ALUMINUM WORK

Level-III
Based on October 2023, Curriculum Version II

Module Title: Glazing Aluminum Joinery Products

Module Code: IND ALW3 M11 0322
Nominal duration: 70 hours

Prepared By: Ministry of Lobar and Skills

October, 2023
Addis Ababa, Ethiopia
 Acknowledgement

Ministry of Labor and Skills wish to extend thanks and appreciation to the many representatives
of TVET instructors and respective industry experts who donated their time and expertise to the
development of this Training module (TM).

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Table of Contents

Acknowledgement ...................................................................................................................... i
Acronym ................................................................................................................................... iv
Introduction to the Module ..........................................................................................................1
Unit one: Glazing work planning .................................................................................................3
1.1. Basics of Gazing ...........................................................................................................4
1.2. Work Sequences ...........................................................................................................5
1.3. Safety Requirements .....................................................................................................9
1.4. Type of Glasses ........................................................................................................... 11
1.5. Material Calculation .................................................................................................... 13
1.6. Tools, Equipment and Manual Handling ..................................................................... 14
1.7. Glass fixing methods ................................................................................................... 18
Self – Check – 1 ........................................................................................................................ 23
Operation sheet – 1.1: window grazing ...................................................................................... 25
LAP test 1.1 .............................................................................................................................. 27
Unit Two: Glass movement and relocating ................................................................................ 28
2.1. Introduction ................................................................................................................ 29
2.2. Transport Glass ........................................................................................................... 29
2.3. Storage of Glass .......................................................................................................... 34
2.4. Label and Store ........................................................................................................... 34
Self – Check – 2 ........................................................................................................................ 37
Unit three: Working area conditions and restraints .................................................................... 38
3.1. Difficulties .................................................................................................................. 39
3.3. Finished Work Correction ........................................................................................... 44
Self-Check – 3 .......................................................................................................................... 45
Unit four: Glazing ..................................................................................................................... 47
4.1. Frame Preparation ....................................................................................................... 48
4.2. Glass Fixing ................................................................................................................ 50
4.3. Cladding Fitting .......................................................................................................... 52

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 4.4. Cleaning...................................................................................................................... 59
Self-Check – 4 .......................................................................................................................... 63
Operation sheet – 4.1: Exterior Wall cladding ........................................................................... 65
LAP test – 4.1 ........................................................................................................................... 67
Unit five: Completion ............................................................................................................... 68
5.1. Check Up .................................................................................................................... 69
5.2. Documentation ............................................................................................................ 69
Self-Check – 5 .......................................................................................................................... 72
Reference .................................................................................................................................. 73

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Acronym

PPE ....................................... personalprotective equipment

OHS ...................................... occupational health and safety

AAMA .................................. the American Architectural Manufacturers Association

NWWDA .............................. the National Wood Window and Door Association

NAMI ................................... the National Accreditation and Management Institute

SHCC ................................... Solar Heat Gain Coefficient

VT ........................................ Visible Transmittance

AL ........................................ Air Leakage

CR ........................................ Condensation Resistance

SSG ..................................... Structural Sealant Glazing

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 Introduction to the Module

Glazed Aluminium windows and doors help enhance energy efficiency and regulate thermal
insulation. Glazed windows are those windows that have multiple panes of glass and a vacuumed
space, often filled with an inert gas, preferably argon between them.

Glazed aluminium windows also come with primary and secondary seals that are specifically
designed to contain the heat and reduce the noise, in a far more superior way than other regular
window systems. Primarily, aluminium glazed windows are made available in two major glazing
options- single glazing and double glazing.
This module is designed to meet the industry requirement under the Aluminium Work
occupational standard, particularly for the unit of competency: Glazing Aluminum Joinery
Products.

Module units

 Glazing work planning

 Glass movement and relocate glass
 Site conditions and restraints
 Glazing
 Finishing and cleaning

Learning objectives of the Module

 Perform glazing work planning

 Perform glass movement and relocate glass
 Perform Site conditions and restraints
 Conduct Glazing
 Practice Finishing and cleaning

Module Learning Instructions:

1. Read the specific objectives of this Learning Guide.

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2. Follow the instructions described below.
3. Read the information written in the information Sheets
4. Accomplish the Self-checks
5. Perform Operation Sheets
6. Do the “LAP test”

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Unit one: Glazing work planning
This learning unit is developed to provide the trainees the necessary information regarding the
following content coverage and topics:
 Introduction
 Work sequences
 OHS requirements
 Type of glasses
 Sheet glass
 Material calculation
 Tools, equipment and manual handling
 Glass fixing methods
This unit will also assist you to attain the learning outcomes stated in the cover page.
Specifically, upon completion of this learning guide, you will be able to:
 Develop Work sequences
 Identify OHS requirements
 Know Type of glasses
 Understand Sheet glass
 Perform Material calculation
 Practice Tools, equipment and manual handling
 Apply Glass fixing methods

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1.1. Basics of Gazing

Glazing, which derives from the Middle English for 'glass', is a part of a wall or window, made
of glass. Glazing also describes the work done by a professional "glazier". Glazing is also less
commonly used to describe the insertion of ophthalmic lenses into an eyeglass frame.
The term ‘window glazing’ refers to three different things: the window glass itself, the sealing
compound that holds window glass in the window frame, and the process of installing the glass
and/or the compound. Most people use these terms interchangeably, but chances are that if
you’re looking to glaze your windows, you’re talking about the process of replacing and
installing new glass or new compound.
Common types of glazing that are used in architectural applications include clear and tinted float
glass, tempered glass, and laminated glass as well as a variety of coated glasses, all of which can
be glazed singly or as double, or even triple, glazing units. Ordinary clear glass has a slight green
tinge, but special colorless glasses are offered by several manufacturers.
Glazing can be mounted on the surface of a window sash or door stile, usually made of wood,
aluminium or PVC. The glass is fixed into a rabbet (rebate) in the frame in a number of ways
including triangular glazing points, putty, etc. Toughened and laminated glass can be glazed by
bolting panes directly to a metal framework by bolts passing through drilled holes.
Glazing is commonly used in low temperature solar thermal collectors because it helps retain the
collected heat.
When it comes to increasing energy-efficiency in the home, “window glazing” is important to
consider. However, this term can mean two different things. The process of fitting new window
glass may come to mind, which is usually done with a special putty called a “glazing
compound.” However, this is not the only definition of window glazing.
Window glazing is also an attribute of windows, pertaining to the kind of glass they have.
In this guide, we will talk about the two definitions of window glazing and why it’s important to
understand both of these if you want to have added energy efficiency and better insulation.

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1.2. Work Sequences

1. Follow below shim placement image for fixed/ picture windows glazing
Place 5 mm shims on the bottom.

Figure 1.1: shim placement image for fixed

2. Place glazing blocks on the bottom glazing cavity of each window and door
Glazing blocks are placed in factory but may shift during handling/transportation. Therefore,
ensure both glazing blocks are present and positioned correctly: 4” away from the inside of the
corner.

