed from our work and thoroughly cleaned off. Protective measures are provided to contain possible damage of our work by others, however, the main contractor will be advised if deliberate abuse take place.
• 18.2 After completion, if the main contractor requires the protection to remain on the aluminum/glass/cladding or until the completion of the building, we will instruct them of the recommended cleaning and removal methods for final inspection.
• 18.3 All opening sections of our installation will be serviced, checked and protection removed prior to handling over to the main contractor.
• 18.4 The protection will be the main contractor’s responsibility from the time our installation has been completed and/or including removal and cleaning has been completed.
• 18.5 Protection at ground level will be left in place until completion, and it should only be removed and cleaned down upon Practical Completion.

Cleaning

• 19.1 Progressive cleaning of the cladding, windows or doors will be done for maintaining the area of work operations in a tidy and workmanlike condition and for maintaining condition in the areas of operations suitable for the installation.
• 19.2 All internally and externally visible surfaces should upon practical completion, be left in a clean condition.
• 19.3 The main contractor should provide Skips in respect of removal from site of debris.

PRACTICAL COMPLETION OF THE WORKS

Upon completion of our sub-contractor works, EMIRAL ALUMINIUM CO L.L.C. will issue according to the Subcontract specification requirement the following documentation.

• 20.1 O&M Manual including specification summary of all materials, manufactures technical details and recommendation for maintenance and cleaning, etc.
• 20.2 Copies of all relevant guarantees, certificates of conformity from Suppliers relating to materials and goods supplied to the project works, etc., and other warranties, as required.
• 20.3 The O&M Manual will be to an approved format and subject to agreement by the consultant.
• 20.4 Snagging of our work will be done on a stage basis whilst installation is in progress according to our company quality management plan. We suggest upon practical completion the main contractor issues us with his own snag list if to ensure satisfactory hand over of the installation to the client.
• 20.5 One C.D. Disk indicating “As Built Drawings” together with two paper prints of work shop drawings for the aluminium and glass installation completed by Emiral Aluminium.

Inspection & testing procedure

Inspection will be carried as per the following different stages.

• 1.0 Receiving Material – Inspections:
• 1.1 Factory Store
  • Material/Products will be checked on time of receipt against purchasing documents by storekeeper.
• 1.2 Site
  • Material/Products received at site will be checked against delivery order by the Site Supervisor.
• 2.0 In Process Material Inspection:
  • QC/Production Incharge will check the material during the different stages of Production.
• 3.0 Final Inspection:
  • QC ensures that only confirming products are send to stores for packing & dispatch.
• Non conforming materials at any stage will be identified until its resolution.
• Non conforming materials will be recorded. A timely corrective order will be taken by the concerned person.

Production & Purchase Manager

• Provides the required equipment and facilities for production activities.
• Control of costs for equipment and accessories from suppliers.
• Ensure that Machinery and equipment are maintained and serviced for safe and efficient operation.
• Ensure the distribution of manpower to required work to reach sets objectives.
• Follow up on production and dispatch of products.
• Provide the required staff to complete production as per deadlines.

Quality Control & Production Planning

• Ensure that the production process and finished product adheres to clients specifications and requirements.
• Inspect work in progress randomly at various stages to ensure its compliance to specifications and quality standards.
• Keep records of inspections.
• Monitor non complying products and proceed with corrective action.
• Ensure that Personal Executive work are qualified and experience to achieve the required standard.
• Prepare the production programme according to site programme and completion date.
• Issue of production orders to relevant sections to ensure continuous production.
• Coordinate with Project Engineer to fulfil requirements and conditions at site.

Production Supervisors

• Report to production and Purchasing Manager
• Ensures that work in progress complies to quality standard
• Reports on daily progress and any relevant information concerning day to day work
• Import corrective actions and production orders as per production plan.

Production Supervisors

This procedure describes the system being followed for inspection and testing of materials / products to ensure that they conform to the specified requirements.

• 1.0 System
• 1.1 Receiving Inspection:
• Central Store
• 1.1.1 On the receipt of materials / products at store keeper shall be responsible to check them against the purchasing order and the supplier’s delivery note for quantity, description and any damage. Materials / products with expressed specifications, shall be checked by him for quantity, size and damage shall be held in (hold area) for further inspection.
• 1.1.2 The storekeeper shall inform the purchase in charge on receipt of material / products with expressed specification to inform the concerned personnel to carry out the required inspection and testing through Good Inward Note.
• 1.1.3 Accessories shall be inspected for quantity, any damage Inspection for size, thickness, etc… shall be carried our by selecting a random sample from every box.
• 1.1.4 Inspected materials / products shall be stored in their allocated areas.
• 1.1.5 Non confirming material if shall be recorded in the supplier’s delivery note and / or material inspection report. Purchase in charge shall be informed before accepting such materials for resolving such cases
• 1.1.6 Non conforming material if accepted shall be held in (hold area) until their resolution.
• Site Store
• 1.1.7 The site storekeeper shall be responsible to check the materials / products against the material transfer sheet. If materials / products are delivered directly to the site the supplier’s delivery note and the purchasing order will be checked by him
• 1.1.8 Non conforming material if any (for site), shall be recorded in the supplier’ s delivery note or material transfer sheet / material inspection report, shall be identified then segregated if possible in “hold are”, the Project Manager will be notified for further resolution.

• 1.2 In Process Inspection:
• 1.2.1 The production In charge / Productions Supervisor (Quality Controller) shall be responsible to check first samples after setting the machines during the different processes.
• 1.2.2 The production In charge / Production Supervisor shall ensure that pieces are checked after the different process like cutting, assembly etc., and recorded in the daily production report.
• 1.2.3 The production In charge / Production Supervisor shall ensure that non- conforming materials or products used during the different stages of the process are identified, stored separately in HOLD AREA if possible to prevent unidentified use until their resolution.
• 1.2.4 The results and testing shall be recorded. As detailed in the ITP.
• 1.2.5 The Project supervisor shall be responsible to checked the products and its installation processes at different stages, to ensure that it meets the specified requirements.
• 1.2.6 The Project Manager shall ensure that non conforming products during the different stages of the process are identified are stored separately in HOLD AREA “(if possible) until their resolution.
• 1.2.7 The results of inspection and testing shall be recorded.
• 1.8 Final Inspection:
• 1.8.1 The Production In charge / QC are responsible to ensure that inly conforming products are sent to stores for packing and dispatch, and record the result of the final inspection and testing.
• 1.8.2 Non conforming products shall be identified stored separately in HOLD AREA: (if possible) until their resolution.
• 1.8.3 The Project Supervisor shall carry out the final inspection and testing to ensure that Products conform to the specified requirements and record the result of the final inspection and testing.