Al Burje Al Fudhi Aluminium & Glass Industries Our Message Welcome to Al Burje Al Fudhi Aluminium and Glass Industry L.L.C. I want to personally extend a warm welcome to you, and to thank you for reading our profile. Al Burje Al Fudhi is a company that is committed to understanding first what our customer’s needs are and then meeting and exceeding all of our customer’s requirements, by providing a quality product at a competitive price at all times. Our synergy now enables us to reach out to new customers in the market place and extending our network in sales and services in the Middle East Region. Thank you and hope you find all that you are looking for with us! Sincerely, GM SHYJU T.K.C SHYJU T.K.C General Manager, Al Burje AL Fudhi 1 Introduction 2 Our Vision, Mission & Management 3 Quality Management System 4 The Team 5 Organization Chart 6 Product Range 7 Aluminium Division 8 Stainless Steel and Steel Fabrication 9 Aluminium Composite Panel Fabrication 10 List of systems used 11 Plant and Machinery Details 12 Team Details 13 Appendix1 – Safety Policy 14 Appendix2 – Method Statements (Fabrication & Installation) 15 Appendix 3 – Quality Management System 16 Contact Details Introduction Al Burje Al Fudhi Aluminium & Glass Industries is a company specializing in planning, designing and executing Aluminum curtain walls, skylights, windows and doors for the various sectors of the construction market in the UAE. We, the management and employees of Glass & Aluminium Factory, are firmly committed towards ensuring that all Aluminium, Glass & Double Glazing works and services are executed in accordance with contract specifications, drawings, within the agreed time frame and with consistent quality level that will meet and exceed customer’s expectations. We have grown into one of the leading suppliers of products and services to Aluminium and glass industry being a member of Al Burje a leading business concern in UAE. We strive hard to operate our objectives to business ethics and of socio economic infrastructure and our everlasting commitment to the public. Our uncompromised commitment to Innovation, Quality and Performance and passion to provide cost-effective solutions has distinguished us as a leader in custom built, structural sky- lights, curtain walling and sloped glazing. Our projects are from conceptual design through engineering, fabrication and installation with a mission to build on time, within budget and to the Customer’s satisfaction. We have also diversified into fabricating custom built Architectural Glass, Stainless steel, Steel and composite panel related products to provide our customers with complete building enveloping solutions. Our Glass technology is based on innovation in structural glass design, glass engineering and fabrication. Our products have been installed in commercial, hospitality, healthcare, museums and high-end residential projects worldwide Our factory is established at Sharjah, is equipped with modern machinery, spans across 3,000 Sqfts of Aluminum and Glass fabrication. Vision Mission & Management Our Vision To become leaders in UAE in façade engineering by providing innovative, cost effective and quality solutions, excellent service and customer care. Our Mission At Al Burje Al Fudhi, we work to help people realize their architectural dreams on facades. Our mission is to contribute to the overall aesthetic and technical performance of buildings and to engineer the best of facades and skylights through innovative architectural designs, adhering to customer requirements. Management Al Burje Al Fudhi is managed by a team of young technocrats, who are involved in the various fields of the building industry. They bring together their collective technical expertise and commercial acumen to produce superior products that measure up to international standards of architectural works. We have a track record of successful projects completed in a time bound manner and our reputation has come from adhering strictly to international standards and consistently delivering high quality according to customer specifications. Quality Management System We believe that Quality is everybody’s responsibility, and continuous improvement is the driving force for success, so we also commit ourselves to continually improve the quality of our projects and services by continually reviewing and monitoring operations and achieving out objectives. This is done by the effective and efficient implementation of ISO 9001:2000 Quality Management system standards in addition to complying with the applicable legal requirements and statutory regulations. Our processes are monitored stringently by eternal and internal auditors to