Figure 1.2. Glazing blocks on the bottom glazing cavity of each window and door
3. Place glazing shims squarely on top of each glazing block.
Glazing shims placed directly into the glazing cavity according to the shim placements

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 Figure 1.3: glazing shims squarely on top of each glazing block
4. Carefully place the glass back into the frame

Figure 1.4: glass placement

5. Using a glazing shovel, adjust the glass position until it’s fitted into the right position
If shim it still angled, adjust to be straight

Figure 1.5:Glazing shovel, adjust the glass position

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6. Check for correct shim and glass unit placement

Figure 1.6: Correct shim and glass unit placement

7. Reattach the glazing beads

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Start with the placing the shortest glazing beads. Insert and tap the bead into place, moving from
the ends and working your way to the middle from both sides.

Figure 1.7: Attach the glazing beads

8. Check gaskets for consistent pressure
Both the interior and exterior gaskets should be reviewed for consistent pressure.

Figure 1.8: Interior and exterior gaskets

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1.3. Safety Requirements

 PPEs like safety belts at height, helmets, safety goggles, ear plugs and hand gloves etc.
should be used properly.
 Ensure the working area is kept clean for easy access.
 Proper illumination to be provided during the work, if required.
 Educate the workmen through pep-talk meeting.
Personal Protective Equipment PPE
Health and safety at work is essential for everybody’s wellbeing. That is why we've carefully
researched, and then selected only the highest performance products from leading manufacturers
around the world to offer you the best range of personal protective equipment (PPE) available.
Protective Work Gloves & Hand Protection: Lightweight and flexible gloves for chemical and
assembly handling, glass handling and general glazing work offering various levels of hazardous
resistance, abrasion, cut, tear and puncture resistance.

Figure 1.9:gloves
Wrist & Arm Protection: Where sharp items are to be lifted or transported our range of wrist
guards can be indispensable. Very popular are the knitted Kevlar sleeves that exhibit an excellent
fit as well as affording great flexibility and breathability.

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 Figure 1.10:Wrist & Arm Protection
Work Aprons:Work aprons are the ideal companion when it comes to glass processing. Our
range of professional work aprons provide various levels of cut resistance as well as maintaining
a safe barrier between you and any dirt, dust, oil or chemicals that you may come into contact
with.

Figure 1.11:Glazier's Work Apron

Eye Protection:A range of stylish, lightweight and comfortable safety glasses and goggles ideal
for environments where there is a risk of small flying particles or debris potentially damaging the
eye such as glazing and glasswork, building or construction, wood or metal. Suitable for a wide
variety of tasks.

Figure 1.12:Safety glass

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Head Protection: Helmets for general use in construction and industry to provide protection to
the wearer against falling objects and consequential brain injury and/or skull fracture.

Figure 1.13:Helmet

1.4. Type of Glasses

Glass windows and doors are essential components to separate and protect the interior of a
building. Moreover, they bring natural light and fresh air into our homes while offering views
that connect the inside to the great outdoors.
Regardless of the style and size, or whether you choose wood or aluminium windows and doors,
the choice of glass is a significant element when it comes to safety. In residential properties,
window-related accidents are common; thus, preventative measures must be considered when
installing any glass windows or doors. This is because ordinary annealed glass is brittle and
breaks easily into big, sharp-edged splinters and shards that could inflict severe injuries.
The window glazing options include clear, tinted, spectrally selective, and reflective, each of
whichsatisfies different design and performance requirements.
 Clear glazing. Glass without any tint or coating to lower its visibility or energy
performance qualifies as “clear” glazing.
 Tinted glazing. Often referred to as heat-absorbing glass, these tinted glazing panels
block solar heat by absorbing it into the glass itself, causing the temperature of the glass
to rise as a result.Common tints are bronze, gray, and green, all of which seem to absorb
heat at the same proportion.Black tint, however, absorbs much more visible energy than
heat energy and therefore presents theworst cooling load reduction.

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  Spectrally selective glazing. These coatings are designed to admit a higher level of
visible light whilecontrolling solar heat. The popular low-emissivity or “low-E” glazings
are spectrally selective glazedcoatings that provide better insulation value, good visibility
characteristics, and good solar control.
 Reflective glazing. These semitransparent metallic coatings are applied to either clear or
tinted glass and provide a high degree of solar heat control due to their reflective nature.
Although they reduce cooling loads, they do so at the expense of daylight transmittance,
and when installed on buildings in close proximity to one another, they can transmit their
reflected solar heat to those nearby buildings.

Sheet glass
Glass sheets and plate glass consist of flat glass materials in the form of thin or wide slab planar
structures. Glass sheets and plate glass come in a wide variety of shapes, sizes, thicknesses, and
with a multitude of physical and chemical characteristics. Glass sheets and plate glass can be
clear or transparent, or treated with other elements to give an opalescent or iridescent quality.
Applications
 Applications
Glass sheets and plate glass are commonly used in architecture as windows, transparent walls,
and glass doors. They are also used in automotive and marine applications, for car and boat
windows and windshields. Glass sheets and plate glass are also used in industrial applications,
including as covers for meters or as optical glass windows.
 Types
Bulletproof or bullet resistant glass is made by using layers of glass sheets or by using a
transparent polycarbonate thermoplastic.
Dichroic glass is glass that has been layered with metal oxides to give the glass a unique color
and texture.
Tempered glass is stronger and more durable than regular glass sheets and plate glass. It is used
in a wide variety of products, including vehicle windows and specialty items like scuba diving
equipment, marine vehicles, and some cookware. Tempered glass is made by heating and then

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rapidly cooling the glass to induce residual compressive stresses in the surface of the glass. The
glass will not break until the residual compressive stresses are exceeded. It is designed to fracture
into small fragments rather than shards, minimizing the likelihood of injury.
Textured or patterned glass can obscure images behind the glass, while still allowing light
through, providing a measure of privacy.
 Manufacturing
Glass sheets and plate glass, also simply called flat glass, is typically made using float glass
technology. In the float glass process, a layer of melted glass is poured onto a molten tin surface,
forming a smooth, uniformly thin layer. The tin bath is progressively cooled until the glass layer
can be removed onto rollers for further cooling and processing.
Glass sheets and plate glass made using the float glass process are usually made from soda ash,
sand, limestone, dolomite, and sodium sulfate. The addition of other elements may enhance the
characteristics of the glass or give it a specific color.
Glass sheets and plate glass can be strengthened chemically using an ion exchange process. In
this process, the glass is immersed in a molten bath of alkali salt that contains ions larger than the
ions in the glass. The smaller sodium ions in the glass are replaced with the larger ions in the
molten salt. The larger ion induces strain in the structure, strengthening the glass material.
Glass sheets and plate glass can also be manufactured by other processes, including rolling;
overflow downdraw, which is used to make flat panels for displays; blown plate, which is used to
make mirrors; broad sheet; cylinder blown; and many others.
1.5. Material Calculation

 Determining Glass Size

Measure the opening width and height. Glass dimensions are always expressed giving the glass
width first.
(Example: WIDTH X HEIGHT X THICKNESS)
Deduct 1/4” from the opening size, and 1/4” from the opening height. This is your exact glass
size, which will provide a 1/8” glazing reveal on all 4 sides between glass and opening. This is
also known as the “glass clearance.”

