Method Statement – Al Fayha

Starting at the Tender stage, AFAF estimation engineers carefully review the drawings and specifications of a project to ensure the accuracy of Bill of Quantities prior to finalizing the aluminium and glazing offer. They carefully liaise with the customer on any potential discrepancies or non-clarities to ensure an accurate estimate is given, and eliminate the potential of future conflict during the execution, which is an advantage to both parties.

Programs for each order are prepared based on the approval construction program supplied by the Main Contractor. The Production Manager in consultation with fabrication staff plan procurement, production and finishing. Programs of work are prepared using MS Project software, and the Production Manager reviews all the programs prior to submission. Co-ordination of the various phases of work is carried out with the Main Contractor as necessary to achieve the project objectives. Programs will include the procurement, fabrication, assembly, delivery and erection phases as necessary. Company staff are always available to coordinate with clients concerning the progress of work at site and manufacturing plant.

Once a project is awarded, the project coordinator meets with the customer to ensure that all his requirements are met. Only high quality samples and accessories meeting the international standards are submitted for approval, along with the required supplier technical data. AFAF always strives to ensure that the customer is totally satisfied with the range of products available, and goes the extra step to provide additional samples from new suppliers should the customer wish to do so.

Our Chief Engineer carefully coordinates with the customer to ensure that all their design and architectural concepts are met and implemented into the aluminium design. The customer can choose from a wide selection of products available with Al Fayha, and in certain cases is able to custom make their own designs to promote their personal touch in the project. Calculations are also incorporated into the drawings to confirm the structural integrity of aluminium connections in withstanding the imposed forces and moments, air and water tightness, and building movements.

During the aluminium shop drawing preparations, any discrepancies or problems in the architectural drawings is highlighted to the customer to avoid future conflicts during execution. Furthermore, any potential unfeasible design requirement by the customer is also highlighted, and alternatives are proposed that are feasible yet do not sacrifice the quality or design envisioned by the customer.

Preparation and submission of drawings are done in sequence with times that are compatible with the approved programs of work. All shop drawings are thoroughly checked and reviewed by the designated Engineer for the project prior to submitting for approval. Only approved drawings are distributed and used for fabrication and erection at
site. Qualified and well-experienced draughtsmen using the latest CAD drafting software prepare all shop drawings. Our Structural Engineers also rely on STAAD and other supplier software for their structural analysis. If required by the contract, on the completion of aluminium work erection, as-built drawings are submitted to the Consultant/Clients.

Following the approval of samples and review of the conditions of contract, work orders are prepared by the estimator and approved by the Production Manager. Work orders will be copied to the Production Manager and Sales Engineer. Relevant technical information will be attached to the orders to correctly describe the specific requirements and approvals given. Furthermore, the program of workflow is always considered when placing orders to ensure the timely manner of material receipt, in order not to jeopardize the project completion time.

All incoming material is carefully inspected by our Quality Engineer to ensure it is defect free and in compliance with the approved samples. Aluminium is only purchased from companies complying with British Standards for Aluminium Extrusion, to monitor the extrusion, alloys, tolerances, tempering and coatings. Glass is also checked for compliance
with BS and ASTM standards for double-glazing, tempering and other heat treatment, lamination, and other aspects. All other accessories are checked using their referenced standards for conformity and approved samples.The compliant material is carefully labelled and stored to ensure it is used for the correct project. All non-compliant material is returned to the supplier, and Al-Fayha always tries to ensure that alternative sources are available so the project program is not affected, regardless of the item required.

All fabrication is carefully done to ensure the proper tolerances, finishes; assembly, performance and quality of the finished product is not compromised in any phase of fabrication. The design department carefully prepares the relevant cutting lists and fabrication drawings using CAD and custom made sheets to simplify the production process and ensure it is error-free. Samples are regularly erected at site to ensure their compatibility with site conditions.

From the taping of the material, to the cutting, machining, assembly and packaging, a foreman is always present to ensure the work is done with the required quality. The standards used for this monitoring are a combination of the different supplier recommendations, and those gained through experience from years in the industry. Several tests are performed on the finished products to ensure their proper performance and quality. This reduces the probability of defective material being installed at site, causing problems during the snagging and handing over phase.

Once the Quality Engineer approves the finished material, it is carefully stored until it is to be loaded to the site. The loading process is carefully done under the supervision of the Quality Engineer to ensure that it is safely transported to the site without damages occurring during the trip. Furthermore, any damaged material received by the site stores are returned to the factory to ensure that they are not installed at site leading to the dissatisfaction of the customer.

The delivery date of the material is coordinated with the site condition, based on the input from the site engineer and the Main Contractor input. If required by the contract, the Consultant/Client is to be notified about the delivery so he may inspect the incoming material and confirm that it is to his compliance.

AFAF coordinates with the Main Contractor to always ensure adequate storage space is provided at site for the proper storage of incoming material. This is vital to avoid damages to stored material and the sacrificing of quality. Different material is stored in different methods, based on its geometry and type. Glass panels are stored in customized A-Frames to ensure that they are stacked stress free, aluminium frames are stacked in a way to prevent inadvertent scratching of the coated surface, gaskets and silicones are stored in a clean environment to avoid contamination, and so on.

The storage is prepared to ensure access is only for AFAF personnel, so we may assume complete responsibility for the quality of the material. A storage foreman is assigned to ensure the compliance of all incoming material and the proper distribution of material in the site so the erection is smooth and delay-free.

Depending on the size of the project, a team consisting of Project Engineers and Foremen is assigned to ensure the proper execution of the works to the satisfaction of the customer. The Project Engineer carefully studies the project and prepares the necessary resources to complete the job within the timeline of the project program.

The Project Engineer is introduced to the Main Contractor and customer, and commences the necessary coordination works. Items of importance are erection sequences of different subcontractors, setting out, agreed tolerances, grid references and levels, and other aspects of erection. All the approved drawings are given to the Project Engineer
with clear markings for the installation locations in terms of the plan, grids and benchmarks. Any potential problems in the sequence of works are highlighted to the Main Contractor at an early stage to avoid future clashes and time loss.

The erection process is done in accordance with the accepted industry standards. These are a combination of the various supplier recommendations, experience, and technical know-how. The suppliers are often called to the site to inspect and confirm the fixing is done as per their requirements. This is especially true to anchoring systems, such as bolts, chemical anchors, cast-in channels, and other systems.

Furthermore, silicone and gasket suppliers are also called to ensure the proper application of their products, as to avoid any faults due to fabrication. A team of experienced Foremen is in charge of the monitoring of the quality and progress of works. They will highlight any problems to the project engineer who will take all necessary action to ensure that the progress is not jeopardized. The Main Contractor is always kept informed of developments and problems at site.

Weekly progress updates are prepared by the Project Engineer to monitor the speed of work, and ensure that it is in line with the project program. Any adjustment in terms of manpower or equipment is made to ensure the end date is met.

Furthermore, correspondence is maintained with the Main Contractor to highlight problems in access, site clearances and others.

Finally, the Project Engineer will routinely offer various areas for the inspection of the Consultant, as per the project requirement, to ensure that work is being done in a satisfactory manner and that no rejections will be made later on that may delay the project. All the snags and comments are rectified to ensure the handing over process is smooth and satisfactory to all parties concerned.