WORK METHOD STATEMENT

ELEVATOR INSTALLATION
(SCAFFOLDLESS METHOD)
WORK METHOD STATEMENT

METHOD STATEMENT FOR LIFT INSTALLATION

Prior to commencement of lift installation works, all the lift shafts and pits have to
be cleared of formworks debris, water, protruding nails and metal rod.

The lift motor room equipment mainly the traction machines, Main hoisting ropes,
controllers and diverter Pulley sheaves shall be hoisted up into the motor room
after taking possession of the site.

Counterweights Frame, (pulley if applicable) and the counterweights are then

hoisted up to the upper terminal floor.

A temporary cantilevered working platform is then erected inside the hoist way at
one floor below upper terminal floor.

1.0 Template Setting

Steel piano wires are used to plumb down from the highest floor to the lift pit at
various points for installation works. Six (6) lengths of wire are used out of which
two (2) for the entrance, two (2) for car guide rails and two (2) for the
counterweight rails. A reference line or point shall be provided by the Building
Contractor at Ground Floor lift lobby as a datum line so as to ensure the door
entrances is in a common line for the installation of two (2) or more lifts in a
common shaft.

2.0 Buffer Channel Bases

Buffer channel bases are fixed to the bottom end of the rails and rail height is
adjusted by using nuts to ensure the buffer channel bases are horizontal. Buffer
channel bases are mounted onto the pit floor slab by anchor bolts after the rail
alignment.

3.0 Pit Equipment

Pit equipment such as Car and Counterweight buffers are then installed. The Car
and Counterweight Rail are then installed until one floor above lowest terminal
floor.

4.0 Car Frame and Cage Assembly

 Supporting beam is erected at the pit for preparation of car frame installation.

Install a chain block at the required height using certified sling. Set the bottom
car frame in position. Next, install the side car sling to the bottom car frame. The
car platform assembly is hoisted by a chain block or a power winch and is set on
its position on top of the safety plank. Before bolting the car platform assembly to
the car frame, carry out the alignment, centering and leveling of car frame. Level
difference should be less than 2 mm for any direction and centering must be
within + 1mm from entrance centre line and car sill must be 30 mm+ 2mm gap
from entrance sill.

The crosshead beam is hoisted by a chain block or a power winch up to a little

above the car slings and is then lowered and mounted on the slings. To install
the car cage assembly, the ceiling is hung firmly to the crosshead beam and
assembles the kickplates, entrance columns and wall panels and tightens. The
ceiling is then placed on the walls. When the car cage assembly work is
completed, set the car door operator motor and then fit in the car operating
panels and other accessories.

a) Preliminary Check

i) The car and entrance sill centre lines should correspond to each
other (+1.0 mm).

ii) Car sill center to entrance column are balanced (Opening Width /
2+0.5 mm).

iii) Car sill and platform are level (+0.5 mm from horizontal).

b) Alignment Check

i) The gap between car and landing sills must be confirmed to be 30

mm +2 mm at all floors. If not, adjusts to meet the clearance by
moving the car platform.

ii) The car entrance columns are checked for verticality in both X and
Y directions. If not, adjust it by inserting shims under anti-vibration
rubber units below the car platform. The verticality tolerance
should be +0.5 mm.

5.0 Lift Motor Room Equipment

a) Machine Beams
 Machine beams are set in position from the template setting below. After
the level of the machine beams has been checked, anchor bolts for the
supporters are tightened and the machine beams are then welded on to
the steel bearing plates on the supporters leaving a small gap between the
motor room floor slab and the machine beams.

b) Machine Bed

Anti-vibration isolator rubber units are fixed to the machine beams before
installing the machine base frame 9bed) in position by rail clips and bolts.

c) Traction Machine Diverter Sheave

Hoist the traction machine by means of a chain block and place it on the
machine bed and adjust its position correctly before fixing it by bolts and
clips.

d) Controller

Set the controller in position using anchor bolts after ascertaining the
correct level.

e) Over speed Governor

Install the governor as per dimensions shown in layout drawing using the
template as a guide with anchor bolts.

6.0 Counterweight Frame Assembly

The counterweight frame is then assemble and bolted tightly before it is hoisted
into the lift shaft at the pit area and set it at the required height using supporting
beams and securely hung.