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  Determining Glazing Tape to Use
First measure the glazing pocket width. Then deduct the glass thickness to find the allowance for
glazing tape. Then divide by 2. This will be the required glazing tape thickness for backstop and
face stop.
(Example: POCKET WIDTH - GLASS THICKNESS = TAPE ALLOWANCE ÷ 2 = TAPE
THICKNESS)
NOTE: Standard glass reveal for Stiles hollow metal doors and frames with 5/8” stops is 1/8”.
(Specific glass types may require different reveal (per manufacturer’s recommendations).

1.6. Tools, Equipment and Manual Handling

Glazing tools: A great range of glazing tools designed to save time and money onsite, from the
traditional to the very latest innovations.
Glass Cutters: Glass cutter for general cutting tasks, especially economical as wheels are
exchangeable and turrets and cutting heads are nickel-plated · 6 cutting wheels made of stainless
steel and tempered by a patented method guarantee high cutting quality and long service life.

Figure1.14:Glass cutter
Glazier's Hammer: The glazier's hammer is a very small precision hammer with a wooden or
metal handle. It has a dovetail head to pull the nails and bevel-shaped handle to clean the grooves
(on the wood moldings which receive the window).

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 Figure 1.15: Glazier's hammer
Glass gun: A type of nailer-stapler designed to plant nails to hold the glass in place. The nails
can also be nailed with a hammer.

Figure 1.16:Glass gun

Glazier nails: For glass guns, the nails are in the form of 1000 piece strips, which are ready to be
inserted into the charger. For manual nailing, they are sold in packs.

Figure: 1.17: Glazier nails

Putty chisel: Spatula made of wood, plastic or metal, the putty chisel is specially designed to
remove traces of old putty.

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 Figure 1.18:Putty chisel
Putty knife: A putty knife in the shape of a sheet, specially designed to insert the putty into the
groove and smooth down after application. The shape is referred to as a bay leaf or laurel leaf.

Figure 1.19Putty knife

Block lever: The block lever is a very useful hand tool used to precisely position the heavy glass
in its housing and avoids unnecessary wedging of the fingers during this delicate operation! It is
made of either wood or plastic.

Figure 1.20:Block lever

Suction Lifters: Equipped with one suction pad only, pump-activated suction lifters enable the
manual transport of different materials with a load capacity of up to 120 kg. The vacuum is
generated by engaging the pump tappet. The vacuum level can be increased at all times, also
while the load is attached. Moreover, due to its position the pump tappet offers the possibility of
visually monitoring the vacuum

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 Figure 1.21:Suction Lifters
Compass cutter: Kind of compass equipped with a suction cup specially designed for circular
cuts (installing an aerator in a window for example). The compass cutter is a tool often used by
burglars to cut a hole in the glass to access a lock or bolt

Figure 1.22:Compass cutter

Glass Cutting Squares, Straight Edges & Shape Templates: L-Squares, T-Squares, straight
edges with intergrated suction pads and shape cutting templates.

T-Squares L-Squares
Figure 1.23: Straight Edges with Integrated Suction Pads

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T-Squares: T-Squares made of an especially wear-resistant synthetic material, made to the
highest possible tolerances
L-Squares:L-Squares made of an especially wear-resistant synthetic material, made to the
highest possible tolerances. Manufactured to be square.
Straight Edges With Integrated Suction Pads: Straight edges with integrated suction pads
available in thicknesses of 5mm or 10mm. Choice of wear-resistant synthetic material or
aluminium construction
Glass Cutting Frames: Glass cutting frame used for cutting equally dimensioned glass panes.

Figure 1.24: Glass Cutting Frames

1.7. Glass fixing methods

Glazing methods are provided as follows:

 Dry glazed
 Wet glazed
 Point supported glass systems
 Cable net
 Double skin wall

Dry Glazed: In this approach, compression stresses are applied to fix metal panels or glass units
into the glazing pocket of the frames. The necessary compression force can be obtained using
rubber gaskets and occasionally structural tapes. Generally, the rubber gasket, which is

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compressed in advance, are placed on either side of the glazed element, and panels may be
glazed from the exterior or interior based on the system.

Figure1.25: Dry Glazed

Wet Glazed: In this technique, the infill element is placed and attached to the frame using
proper attaching agents such as silicone sealant. The sealant application process should be
conducted properly otherwise the attachment agent would not work suitably. For example, the
perimeter need to be prepared sufficiently and then the sealant element is applied to the
perimeter. Structural silicone glazing as shown in figure below is a particular kind of wet glazed
utilization that need utmost attention and observation of the sealant. The process begins with
applying the adhering agent to the aluminum frame and then the panel is placed into its position.
The silicone would create a bond, which can withstand lateral loading, between the aluminum
frame and the panel. It is recommended to carry out such process in closed spaces such as
factories and shops since the adhesion of the agent would decease when dusts are present on the
surfaces. The structural silicone glazing can be made for one or two storey heights.

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 Figure 1.26: Structural Silicone Glazing

Point Supported Glass Systems: This system has been used since 1960s and it has undergone
some development but its basics remain the same. It consists of strengthened or tempered glass
through which holes are provided to attach it to the structure using proper means such as bolted
fittings as shown in Figure-6 and Figure-7. It can be observed form these figures that the fittings
cause smallest obstruction of views due to their small sizes. The glass is commonly tempered by
exposing it to high degree of temperature during its processing. This will reduce possible
damages during its life service.

Figure 1.27: Fitting in the Point Supported Glass System

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Fitting manufacturing are mostly controlled by architectural intent. Point supported systems are
considerably pleasing aesthetically but it needs great cautions to obtain required detailing and
precision. The analysis of point supported system is quite complicated and it may need to use
finite element modeling to specify loads transfer and stress through by fittings.

Figure 1.28: Point Supported Glazing System

Cable Net: Cable is another type of glazing panel construction that provide substantial views. It
is an elegant glazing panels that does not need framing but it could be costly and expensive. Due
to the effect on loading on the panels, not only does cable net structural analysis is required to be
carry out accurately but also construction works need massive coordination. Cable net walls are
commonly flexible that is why they are likely to deflect extremely. This may make occupants
uncomfortable but the functionality of the building will not be influenced and its aesthetic views
would not be distorted.

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 Figure 1.29: Use of Cable Net

Double Skin Wall: This type of curtain is considered to be the most expensive compared to
other ordinary types of panel construction.