ensure quality control procedures which are implemented across all processes in the value chain of the company. The quality considerations taken into account while developing our products include: 1. Principles of Design 2. Structural Integrity 3. Thermal Performance 4. Pressure Equalization 5. Aesthetic elegance 6. Safety factors The Team A comprehensive design team allows Glass & Aluminium to manufacture tailor made engineering solutions to meet the requirements of consultants and clients. Our design team is highly skilled and well experienced to do skylights and curtain walling. They closely follow the latest trends in façade engineering and are fully conversant to international standards. All machinery and equipment used in Al Burje Al Fudhi Glass & Aluminium factory are latest and technically advanced with the use of computer-controls; and with highly qualified personnel, we can consistently deliver high quality products to our customers on time and on budget. Experienced factory and site team ensure that exact standards are met and that production targets are met. All procedures are set to ensure that the quality of our manufactured products is highest till the end. The site installation teams consist of well trained and experienced, highly skilled field operatives. Established lines of communication between the worksite, design and the factory en- sure that the customer is always provided with the best possible cost effective and practical solutions for his requirements. Organization Chart Al Burje Al Fudhi Aluminium And Glass General Manager Secretary Project Manager Production Manager Estimator Accounts Production Engineer Store Keeper Designer Supervisor Factory Incharge Site Incharge Product Range Al Burje Al Fudhi Aluminium & Glass Industry has a product range that addresses the wide range of requirements. Our Product range encompasses: ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ Structural Glazing Aluminum Doors and Windows Aluminum Curtain Wall ( 2 and 4 Ways) Canopies, Pergolas and Entrance enhancers Spider Glazing Facade Frameless Doors Bolted Glass Assemblies Hand rails, Balustrades, Glass Doors, Shower Cubicles Skylights Aluminum composite panels Unitized Curtain Wall Sliding/ Folding Doors and Windows Stainless steel cladded doors and columns Aluminium Division Al Burje Al Fudhi Aluminium & Glass Industry has the latest state of the art machinery on Aluminum fabrication of Curtain Walls, Windows and Doors. These machines can process accurate miter cut for windows and doors requirement with less than a millimeter accuracy as the lengths are measured through accurate digital meters. In the curtain wall the transom levels are measured and drilled through the CNC machining center. Currently Al Burje Al Fudhi has the capabilities and expertise to process any system that is available in the market. In addition it has the expertise to develop special systems that are suitable to meet the unique requirements of the architects and engineers. Stainless Steel and Steel Fabrication To provide a holistic solution and to provide customers with a freedom on designing architectural marvels, Al Burje Al Fudhi has diversified into Stainless Steel fabrication. Our expertise lies in designing vertically suspended spider glazing system and curved structures. Our specialization in stainless steel includes cladding of Automatic door frames, column cladding, canopies, ladders and balustrades with and without glass. Other design includes patch fitted doors and frameless glass screens with stainless steel envelope on the perimeter. Aluminium Composite Panel Fabrication Al Burje Al Fudhi Aluminium & Glass Industry provides architectural beautification and long standing appeal of buildings by using high quality composite panel for external envelope. Our team has the expertise to design and Fabricate cladding panels as per the architectural requirements. The factory has a cutting and grooving machine of 4m bed length in order to work in a faster so that more than 500 Sqmts / day of production capacity for straight panels. Plant and Machinery Details The Following machinery is used for fabrication, milling, cutting, notching, rolling, punching, and drilling of profiles. Aluminium Fabrication machinery 1 2 3 4 5 6 7 8 9 Thomas Single Head Cutting Machine TMS 450G Thomas Single Head Cutting Machine Router machine Welding machine Compressor large Compressor small Ripping Machine Profile Bending Machine Freezing Machine 1 1 1 1 1 1 1 1 1 Cladding Machinery 1 Cladding Cutting and Grooving Machine Inspection Tools 1 2 3 4 5 6 7 Vernier Calipers 300mm Vernier Calipers 600mm Slip Gauge Dial Gauge Set Laser Beam Optical Theodolite Total