7.0 Roping

a) Main Hoisting Ropes

The main ropes are laid down from the motor room with one end attached
to the crosshead beam on the car top and the other end attached to the
counterweight top frame. The ropes are held at both ends by thimble
rods. After the roping is completed, the filler are then loaded into the
counterweight frame (Number of fillers equal to balance load for easy
manual brake release operation).

Fix CWT filler clamp on top of the fillers to stop the fillers from falling off the
frame.
 To keep Counterweight frame in place during operation, fix rope clamp in
between the guide shoe. Then fix CWT rail clamp at the base of both CWT
rails using rail clips.

Drop 8mm or 10 mm steel rope (any old used rope from modernized job site
can be used) from machine room. Each end of the rope to be dropped from
the CWT rail pockets to the lift pit. Both ends to be passed through the rope
clamp fixed on the CWT frame and terminated on the eye bolt of the CWT rail
clamp using rope grips. The extra rope, if any, can be retained in the lift pit in
a neat coil. The eye bolts should than be used to tension the rope so that the
CWT frame movement is restricted until the frame reaches the CWT guide
rails.

b) Governor Rope

The governor rope is also laid down from the motor room passing through
the tension sheave in the lift pit. A long manila rope is used to bring up
the governor rope. The governor rope ends are also connected to the rod
of the safety gear device at the car top by wire clips and the U-bolts of the
clips must be applied from guide rail side.

The partially installed lift’s equipment is now ready to be manually moved vertically
for the installation of the remaining car & counterweight rails and entrances works.
The car top with fall protection railing will now acts as a working platform.

Prior to moving the car, it is necessary to reconfirm that the safety gears are
activated at all times. The counter balance between the car and counterweights has
to be reconfirmed as well.

During manual movement of the car, there shall not be any workmen riding on the
car at all times.

Effective communication i.e. Walkie Talkie must be implemented and used.

The next stage of rails and entrance works shall be carried out and as follows, as the
lifts is manually moved upwards.

8.0 Car and Counterweight Rail Brackets

Rail brackets are fastened to the building by anchor bolts on reinforced concrete
walls or welded to steel support beams. These brackets are normally spaced at
2500 mm apart along the entire height of the hoist way.

Each rail normally has two (2) bracket support points. After the completion of the
bracket installation, the installation of guide rails shall commence.

9.0 Guide Rail Erection

Car and counterweight rails are erected vertically in the lift shaft by means of a
winch starting from the pit where these rails sit on the buffer channel bases.
 Most guide rails are 5000 mm in length and are joined by fish plates with bolts
and nuts at every rail end. These rails have to reach the soffit of the motor room
slab leaving a gap of about 100 mm clear. After the rails have been installed,
their alignment is checked for verticality using a rail gauge. The rail verticality
has to be precise to ensure smooth riding comfort in the car upon
commissioning.

10.0 Landing Entrance Sills

Prior to the landing sill setting, the reinforced concrete sill supports or sill
supporting angle installation has to be completed. The finished floor level (datum
line) has to be provided at each landing entrance and marked on the wall by the
building Contractor. Setting of the sills is done based on the datum line and the
plumb line. After the completion of the sill setting, all gaps around the sills are to
be grouted with cement.

11.0 Landing Door Frames (Jambs)

The frames are assembled and mounted on the landing sills and fastened by
bolts. The entrance width and verticality of the door frames are checked. Once
the alignment has been verified, the door frames are then set in position by
welding the frame steel bracing to the anchor bolts or steel bars protruding from
the side of the reinforced concrete walls.

12.0 Landing Door Header

The door header assembly is set in position on top of the door frame with bolts
and brackets after its vertical alignment has been checked against the plumb line.
The assembly position is also adjusted to meet the entrance width plumb lines.
Spot welding on the brackets and door header assembly is also done to prevent
movement. Upon completion of the door frame and header assembly at each
entrance opening, cement grouting to all the gaps between the door frames and
structural openings shall be carried out by the building Contractor. The
installation of the landing doors shall commence after the completion of the
grouting works.

13.0 Landing Door Installation and Adjustment

Mechanical adjustment of landing entrance door assembly is almost the same for
all types of door mechanism. In case of pre-assembled door unit, door
mechanism is normally adjusted in the factory but check is necessary.