Double skin wall construction is quite complex and consist of two skin of glass or façade, and
the space between the facades is employed to manipulate energy comes from sunlight and
ventilation are installed that employs the warm air in the space between glass walls. It should be
said that the ventilation could be natural, fans, or mechanically controlled.

Figure 1.30: Double Skin Façade

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Self – Check – 1
Part I: Choose the correct answer

1. ________________________is glass without any tint or coating to lower its visibility or

energy performance qualifies.
A. Clear glazing C. Reflective glazing
B. Tinted glazing D. Spectrally selective glazing
2. ________________are semitransparent metallic coatings are applied to either clear or tinted
glass and provide a high degree of solar heat control due to their reflective nature.
A. Clear glazing C. Spectrally selective glazing
B. Reflective glazing D. Tinted glazing
E.
3. ________________glass is made by using layers of glass sheets or by using a transparent
polycarbonate thermoplastic.
A. Bulletproof or bullet resistant C. Dichroic
B. Tempered D. Textured or patterned
4. __________________glass is glass that has been layered with metal oxides to give the glass
a unique color and texture.
A. Bulletproof or bullet resistant C. Tempered
B. Dichroic D. Textured or patterned
5. _____________________glass can obscure images behind the glass, while still allowing
light through, providing a measure of privacy.
A. Bulletproof or bullet resistant C. Textured or patterned
B. Dichroic D. Tempered

Part II: Fill the blank space

1. ____________________to provide protection to the wearer against falling objects and

consequential brain injury and/or skull fracture.

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2. ___________________is used where sharp items are to be lifted or transported our range
of wrist guards can be indispensable.
3. ____________________is used for chemical and assembly handling, glass handling and
general glazing work offering various levels of hazardous resistance, abrasion, cut, tear
and puncture resistance.
4. ____________________work aprons provide various levels of cut resistance as well as
maintaining a safe barrier between you and any dirt, dust, oil or chemicals that you may
come into contact with.
5. ____________________ideal for environments where there is a risk of small flying
particles or debris potentially damaging the eye.

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Operation sheet– 1.1:window grazing
Operation Title: Window grazing

Purpose:To perform glazing work

Conditions or situations for the operations:

 Safe working area
 Properly operated tools and equipment
 Appropriate working cloths fit with the body
Machine and Tools for Glazing

 Cutting machine with minimum 300 Dia blade.

 Copy router for hole, cut outs etc.
 Drilling machine for screw holes.
 Hammer drilling machine for anchors.
 Screw driver and spanners.
 Silicone Gun for bonding.
 Small silicone gun for weather silicon.
 Scrapper for tooling.
 Plumb bob, sprit level and right angles for checking.

Aluminium Glazing Work Procedure

 Check all the windows for its straightness and, bends, fixity, rigidity in fixing, etc.
 Before fixing the glass, ensure that all the work inside the flats is complete. A coat of
distemper painting should also be completed to minimize the chances of breakage of glass.
 Ensure that the window is properly scraped, cleaned, and painted with a coat of oil paint.
 The measurements of glass panels should be taken at the site.
 Glasses are cut to the required size and brought to the site for fixing.
 Check the glass for thickness and quality as per the ordered specifications.
 Check the glazing clips and putty (lambi) for quality and brand.

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 Glass is fixed in the panels from outside, with the help of a ladder or zula for external
windows.
 Glass panes should be perfectly cut to match the size of each panel. Ensure that the fitting is
not loose.
 Cut the glass using a glass cutter with a diamond point.
 M.S. clips are fixed to support the glass in T/Z section.
 See that clips are fixed in every hole.
 Apply putty to the corners of the panels. The quality of the putty is important. The roll
should be prepared by using whiting to get a consistent uncracked filling.
 The putty should cover the M.S. clip.
 Cut the putty at an angle, i.e., about 45 degrees to glass.
 Smooth the surface of the putty with a cut piece of glass.
 After the putty is dry, the final coat of oil paint should be given.
 Clean the window glasses with wet dusters paper to remove paint stains.

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LAP test 1.1

Given all the necessary materials and preform the following task

Task 1: Perform Aluminum window glazing

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Unit Two: Glass movement and relocating
This learning unit is developed to provide the trainees the necessary information regarding the
following content coverage and topics:
 Locations for glass
 Clearance adjustments
 Planning relocating glass
 Relocate glass
 Team lifting tasks
 Label and store
 Relocation check up
This unit will also assist you to attain the learning outcomes stated in the cover page.
Specifically, upon completion of this learning guide, you will be able to:
 Perform locations for glass
 Perform clearance adjustments
 Able Planning relocating glass
 Conduct relocate glass
 Conduct Team lifting tasks
 Perform Label and store
 Perform Relocation check up

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 2.1. Introduction

When working with glazing knowing how to transport and install glass is more than just good
knowledge to have, it is a requirement for the safety of you and those around you. Health and
safety are the most important parts of handling glass as mishandling can cause life-changing
injuries so all the proper steps must be taken no matter how easy a job may appear. Loss is also
an important factor, especially when the glass has been specially supplied. Any damage to the
glass costs both time and money to yourself and potentially your customer as well.

2.2. Transport Glass

When working with glazing knowing how to transport and install glass is more than just good
knowledge to have, it is a requirement for the safety of you and those around you. Health and
safety are the most important parts of handling glass as mishandling can cause life-changing
injuries so all the proper steps must be taken no matter how easy a job may appear. Loss is also
an important factor, especially when the glass has been specially supplied. Any damage to the
glass costs both time and money to yourself and potentially your customer as well.

 How to Transport Glass Safely

Before you can install glass you first need to transport it safely, ideally, the company supplying it
will be transporting it to you. This is because if any damage did occur, they would cover the cost,
but if they cannot then it is up to you to replace any sheets that are broken during transportation.

 Safe Packaging for Glass Transportation

 Start by putting on some safety gloves that are suitable for glass handling i.e., cut
resistant, PU coating, and good sensitivity so you can still feel the glass in your hands.
 If not already packaged, you should place masking tape along the sharp edges of the
glass; this will help to prevent the glass from cutting anyone – do not run your hand over
the tape as you could cut yourself.

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  It may also be a good idea to apply tape on the smooth sides as well, assuming you are
not using any glass handling tools. Stick masking tape in a cross shape across the glass,
then tape X shapes in the new boxes you have created – this prevents the glass from
going everywhere in the event it does shatter.
 Next, place both corner and edge protection blocks on your glazing for protection. If you
do not have these tools on hand you can wrap your glass in thin foam sheeting (if you
don’t have any foam sheeting use anything soft you have such as blankets). Cut your
foam sheeting down to size and tape it securely to the glass so it does not slide around.
Now take some corrugated cardboard and encase your glass in this, with pieces to cover
each side of the glass, including the edges, and tape these on.
 Ways of Lift Glass Safely

There are a few things you must do before you attempt to lift glass. Preparation will help you and
will ensure that you remain safe at all times.
Some top tips to be aware and mindful of when lifting glass are as follows:
 Be Aware of Your Surroundings: Take note of obstacles in your way, uneven ground,
as well as people and machinery that can cross your path when lifting or carrying glass to
a destination.
 Have Help When Lifting: Two people are better than one when it comes to glass lifting,
no matter how small and manageable you think the glass may be. Having help from at
least one other person can make the job feel so much easier.
 Carry Glass with Two Hands: Whether you are on your own or you have help, always
carry glass with two hands. Two hands ensure a safer lift and a tighter and more secure
hold and grip.
 Wear the Correct Safety PPE: Protect yourself with the appropriate gloves, safety
goggles, steel-toe boots or hard hat if applicable - such as when working on a
construction or building site.