Station 1 1 1 1 1 1 1 Power hand tools 1 2 3 4 5 6 7 8 Hilti Electric Drills Hand saw cutting machine Grinder Air tighter Air gun Benchwise Stand drill 5 4 2 2 6 6 2 2 1 Team Details Management Team 1 General Manager 2 Secretary 1 1 Project Team 1 2 1 1 Project Manager Project Supervisor Production Team 1 Production Manager 2 Production Engineer 3 Skilled Fabricators 4 Semi Skilled Fabricators 5 Driver 1 1 10 2 1 Technical Team 1 Designer 2 Estimator 1 1 Appendix1 – Safety Policy Al Burje Al Fudhi Glass and Aluminum’s environmental health and safety rulebook serves as working document for the team at work. The policies and procedures ensure that all employees of the company adhere to the safety rules while working at the factory or at the site. Personal protective Gear • Hard Hat It is compulsory to were the Hard hat at all times while at work on site • Safety shoes Steel toe boots with reinforced sole must be worn by all employees at their work spot. • Coverall Boiler suit is to be worn by all the employees who are directly handling the frames and glass • Safety belt Always use safety full body harness when working above on scaffolding and cradle • Safety goggles Safety goggles with side shield to be used while any ripping, cutting and welding operations Scaffolding Safety officer will inspect before any erected scaffolding for its safety and also ensure that the platforms are secured properly to the Scaffolding Fire extinguishers Fire extinguishers are placed while doing welding and gas cutting at site and also in the factory at relevant places. Extinguishers like water, sand and canisters are kept in factory premises near power supply. Electric tools a) While using drills, Screw drivers, grinders’ etc. industrial type plug and sockets are to be used b) Wires with joint exposed are strictly prohibited in the workshop Appendix1 – Safety Policy Safety inductions All employees must undergo safety induction program. They should be made to understand about various safety precautions and measures while working at the site and in the factory. Handling glass All the glass panels and stock sheets are to be handled in well illuminated area. While handling glass sheet ensure that glass suckers are to be used. Persons handling glass must wear hard hat, safety shoes hand gloves. Cradle operations While working guide line of operating the cradle should be strictly followed A safety officer inspection is required before the operation of the cradle Hand protections Hand protection (leather work gloves / welder gloves) is a must in case glass cutting and welding House keeping Work spot and job site is to be maintained clean and organized condition every day. Foreman is responsible for ensuring the above activity. First aid First aid box should be accessible in work shop and project site. Foreman shall be responsible for maintaining the first aid box. Appendix2 – Method Statements A. Fabrication B. Installation Fabrication Fabrication of Hinged Windows In this the extruded bar as per the optimized length and profile section number is selected and placed in a double header cutting machine. Then as per the cutting dimension mentioned in the cutting list the profiles are cut at 45o (miter) on both sides. The Dimension is checked by tape measure and placed in the trolley. Fixing holes are drilled for all the width and height outer frame profiles at suitable centers as per the height and width (it is always 600mm max centers spacing). Incase of window with shutter the shutter profile related to handle side is milled for the slot in the router machine according to the suitable handle. The Miter cut profiles are taken to Corner crimping machine, where in the corners of suitable width and length profiles are selected and wiped for the coolant oil. Then suitable corner cleats with glue (applied over it) are inserted in the corner. Then the clear sealant is applied on the cut corners and assembled. The assembled frame is placed in the crimping machine and punched. In the same manner all the four corners are crimped. The same procedure is followed in case of shutter profile also with the notching done as per the suitable handle. The crimped frame and shutter are taken to assembly table for fixing the suitable gaskets(EPDM) and Hinges. Then the assembled widow is taken to single head cutting machine and as per the suitable size glazing bead is cut and matched. Incase of widow with shutter the glazing bead is removed and suitable size glass is placed and Tight packing is given as shown, The allowed maximum difference when measured in diagonal for the assembled outer or shutter is 2 mm The tolerance for width & height is +/- 1mm Fabrication of Doors