Preliminary arrangement and check is conducted to ensure that the dirt and dust
in the groove for door shoes are removed. Confirm that the door can move
 smoothly and door panels are not twisted. Check that the gap between sill and
bottom of the door panel is 5+ 1mm when door is in closed position. Confirm that
the gap between door panels is less than 0.5 mm, otherwise shims are used for
adjustment.

The gap between door rail and up thrust roller is adjusted to be 0.1 mm to 0.3
mm, and nuts are tightened to the standard torque. The gap between door
panels and door frames is 4+ 2mm. In case of 2-panel side-opening door, gap
between sliding door panels is also 4+ 2mm. Door panels must move parallel to
the door frames. The link wire rope is adjusted so that the door panels are in line
with entrance jamb when the door is fully open. In case of 2-panel side-opening
door, confirm that the overlap of door panel with jamb is 20+ 2mm when the door
is closed.

14.0 Wiring In Hoistway

Hoist way wiring is run from the lift motor room to the pit. Hoist way wiring is by
multi-core cables which are laid down from the motor room to the pit. Some
wires are diverted to the respective floors for connection to hall button, indicator
and door interlock mechanism. Sharp bending and strong twist of cables must
be avoided.

In the motor room, the wires are connected / terminated at the respective
terminal points. Travelling cables are laid down from the motor room to the car
cage and terminated at the respective terminal points.

15.0 Hall Call Button and Position Indicator

Remove the faceplate of the hall button and indicator from the box to avoid
scratched and damage. Set the box at the required level and dimension.
Cement grout around the box to hold it in position.

16.0 Labeling & Identification

Main parts are labeled in the motor room such as the motor, lift no. , EBOPS,
governor, etc. Hazard labels are also provided in the motor room and car top
highlighting the main hazards present such as high voltage, hoisting beam SWL,
trip hazard, etc. Signage on motor room door is provided by others.

17.0 Pre Testing & Commissioning

Prior to T&C (testing and commissioning), several requirements that must be

fulfilled are checked:
a) Power supply to lift motor room switchboard is verified with a Voltage Tester
measured from the DB outgoing and also the incoming on Sigma
switchboard.

b) Lighting and exhaust fan in lift motor room.

c) Lift motor room cleanliness, debris and rubbish to be cleared before

commencement of T&C.

d) Lift motor room signage and door with lock provided

e) Lift pit dry and no signs of water seepage. Sufficient water proofing provided.

f) All openings at lift landings grouted and covered properly.

 LIFT INSTALLATION & QA/QC FLOW CHART.
E R E C T I O N O F
TEMPORARY WORKING
P L A T F O R M

TEMPLATE SETTING &

PLUMB LINE

NOT ACCEPT
CONFIRMATION OF PLUMB LINE REMEDIAL
(ON THE VERTICALITY OF THE LIFT WORKS
SHAFT)

ACCEPTABLE

CONFIRMATION OF LIFT PIT EQUIPMENTS

FINISH FLOOR LEVEL (to INSTALLTION
be provided by builder)

SETTING OF MOTOR &

CONTROL PANEL

LIFT MOTOR ROOM

WIRING

CAR FRAME & CWT

INSTALLATION

CAR CAGE PANEL

INSTALLAION CAR & CWT ROPING

INSTALLATION OF GUIDE
RAIL LANDING DOOR
INSTALLATION

INSTALLATION OF LANDING SILL,

DOOR HEADER & ARCHITRAVE

ENTRANCE
GROUTING PREPARATION
(BY Builder) WORKS FOR HOISTWAY WIRING
TESTING

CAR CAGE
WIRING
 TESTING AND COMMISSIONING FLOW CHART

PRE-TESTING &
COMMISSIONING
REQUIREMENT

CONNECTION & CONFIRMATION OF WIRINGS

AT CONTROL PANEL AND LIFT CAR

LIFT RUNNING AT
SLOW SPEED

CLEANINGWORKS (GUIDE
RAILS, LANDING SILL & ETC)

MECHANICAL SETTING INSTALLATION & SETTING OF

AND ADJUSMENT SAFETY DEVICES

PRE-AUTHORITY
INSPECTION
REQUIREMENTS

AUTHORITY (JKKP)
INSPECTION

INSTALLATION & SETTING OF FIRE &

GENSET HOMING FEATURES

INSTALLATION OF HALL TESTING & COMMISSIONING OF

OPERATING FIXTURES SUPERVISORY PANEL
(FACE PLATE)

READY FOR THE

JKKP INSPECTION