Accidents can happen when you least expect them to, wearing the right clothing and safety gear
will help protect your body, skin and eyes and keep you safe from potential injuries.

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  Check for Faults: Before you put on your personal protective equipment, check to see if
it is worn out, damaged or faulty in any way. Damaged safety gear can mean its
protective nature is void, so it is very important to check for faults before you put it on.
You should get replacements if you do find an issue with your safety gear.
 Be Mindful of How Fragile Glass Can Be: Even with your safe tools and PPE, glass is
prone to breaking, cracking or smashing and accidents with glass can happen at any time.
From these pointers and tips on how to follow and prepare for when you come to lift glass, you
are in a much better position for lifting.
You should seek the appropriate tools, equipment and machinery to help you lift. Sometimes
glass is just too difficult to handle and lift on your own even with the help of others. This is when
special glass lifting tools come in handy.
 Glass Lifting Equipment
Here we will go over some of the top glass lifting equipment so that you can understand what it
is that you need, in order to lift glass of all shapes, sizes and weights.
 Suction Cups
First up we have suction cups. Professional glaziers are not without these handy devices in their
kit. They come in all sizes, featuring various lifting capacities and capabilities so you can tailor
the right tool for different uses.
Suction cups can essentially give glass some handles for you to hold. This means you can carry
glass with ease as glass is hard to grip using just your bare hands.
Suction cups can also be used on not only glass but various other materials and objects too, think
metals such as stainless steel, hard plastics like acrylic and even furniture and kitchen appliances
too. For anything that has a smooth, flat and non-porous surface, suction cups can manage to lift.
These tools are worth having in your tool equipment kit if you need to lift glass, whilst they can
come in handy for many other uses too.
 Glass Transport
A great piece of lifting equipment used to lift and move glass. Glass transport is the way to go,
especially when planning on moving glass of a large and heavy nature.

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Types of glass transport, such as the Self-Locking Transport Dolly, a device that is complete
with large robust tyres for the easy moving of loads and designed to take the impact of uneven
and bumpy ground. Carrying heavy weight including large glass loads of up to a staggering
250kg capacity.
Having the right glass transport can ease off your manual handling and it is a safe way to
manoeuvre glass from one place to another.
 Vacuum Pump Suction Cups
Just like suction cups, vacuum pump suction cups are a great way to add that handle to some
glass but with the help of glass vacuum lifters.
Vacuum glass lifters help to create a strong clamp onto the surface for the safest and most secure
hold.
 Lifting Accessories
Lifting accessories are also available to purchase, to aid you when lifting glass. This includes
lifting slings made from strong polyester webbing that can withstand up to crazy 3 tons worth of
weight.
 Hoist or Crane
For lifting and lowering much larger loads, a hoist or crane should be your choice. Mainly used
in commercial glazing projects, both a hoist and crane are accompanied by chains, ropes and
cords to help them operate.
 Check the Lifting Capabilities
Before you jump straight into lifting any type of glass, even with the tools listed above which
help you to complete glass lifting safely, you must make sure that you are using a tool that can
handle the weight you are about to lift.
Every glass lifting tool and piece of equipment will have a certain lifting weight capacity that
you must abide by. Failing to lift within the lifting capacity range can result in damage to the tool
or material you are carrying as well as a risk and danger to your health.

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  Moving Glass Safely

Now your glass is safely packaged you need to transfer it to your mode of transportation. The
best way to transport your glass would be on a specialized glass trolley/dolly, but without these,
you can still proceed with your project.

 Begin with evaluating the size and weight of your glass and any obstacles there may be
when moving it to your vehicle – for more on lifting heavy glass click here. Make sure
both the door you are exiting, and your vehicle doors are open, ready for when you move
the glass.
 If required have someone assist you with moving the glass, ensuring they also have the
correct safety gear.
 With your safety gloves on first lift from the base of the glass, keeping it upright and
always supporting it from the bottom.
 Safe Glass Transportation

Your vehicle should hopefully have a stillage or frame that can support the glass at the angle it
needs to be transported in, but if not, there will just be a few extra steps.

 Slide your glass into the stillage at a 3–5-degree angle, this prevents the sheets from
tipping or bowing.
 Without a stillage you should attempt to store your sheets at this same 3–5-degree angle,
this can be done by leaning it against the wall of your van horizontally and using straps to
secure it in place.
 If your vehicle cannot accommodate the glass upright, then you should place the glass
sheet on a flat surface in your vehicle and secure it so it cannot move. You can help
create a flat surface by either putting down or removing your back car seats, as well as
placing a piece of plywood in your vehicle.
 If everything is safely secured you can set off towards your destination, making sure to
drive slowly and avoiding erratic movement of the vehicle.

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  When you arrive at your location repeat these steps in reverse in order to remove the
glass safely.

2.3. Storage of Glass

Glass should always be stored upright and the edge of the glass should be placed on a horizontal
base, which must be dry and soft (wood, plastic, rubber, etc.). The base must not be in direct
contact with the ground to avoid moisture from penetrating the base and damaging the glass.
Glass must be protected from sunlight, rain, cement dust, and welding sparks, and for extended
storage, glass should be kept in a dry and ventilated area to prevent tarnishing and the formation
of mildew. For short-term storage, follow the instructions above and ensure there is adequate
ventilation. Glass placed on pallets should be protected from sunlight to avoid thermal shock;
laminated and fire-resistant glass, in particular, should be stored indoors and protected against
moisture and cold.
 Glass should always be stored in a dry and ventilated place which is not exposed to solar
radiation and on its edge.
 Soft spacers should be placed between each unit
 Not more than 20 units per stack
 Glass should be stored on its edge and supported over its full height and with
 The back should be slightly inclines (60 to 100 from vertical) with the feet being at 900
to the back rest
 Glass should not be in contact with anything harder than itself, eg, concrete, stone, metals
etc ad this will minimise the risk of breakage and damage
 Glass should be transported on a suitably designed vehicle and care should be taken when
loading and unloading evenly.

2.4. Label and Store

Three types of labels can be affixed to windows: AAMA, NWWDA, and NAMI.
 AAMA. The American Architectural Manufacturers Association certifies that the design
and fabrication of the window have met the requirements as specified on the label.