In this the extruded bar as per the optimized length and profile section number is selected and placed in a double header cutting machine. Then as per the cutting dimension mentioned in the cutting list the profiles are cut at 45o (miter) on both sides. The Dimension is checked by tape measure and placed in the trolley. Fixing holes are drilled for all the width and height outer frame profiles at suitable centers as per the height and width (it is always 600mm max centers spacing). The shutter profile related to handle side is milled for the suitable latch lock slot in the router machine Incase of double door the fixed sash suitable profile (height) is notched for suitable top and bottom flush bolt. The Miter cut profiles are taken grouped to the Corner crimping machine, where in the corners of suitable width and length profiles are selected and wiped for the coolant oil. Then suitable corner cleats with glue (applied over it) are inserted in the corner. Then the clear sealant is applied on the cut corners and assembled. The assembled frame is placed in the crimping ma- chine and punched. In the same manner all the four corners are crimped. The same procedure is followed in case of shutter profile also with the notching done as per the suitable handle. The crimped frame and shutter are taken to assembly table for fixing the suitable gaskets(EPDM) and Hinges. Then the assembled shutter is taken to single head cutting machine and as per the suitable size glazing bead is cut and matched. In the shutter the glazing bead is removed and suitable size glass is placed and Tight packing is given as shown, The allowed maximum difference when measured in diagonal for the assembled outer or shutter is 2 mm. The tolerance for width & height is +/- 1mm Fabrication of Sliding windows and doors In this the extruded bar as per the optimized length and profile section number is selected and placed in a double header cutting machine. Then as per the cutting dimension mentioned in the cutting list the profiles are cut at 45o (miter) on both sides for the outer frame and 90o (Straight cut) for the shutter profiles. The Dimension is checked by tape measure and placed in the trolley. The shutter profile related to handle side is milled for the suitable latch lock slot in the router machine. The interlock profiles and jamb profiles at either ends are notched for the end cover slots. Then for assembly of the top and bottom profile suitable notching is done on the top and bottom of the jamb and Interlock profiles. The Miter cut outer frame profiles are inserted with suitable brush seal and grouped to the Corner crimping machine, where in the corners of suitable width and length profiles are selected and wiped for the coolant oil. Then suitable corner cleats with glue (applied over it) are inserted in the corner. Then the clear sealant is applied on the cut corners and assembled. The assembled frame is placed in the crimping machine and punched. In the same manner all the four corners are crimped. The shutter profiles are assembled while glazing the glass with suitable gaskets and tight packing on the bottom and sides. The allowed maximum difference when measured in diagonal for the assembled outer or shutter is 2 mm. The tolerance for width & height is +/- 1mm. Fabrication of Curtain wall In this the extruded bar as per the optimized length and profile section number is selected and placed in a double header cutting machine. Then as per the cutting dimension mentioned in the cutting list the profiles are cut at 90o (Straight cut) for Mullions (Verticals) and Transoms (Horizontal). The Dimension is checked by tape measure and placed in the trolley. The Mullions are taken to Fabrication table and are marked for the transom positions and also suitable notching are done on the top and bottom in the nose for the fixing the drainage adaptor. Suitable slot or hole is drilled in the top or bottom of the mullion for fixing the brackets (double side) with center bolt as per the drawing. Then the mullions are pre drilled as per a gauge suitable to the hole position of the transom cleat. Then the transom cleats are fixed to the Mullion as per the drawing related to the particular part of the frame. Now the Transoms are drilled suitable to cleat fixing. The transoms and Mullions are fixed as per the suitable sizes as per the drawing. The nose adaptor is fixed on the nose of all the mullion and transoms in the frame. The suitable cut size sleeve is fixed to the bottom part of the mullions. Along with the sleeve the drainage adaptor also fixed to the bottom of the mullion. Suitable adaptor is fixed in the spandrel area of the frame in the Mullion and transom. Suitable