BI No.

BI-10-01055-0006
CONTRACT No. 6600036947
AYC Doc. No.<Rev. No.> AYC-QCP-CVL-084<Rev.00>

Jezan Refinery & IGCC Industrial Support Facilities

Jezan, Kingdom of Saudi Arabia

METHOD STATEMENT for Roll-Up Doors Installation

(Civil Scope)

SAUDI ARAMCO APPROVAL STATUS

EAE
Approved
Signature / Date Name / Designation

AL YAMAMA SUBMISSION STATUS

Description Name Designation Signature Date

Prepared by George Pimentel QC Supervisor

Reviewed &
Moises Tabura QC Manager
Approved by
Reviewed &
Khalid Murudhkar QA Manager
Approved by

Approved by Abdulrahman Al Khaseeb Project Manager

Document Issue Purpose

>
√ For Approval For Information For Construction

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INDEX

1. Scope and Purpose

2. Limitations

3. References

4. Responsibilities

5. Submittals

6. Product Delivery, Storage and Handling

7. Execution

8. Quality Control and Quality Assurance

9. Health, Safety and Environment

10. Attachment

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1. Scope and Purpose:

1.1 This purpose / methods define and described the Quality

Control Procedure and Inspection Test Plan for overhead coiling
doors and upward-acting rolling steel fire doors installation, as
indicated on IFC and/or approved shop drawings at in
accordance with project specification section GEN-E0004
revision 00F1, includes complete operating doors assemblies,
including door curtains, guides, counter balance mechanism,
and accessories.
1.2 The work shall comply with the Saudi Aramco Standard
Requirements and Contract Documents to perform,
implemented and adhere to Quality Assurance and Quality
Control requirements and Approved Quality Plan at ISFB project
/ EPC-6.

2. Limitations:

2.1 This quality procedure should be applicable for the duration of

the project as per schedule of contract in line with the IFC
and/or approved revisions of drawings or approved shop
drawings, and/or project specification requirements and/or
other related standards.

3. References:

3.1 ASTM A 446 – Steel Sheet, Zinc-Coated (Galvanized) by the Hot-

Dip Process, Structural (Physical) Quality
3.2 Process Industry Practice (PIP) ARS08111
3.3 Process Industry Practice (PIP) ARS08710
3.4 ASTM A525 - Steel Sheet, Zinc-Coated (Galvanized) by the Hot-
Dip Process, General Requirements.
3.5 ASTM A526 - Steel Sheet, Zinc-Coated (Galvanized) by the Hot-
Dip Process, Commercial Quality
3.6 U.S. National Electrical Manufacturers Association (NEMA)
3.7 U.S. Underwriter Laboratories (U.L) Inc.
3.8 National Fire Protection Association (NFPA)
3.9 Approved Drawing / Shop Drawing / Plan – Details
3.10 12-SAMSS-014 Section 8.5 – Overhead Roll-Up doors
3.11 Manufacturer’s Installation Manual

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4. Responsibilities:
 Site Engineer - shall be responsible for the implementation and
execution of this procedure under the direct supervision of the
Construction Managers.
 QC Inspectors shall perform monitoring during execution
process ensure that work was executed according to approved
procedure
 Quality Managers shall ensure that the approved quality
procedure has been applied in the work execution

5. Submitals:
5.1. The following shall submit such as Shop Drawings, Product Data
Sheets, to the SAUDI ARAMCO Representative for their review
and approval
5.2. Manufacturer's Data: Submit manufacturers product, roughing-in
diagrams, and installations for the type and size of overhead
coiling door, include operating instruction maintenance
information.
5.3. Shop Drawings: Submit shop drawings showing all materials,
gauges, size, sections, method of constructions and operation,
anchoring, and all other pertinent information. Shop drawings
shall include wiring for motors, support brackets for motors,
location of motor and controls, and type and rating of motor.
5.4. Wiring Diagrams: Wiring diagrams shall submit complete and
legible wiring diagrams together with a list of repair parts with
part numbers and written instructions relative to the care,
adjustment, and operation of the equipment.

6. Product Delivery, Storage and Handling:

5.1. Receive materials shall be in accordance with approved
submitted products and manufacturers / supplier as indicated in
approved drawings, and shall be in compliance with project
specification requirements and/or other related standards.
5.2. Receive product shall be complete electric door operator
assembly of size and capacity recommended and provided by
door manufacturer for each type of operation.

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5.3. Product shall be in accordance with accepted quality assurance

guidelines for motor-operated doors, both the door and electric
operator shall be manufactured by a single-source producer of
door systems, such as by Overhead Door Corporation.
5.4. Receive product shall be electrically (motor) operated.
5.5. Receive product shall stored off the ground in dry weathertight
enclosures with adequate ventilation to avoid condensation.