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  NWWDA. The National Wood Window and Door Association covers only wood
windows and doors and its primary function is to develop industry standards and
certification programs for wood windows, doors, and skylights.
 NAMI. The National Accreditation and Management Institute is an independent
organization that provides third-party certification and inspection services for the
fenestration industry. NAMI works in conjunction with two government agencies, the
Department of Housing and Urban Development (HUD) and the American National
Standards Institute (ANSI), to create national standards for the industry.
Sample Window Sticker and Explanation of Energy and Performance Ratings

Figure 2.1:Sample Window Sticker

 U-Factor measures how well a product prevents heat from escaping a home or building.
U-Factor ratings generally fall between 0.20 and 1.20. The lower the U-Factor, the better
a product is at keeping heat in, U-Factor is particularly important during the winter
heating season. This label displays U-Factor in U.S. units. Labels on products sold in
markets outside the United States may display U-Factor in metric units.

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 Solar Heat Gain Coefficient (SHCC) measures how well a product blocks heat from the
sun. SHGC is expressed as a number between 0 and 7. The tower the SHGC, the better a
product is at blocking unwanted heat gain. Blocking solar heat gain is particularly
important during the summer cooling season.
 Visible Transmittance (VT) measures how much light comes through a product. VT is
expressed as a number between 0 and 1. The higher the VT, the higher the potential for
daylighting.
 Air Leakage (AL) measures how much outside air comes into a home or building
through a product. AL rates typically fall in a range between 0. 1 and 0.3. The lower
theAL, the better a product is at keeping air out. AL is an optional rating, and
manufacturers can choose not to include it on their labels. This label displays AL in U.S.
units.Labels on products sold in markets outside the UnitedStates may display AL in
metric units.
 Condensation Resistance (CR) measures how well a product resists the formation of
condensation. CR is expressed as a number between ^ and 700. The higher the number,
the better a product is able to resist condensation. CR is an optional rating, and
manufacturers can choose not to include it on their NFRC labels.

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Self – Check – 2
Part I: Say true or false

1. Suction cups can essentially give glass some handles for you to hold.
2. Glass Transport is not a great piece of lifting equipment used to lift and move glass.
3. Vacuum pump suction cups are a great way to add that handle to some glass but with the
help of glass vacuum lifters.

Part II: Fill the blank space

1. __________________________measures how well a product resists the formation of

condensation.
2. __________________measures how much outside air comes into a home or building
through a product.
3. ___________________ measures how much light comes through a product.
4. ___________________ measures how well a product blocks heat from the sun.
5. ___________________measures how well a product prevents heat from escaping a home or
building.

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Unit three: Working area conditions and restraints
This learning unit is developed to provide the trainees the necessary information regarding the
following content coverage and topics:
 Difficulties
 Covering fixtures and fittings
 Finished work correction
This unit will also assist you to attain the learning outcomes stated in the cover page.
Specifically, upon completion of this learning guide, you will be able to:
 Understand Difficulties
 Conduct Covering fixtures and fittings
 Perform Finished work correction

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 3.1. Difficulties

Problems after double glazing was installed

So it's revealed that 18% (the majority of unhappy customers) had issues with the double glazing
after it was installed, and they fall into the following 6 areas:
Windows/doors becoming difficult to open/close (30%)
This is usual for a fresh installation and should ease up with time, however if they are really just
too stiff, or if they become stiff that you’re worried about the wear and tear of your handle, then
there are a few things you can do to make life easier. Firstly, try and use lubrication to ease the
tension on the hinges such as oil or WD40 - failing that you may want to adjust some screws but
this is best done with guidance so be sure to contact the supplier for advice and ensure you don’t
do anything that could affect your guarantee.
Windows/doors dropping over time so that they don’t fit as well (20%)
This is likely to be down to a lack of detail provided by the installer, or the quality of the
materials used by the manufacturer. You’ll be glad to know that we ensure a premium quality
finish in terms of both the manufacturer's product including screws, hinges and seal etc, along
with the professional standard of installation we offer. Go browse our check trade profile to find
our 450+ outstanding reviews!
Locks not working (15%)
Often if the locks on your double glazing window aren’t working, the chances are that they never
did! Locks are usually overlooked as a minor detail, as long as the hinge is smooth and handles
function well, people forget to give their window lock a quick check - so remember to do this
while you installer is there so you don’t have to rebook for lock repair. Or alternatively, choose a
glazing installer like Window SOS, who double checks every part of the installation prior to
signing it off!
Glass steaming up/ problems with condensation (14%)
This is a very common issue that people get with double glazing and is mostly preventable,
however it is also mostly down to installer error or a lack of maintenance. Discover some of the
best ways to maintain your windows and prevent condensation in our winter blog post!

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Fact: Over 90% of windows that become misted are south-east to south-west facing, this is due
to the fact that the sun rises in the east and sets in the west, providing the greatest change in daily
temperature, and expanding the seal/panes more dramatically than other windows in the house.
Seals around the door/ window failing (12%)
This can occur even without causing condensation to build up inside until later down the line, but
even if that time never comes you can be sure that energy bills are being increased slowly with
the reduced efficiency of your airtight seal. This can happen if you’ve allowed moisture to build
up and set into the seal causing it to rot, and eventually breaking, so be sure to clean with soapy
water and dry if this happens regularly, or get some ventilation installed. The other common
cause would be a fault in the seal provided, for example, if it has received a puncture in transit -
however in our case, you can guarantee that this would be assessed by our team before installing.
Double glazing cracking or shattering (4%)
This is most common with the taller, long shaped windows, and is down to the pressure of the
inert gas within the panes, along with the climate on both sides of the window. So let's say
you’re living in a cold region with tall windows that face the sunrise/sunset, your windows may
be at risk of a spontaneous stress crack due to the building pressure within. There’s not much that
could be done in this case other than ensuring you have used a professional installer like
ourselves who pay extra attention to detail, as well as taking extra precautions such as ventilation
and keeping the seal free from dampness.
Had problems with double glazing installation
It was reported that 10% of customers had a problem with the actual installation process, which
falls into the following areas:
Windows didn’t fit as well as they should (27%)
As mentioned before, fixing stiff window hinges is best done with guidance rather than just
attacking it yourself, however always be sure to test your windows before the installer leaves,
and get them to rectify the installation before they sign the job off. However choosing us to
install your double glazing, is choosing a transparent service, whereby we’re not happy unless

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you’re happy with our installation, so there’s little chance you’ll have this problem with our
professional installers.
Installation took longer than planned (25%)
Timekeeping is important when it comes to working on your home, we understand that life
doesn’t just stop for the installer, and if there’s one thing you can’t do when installing new
windows is to rush - which is why punctuality is a priority to us. If ever there's a time where we
have gone over schedule, we can assure it’s down to either the extra attention to detail required,
or the time we spend making the place spotless for when we leave.
Panes or parts were in the wrong position (20%)
Things like this come down to whether you chose Graham the local glazer, or went with a
reputable company like Window SOS, and annoyingly, unless you know what you’re looking
for, you might not even realise things have been installed incorrectly until much later down the
line. Don’t be one of these people, ensure you contact a company that has a good amount of
years under their belt, as well as a large amount of positive reviews, a product guarantee, and the
necessary certification like FENSA certificates.
18% – Work started later than planned
Sometimes things just don’t go to plan on the day, and things can take a little longer to ensure we
take the sufficient level of detail when installing windows. Arriving on time is the first step to
completing the job on time, so you’ll be glad to know punctuality is highly valued by our team!
15% – Installers left a mess in home
By making timekeeping a priority from the get-go, we find there’s always enough time for our
team to leave the place exactly how they left it - with the exception of a sparkly new window!
Every member of our team ensures a clean and safe space during and after the job is carried out,
we wish we could say the same about the inside of their work vans, but we’re not so sure!