size gaskets (Section Number) are placed in the transom and mullions. The size of the gaskets in the transoms are cut 10mm to 15mm longer to transom size and then compressed and placed with non setting glue at the joints to the vertical. The gap behind the Nose adaptor and the mullion at the corners are filled up with suitable baking foam and applied with sealant and tooled properly forming the thickness of the nose exactly. The pressure plates are drilled for the fixing hole at 300mm max centers. Notching of the drainage slots are done as per the drawing. The slots are placed in such a manner that it will not in inter face with the glass supports when they are to be placed while installation. The tolerance for width & height of the frame is +/- 1mm. This condition is applicable for 3m width of the frame. For continuous frame more than 3m tolerance is considered according to the width. Installation Installation of Windows and doors Assembled Outer frame is placed in the opening and packing is placed to the gaps between the frame and wall. These are placed on all the ends of the frame and checked for water level for the Horizontal straightness by adjusting the packing on either sides of the frame. Then the vertical straightness is achieved using the plumb bob and sting on both the sides of the frame and packing are then again adjusted and packed tightly. Through the fixing hole, screw fixing holes are drilled in the concrete and fixing screws are fixed with suitable plug inserted before the screw. The central gasket is fixed in case of widows with shutters. Then the shutter is placed in the hinges pin of the frame. Then Lock is checked and adjusted. Shutters are checked for sagging and corrected if required by re-glazing the glass in the shutter frame. Installation of Sliding windows and doors Assembled Outer frame is placed in the opening and packing is placed to the gaps between the frame and wall. These are placed on all the ends of the frame and checked for water level for the Horizontal straightness by adjusting the packing on either sides of the frame. Then the vertical straightness is achieved using the plumb bob and sting on both the sides of the frame and packing are then again adjusted and packed tightly. Through the fixing hole, screw fixing holes are drilled in the concrete and fixing screws are fixed with suitable plug inserted before the screw. Then the shutter is placed in the bottom track and checked for smoothness of the sliders on the track. of the frame. Then Lock is checked and adjusted. Shutters are checked for sagging and corrected if required by re-glazing the glass in the shutter frame. Installation of Curtain wall The frame one is selected in case of continuous frame and placed in the exact location and checked for water level for horizontal straightness. Then using a plumb bob levels both sides to align the vertical, also check for the diagonal. After this through the fixing holes drill the proper size of the anchors. Fix the anchors and again check for the water level and plump once again and mount the second frame by inserting the sleeve in the top of the frame which is already fixed. In the same way all frames are fixed by checking in the same way. Then the glass supports are placed for placing the glass and it is placed in such a way that it is not blocking the drain slots of the pressure plates. Sleeve joints are placed for correct gap and then filled up weather sealant. Also tool the sleeve adaptor also so that water when entered will flow down. After placing each glass stitch plates are fixed to hold the glass. Once all the glasses are placed pressure plates are fixed replacing the stitch plates vertically initially and then horizontally. Seal the expansion of the pressure plate in the verticals. Then place the cover clips and seal the expansion of them too. Appendix 3 – Quality Management System Al Burje Al Fudhi Glass & Aluminum has initiated the process of implementing the Quality management system in order to achieve ISO 9001: 2000 by end of this year. These procedures are carefully implemented by regress training to the personal who are involved in the processes. Al Burje Al Fudhi is in the initial stage of implementing QMS, Hence a lot of changes can happen in due course of time. The procedure is drafted and attached in the profile. These are under review with the certificate body. List of Completed Projects Mr.AHAMAD ISSA VILLA, UAQ Mr.SALIEM MELAHI VILLA, UAQ Al Burje Al Fudhi Aluminium & Glass Ind. : 33272 15 Sharjah Emirates Mobile Email Website : +971 6 5242247 : 3439721 : +971 6 5242217 :[email protected] : www.rhemagroup.org
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