5.6. Receive product shall be free from warp, twist or distortion, and
shall be fitting weather tight for entire perimeter.
5.7. Any product receive with damaged shall be return to the supplier
and shall be replace by new.
5.8. All product / material shall be protected from damage during
shipping, handling.
5.9. Receive each door shall be with automatic safety switch,
extending full width of door bottom, and located within neoprene
of rubber astragal mounted to bottom door rail.

7. Execution:
7.1. Preparations
7.1.1 Prior to start commencing of work, ensure that shop
drawings are available on site and shall be approved with
stamped and signed by company representative.
7.1.2 Shop drawings shall indicates the locations, sections,
details, orientation, and directions.
7.1.3 Installer shall establish the layout, position or orientation
of the door assembly and shall be in accordance with
manufacturers written installation instructions and
recommendations.
7.1.4 Installer shall inform the site engineer or quality control
inspector or company representative for any found
discrepancies with the structure for verification prior to
installation.
7.1.5 Ensure that the locations of anchorage devices are
marked prior to installation.
7.2. Installation:

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Provide complete overhead roll-up door assemblies including

door curtain, guides, counterbalance, hardware, operators, and
installation accessories as specified. (12-SAMSS-014 Section 8.5 Para.
8.5.1)

A. Roll-Up Door Guide Installations:

A-.1. Verify opening size, sill and header level and jamb
plumb. If sill out of level, Mark high sill level location
on low sill side. (Manufacturer’s Installation Manual)
A-.2. Identify the guide assembly. Verify the configuration
with the actual jamb construction. (Manufacturer’s
Installation Manual)
A-.3. Check curtain width including end locks with guide
locations. (Manufacturer’s Installation Manual)

A-.4. Locate guide assemblies such that “S” Dimension

results between back of guide grooves. Bottom of
guides must be on a level line and guides must be
plumb. “S” dimensions must be held +/- 3mm over
entire height of guides. (Manufacturer’s Installation
Manual)

A-.5. Locate guide assemblies such that “S” Dimension

results between back of guide grooves. Bottom of
guides must be on a level line and guides must be

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plumb. “S” dimensions must be held +/- 3mm over

entire height of guides. (Manufacturer’s Installation
Manual)
A-.6. Hold “Z” guide, or wall angle. Alternatively, jamb angle
again and drill mounting holes thru the slots using drill
size shown below. Install wall fasteners.
(Manufacturer’s Installation Manual)

A-.7. Hold “E” guide against steel jamb and mark the spot
to be drilled, or hold wall angle or jamb against steel
jamb and drill holes thru the slots using drill size
shown below. Install jamb fasteners. (Manufacturer’s
Installation Manual)

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A-.8. Hold “E” guide against steel jamb and tack weld wall
angle {jamb angle) in place. Recheck “S” distance
before proceeding. All welds must be good quality
5mm fillet welds. Weld the angle to the steel jamb
along the top of the angle. (Manufacturer’s
Installation Manual)

A-.9.

A-.10. The guide gap MUST be set to the “Guide Gap

Dimension shown on chart below: (Manufacturer’s
Installation Manual)

A-.11. Fix Guide assemblies on jambs over drilled holes with

required fasteners. (Manufacturer’s Installation
Manual)

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A-.12. Identify Bracket Plates. Right hand door, drive end

brackets locates on right guide assembly. On left hand
door, drive end bracket locates on the left guide
assembly (Standing inside looking outside)
(Manufacturer’s Installation Manual)

A-.13. Identify Barrel Assembly Drive End: Right Hand Drive

shown. Left Hand Drive opposite. Look for an “R” or an
“L” stamped on the Drive End Shaft. Verify the
configuration with actual jamb construction.
(Manufacturer’s Installation Manual)

A-.14. Orient Barrel and Head Plate Brackets: Slide Drive End
barrel Assembly through Drive Bracket bearing and
tension end through Tension Bracket. Install Set Collars
on Shafts on outside of Head Plate Brackets.
(Manufacturer’s Installation Manual)

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B. Curtain Installations:

B-1

B-1-A Locate the holes to be drilled in the top of the

curtain along with fasteners position on the
axle. (Manufacturer’s Installation Manual)

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B-1-B Attach the top slat of curtain to the barrel, roll

them together, and make sure it is rolled evenly.
(Manufacturer’s Installation Manual)

B-1-C Attach the bracket to the roll of curtain and axle

and raise the complete assembly to their
position on the guides using skid under the
curtain or hanging the assembly by wide slings.
(Manufacturer’s Installation Manual)