3.2. Covering Fixtures and Fittings

Glass fittings are very popular in today’s architecture and can be seen in various places like
Malls, Hotels, Offices, Airports, etc. The glass fittings are elegant in design and give

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transparency which provides a brilliant look in the overall architecture. There are different types
of accessories we use in glass fittings like hinges, connectors, patch fittings, etc.

Different Types of Hardware Fixtures Used in Glass Fittings

These are the complete list of different types of hardware fixtures that are used in the glass
fittings

 Glass Hinges

The Glass Hinges are used to fix two glasses in a particular form. These hinges are made-up of
high grade steel and require a minor guidance to fit on the glass. Some popular brands like
Dorma, Zaha, Doset etc. are available at Industrybuying on very nominal prices.

 Glass Connectors

Glass connectors seem like glass hinges and come in different types like glass to glass and glass
to wall types. These connectors are basically used at the time of adding multiple glasses in a
straight form. They come in various shapes like rectangle and round shapes and in various angles
of positioning like 90 degree and 180 degree.

 Patch fitting

Patch fittings are a frame-less glass fixing, which evolved as modern interior and exterior design
architecture option for commercial and residential purpose. Patch fitting concepts are a perfect
mix of toughened glass and glass hardware accessories. The toughened glasses are designed for
patch fittings concept with tailor made glasses.
Cut-outs and holes are given to fix the glass architectural hardware patch fittings whereas the
frame-less patch fittings of glass doors act as security control in major interior and exterior glass
frames. In patch fitting doors, some hardware is used like top , bottom patch fittings, patch
fittings lock, clamps and lock. Some excellent glass design can be made with the help of frame-
less patch fittings widely used for glass partition work in interior and exterior concept.

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In patch fittings hardware is made of forged brass and 316 stainless steel (SS) cover plates. Patch
fittings is the best concept available till date with many designing features available for the
architecture and interior designers. The glass partition architecture is one of the premier
replacement for all other partition works.
Apart from wall glass fixing, glass partition can be used as roof partition and floor partition
works involving various hardware fixtures and models to suit almost all the remarkable
architecture. In upcoming days glass partition architecture will dominate the rest of the partition
work and the complete building architecture work can be glass made with the emergence of glass
partition design.

 Spider fittings

Spider fittings are quite popular in glass fittings in terms of safety and security for the end-users.
Various toughened glass thicknesses can be used in spider fittings like 12mm toughened glass,
15mm toughened glass and 19mm toughened glass panels. The body support for the spider
glazing fittings can be taken from the architecture of the building and for the larger elevations
structural support should be created with mild steel or high-grade stainless steel.
In the spider glazing fittings, a glass of15mm is used as dead weight and pressure withstanding
force. Some Popular types of spider glazing fittings are available in 4-way spiders, 2-way spiders
and single way spider fittings to facilitate various spider glazing fittings design architecture.

Which One to Choose Between the Different Types of Fixtures

With a choice of color and many different types of accessories, including glass door hinges, glass
clamps and glass connectors, they are prevalent in making your interiors impressive. The door
hinges should be sturdy and secure with long screws but for added security hinge bolts help
reinforce the hinge side of a door against force. Glass door accessories are used widely as glass
does not rust or corrode and is incredibly durable as well as extremely easy to clean.

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 3.3. Finished Work Correction

Follow the procedure below for reglazingunits with Structural Glazing Sealant

Reglazing Procedure

1. Perform a field adhesion test to confirm the adhesion of the existing silicone to the
substrates. If poor adhesion is observed, contact your Representative immediately.
2. Deglaze the area. Depending on the joint design, this may require specially designed
tools or piano wire to cut behind the silicone.
3. Cut away the silicone, leaving a thin film (approximately 0.02-0.04 inches/0.5-1 mm
thick) of adhesive on the frame. Do not damage the surface finish of the substrate.
4. Clean the residual sealant with solvent using the ‘two-cloth’ cleaning technique described
previously. If fresh sealant will be applied immediately after cutting the cured sealant,
then cleaning of the residual cured sealant may not be necessary.
5. Structural Glazing Sealant will adhere to the fresh cut surface of the original cured
sealant without primer.
6. The silicone may absorb some solvent. Allow this solvent to evaporate so that the
existing cured sealant is completely dry before applying additional sealant.
7. If new or exposed framing material (such as anodized aluminum or PVDF coated metal)
will be part of the newly installed structural joint, the surface should be cleaned and
primed according to original test recommendations. In absence of testing
recommendations, field adhesion testing may be needed to determine the appropriate use
of primer.
8. Clean the new glass or panel and setin place. Install temporary fasteners.Mask the joint.
9. Fill the joint with a bead of Structural Glazing Sealant andtool the sealant.

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Self-Check – 3

Part I: Fill in the blank space

1. __________________ are quite popular in glass fittings in terms of safety and

security for the end-users.
2. _________________ are a frame-less glass fixing, which evolved as modern
interior and exterior design architecture option for commercial and residential purpose.
3. ________________ seem like glass hinges and come in different types like glass
to glass and glass to wall types.
4. ___________________ are used to fix two glasses in a particular form.

Part II Explain the following Problems after glazing was installed

1. Windows/doors becoming difficult to open/close

2. Windows/doors dropping over time so that they don’t fit as well
3. Locks not working
4. Glass steaming up/ problems with condensation

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5. Seals around the door/ window failing
6. Double glazing cracking or shattering
7. Windows didn’t fit as well as they should
8. Installation took longer than planned
9. Panes or parts were in the wrong position

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Unit four: Glazing
This learning unit is developed to provide the trainees the necessary information regarding the
following content coverage and topics:
 Frame preparation
 Glass fixing
 Cladding fitting

 Cleaning

This unit will also assist you to attain the learning outcomes stated in the cover page.
Specifically, upon completion of this learning guide, you will be able to:
 Frame preparation
 Glass fixing
 Cladding fitting
 Cleaning

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 4.1. Frame Preparation

All framing shall be checked prior to glazing to make certain that the opening is square, plumb,
and secure in order that uniform sealant bite, face and edge clearances are maintained. Inspect all
butt and miter joints. If these joints are open, they shall be sealed prior to glazing using a sealant
confirmed to be compatible with the structural silicone sealant. Maintain minimum edge
clearances between glass and sash, as outlined by the glass manufacturer, and sealant contact
depth (sealant bite) as recommended by Tremco for this specific project.