B-1-D Raise the assembly of curtain, axle, and brackets

into the position and bolt them to wall angle as
shown in the figure. Brackets are to be square to
wall and parallel. (Manufacturer’s Installation
Manual)

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B-2

B-2-A Lift Brackets and Barrel and Bolt to Guide Wall

Angles: Use Hex Bolts to fasten Head plate
Brackets to inside of Guide Wall Angles. Bolt
heads are to be inside of Brackets. Brackets are
to be square to Wall and parallel.
(Manufacturer’s Installation Manual)

B-2-B Installation of Curtain: Hang the curtain on two

or more Slings or Heavy ropes capable of
suspending the curtain weight. Ropes /Slings
MUST be able to suspend the curtain weight.
Fasten the top Slat to the Slings or Ropes with
wire. Rotate the Barrel to bring the Top Slat in
place. Center the Curtain between the Head
plate Brackets. (Manufacturer’s Installation
Manual)

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B-2-C Install and connect the operator or chain as

shown.

B-2-D After installing the motor or chain, this is the

time to untie the Slats Rope and insert the
Bottom Bar to slats. (Manufacturer’s Installation Manual)

C. Complete Curtain Installation: (Manufacturer’s Installation Manual)

 Coil Curtain completely onto Barrel

 If guides are flared, then install the Middle Angle and
Outside Guide and Outside Guide Angles according to
7.2.1.7 & 7.2.1.8
 Place locking pliers on the guides
 Lock the drive to prevent the curtain from falling
 If the guide is not flared, install Curtain stop
 If guides are flared Slide Stop Bar into channel holder
welded to
Guide, and install 5mm cap screw

D. Apply Initial Tension: (Manufacturer’s Installation Manual)

Open and close door five (5) times and evaluate
adjustment.

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A rolling door should snap into the head and barely tend to
rise off the floor. It was also fall through the middle of its
height
Larger doors may require a 16 KG pull to rise with hand
chain. A chain pull of up to 16 KG is permissible.

E. Adjust tension with door in fully open position: Adjust

Tension one notch at a time to increase or decrease torque
as required.
F. Final Checkout: (To be completed before installing the
hood) (Manufacturer’s Installation Manual)
a. The guides maybe lubricated with a Paste Wax or
Silicone Spray
b. Verify through entire travel of the door that the End
locks or Wind locks on the end of the Curtain are not
rubbing the Head plate Brackets. Operate door several
times to check for problems.
c. Check that Bottom Bar is level in full down and full up
position and that Curtain is not binding against back of
Guide.
d. If Curtain is level at bottom and not at top, put shims
between Curtain and Counterbalance on the side.

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e. Install the Hood Cover: (Manufacturer’s Installation Manual)

If Hood Supports are provided, snap a line across top
of Head plate Brackets on the Wall. Measure Length of
Hood Sections and locate Hood Supports so that Hood
Splice will fall on center of Support

7.2 Adjustments/Cleaning/Touch-ups:
7.2.1 The Touch-up scratched surfaces with primer equivalent
to that of shop coat.
7.2.2 Replace hardware items that have been damaged or
cannot be adjusted to operate as intended. (PIP ARS08710
Para. 6.3.2)
7.2.3 Clean all hardware and surfaces around the hardware
that have been soiled by installation. (PIP ARS08710 Para. 6.3.5)
7.2.4 Clean all metal surfaces promptly after installation of
components, exercising care to avoid damage to the
protective coating.
7.2.5 Clean all surfaces of grease, oil, dirt, and other impurities.
8 Quality Control and Quality Assurance:

 The manufacturer shall provide and the contactor shall install

doors and frames complying with ANSI A250.8 and as specified
herein. Refer SDI-122 to ensure that a quality installation has
been achieved.
 Inspection to be carried out with the intended Inspection and
Test Plan (ITP)

9 Health, Safety and Environment:

9.1 Safety precautions from manufacturers has to be followed:

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a) Use a right Hand Drive Bracket with a Right Hand Drive

barrel to prevent Torsion Spring failure, which can allow
Curtain to free fall causing Death or Serious Injury. Ensure
that the safety policy are implemented.
b) Use proper lifting equipment and correct lifting procedure
to avoid injury.
c) Do not allow uncontrolled free fall closing of door. Instruct
customer to use both hands to control both hand chain
during the closing operation.
9.2 Health, Safety and Environment issues shall be guided by AYC
safety procedures and ARAMCO Standard.
9.3 Work area to be kept clean, safe and easily accessible
9.4 Appropriate PPE shall be worn at all times
9.5 Safety talk shall be conducted to remind the workers about the
risk involved before commencing the activity
10 Attachment:

Manufacturers Installation Manual

END OF THE QUALITY CONTROL PROCEDURE

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