Creating aluminium doors and windows requires careful measurement, precise cutting, and
skillful assembly. Follow this step-by-step guide to successfully fabricate your own aluminium
doors and windows:
i. Measure and Plan: Begin by measuring the dimensions of the opening where the door
or window will be installed. Take accurate measurements of the height, width, and depth.
Use these measurements to determine the size of the aluminium profiles needed.
ii. Cut the Aluminium Profiles: Using a cutting machine or saw, carefully cut the
aluminium profiles according to the measurements taken in the previous step. Ensure
clean and precise cuts to ensure proper fitting and alignment.
iii. Assemble the Aluminium Profiles: Take the cut aluminium profiles and assemble them
according to the design and type of door or window being created. Use screws or
connectors specifically designed for aluminium profiles to securely join the pieces
together.
iv. Install Hinges, Handles, and Locks: Once the aluminium profiles are assembled, it’s
time to install the necessary hardware. Attach hinges to the door or window frame,
ensuring they are properly aligned and securely fastened. Install handles and locks
according to the manufacturer’s instructions.
v. Additional Steps for Specific Types of Doors and Windows: Depending on the type of
door or window being fabricated, there may be additional steps or considerations:

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  Sliding Doors: Install the sliding mechanism and ensure smooth operation. Apply
weather-stripping to enhance insulation.
 Casement Windows: Install the crank mechanism for opening and closing the
window. Check for proper sealing when closed.
 Double-Hung Windows: Install the counterbalance mechanism to allow for easy
opening and closing of the sashes.
Ensure that all components are properly aligned, securely fastened, and operate smoothly before
proceeding with the installation.

By following these step-by-step instructions, you can successfully create your own aluminium
doors and windows. Remember to prioritize accuracy, precision, and safety throughout the
fabrication process.
Tips for Quality and Precision
When it comes to fabricating aluminium doors and windows, achieving high-quality and precise
results is crucial. Here are some tips and techniques to ensure your fabrication process meets the
highest standards:
Accurate Measurements and Proper Alignment: Before starting any fabrication work, take
precise measurements of the door or window opening. Use a reliable measuring tool, such as a
tape measure or laser level, to ensure accuracy. Double-check your measurements to avoid any
errors that could lead to ill-fitting doors or windows.
In addition to accurate measurements, proper alignment is essential for a seamless installation.
Use a square or level to ensure that the frames and profiles are aligned correctly. This will help
prevent any issues with functionality and aesthetics.

Use Quality Materials and Tools: The quality of the materials and tools you use directly
impacts the final outcome of your aluminium doors and windows. Invest in high-quality
aluminium extrusions/profiles from reputable suppliers. These profiles should be durable,
corrosion-resistant, and meet industry standards.

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Similarly, ensure that you have the right tools for the job. This may include cutting and crimping
machines, measuring tools, screws, hinges, and handles. Using reliable and well-maintained tools
will contribute to the precision and longevity of your fabricated doors and windows.
Follow Safety Guidelines and Wear Protective Gear: Working with aluminium doors and
windows involves various processes that may pose safety risks. It is crucial to prioritize safety by
following proper guidelines and wearing appropriate protective gear.

When cutting or crimping aluminium profiles, wear safety goggles, gloves, and a dust mask to
protect yourself from metal shavings and debris. Additionally, ensure that your workspace is
well-ventilated to minimize exposure to fumes or dust particles.
Furthermore, follow safety guidelines for operating machinery and tools. Familiarize yourself
with the manufacturer’s instructions and take necessary precautions to prevent accidents or
injuries.
By implementing these tips and techniques, you can ensure that your aluminium doors and
windows are fabricated with precision and meet the highest quality standards. Remember to
prioritize accuracy, use quality materials and tools, and prioritize safety throughout the
fabrication process.

4.2. Glass Fixing

 Temperature conditions during glazing must be within the limits required by the sealant
and gasket manufacturer(s).
 Measure glass for proper dimensions.
 Ensure the glass edges are free of damage (chips, shells, starts, etc.) and that the cut edge
qualityis good. Glass with poor edgecondition can lead to stresscracking and failure, even
after thewindow has been in service. Glasswith questionable edge conditionsshould be set
aside for inspectionby the glass manufacturer orfabricator.
 Do not impact the glass against the framing during installation. This can cause edge
damage. Pocket, or ‘Flush Glazing’, is particularly susceptible to glass edge damage from

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 impacting the frame and requires precise sizing of the glass and extra care during
installation.
 Always use suction cups to shift a light of glass within the opening. Raising or drifting
the glass with a pry bar can cause edge damage.
 Some insulating and laminated glass fabricators place temporary glazing instruction
labels on their product such as ‘Glaze This Side In’ and/or ‘Glaze This Edge Up’. It is
important field supervision instruct installers to adhere to these instructions. Some
products are provided with specific performance characteristics (energy, security) that
will not perform appropriately if not properly installed.
 When the glass is located in place, sufficient pressure must be placed against the glass as
it is lowered onto the setting blocks to properly place the gasket, sealant or tape under
pressure or compression. Uneven or point pressures on glass can result from improper
positioning of the glass on the setting blocks, which can in turn result in insufficient
weather seal and/or glass breakage.
 Rubber
Using the right glazes and rubber parts is required for performing their base function of shedding
and draining water, supporting the pressure points of the glass, and seal against air and water
leaks. The main benefit this provides is better performance of glass and increasing energy
efficiency.
Installation instructions:
 Remove a piece of wedge rubber from your window.
 Match the thickness with a sample as best as you can. If particularly dry and old,
you may need a sample slightly bigger than original.
 Spray the area with a little soapy water to lubricate for ease of insertion.
 Wedge rubber should fit snugly. Do not force the wedge rubber into place as it
may break the glass.
 Sealants
Glass glue is a material for bonding and sealing various glasses with other substrates. There are
two main categories: silicone and polyurethane (PU). Silicone glue is divided into acid glue and

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neutral glue, structural glue, weather glue and so on. Polyurethane glue is divided into bonding
glue and sealant.
Structural Sealant Glazing or SSG hereafter, is the work result of bonding glass or other
materials to curtain wall or other framing members utilizing a high-strength, high-performance
silicone sealant specifically designed and tested for SSG. In SSG applications wind, seismic,
dead, and live loads are transferred from the glass lite or panel by the structural silicone sealant,
to the supporting framing mullions.

4.3. Cladding Fitting

Cladding is the application of one material over another to provide a skin or layer. In
construction, cladding is used to provide a degree of thermal insulation and weather resistance,
and to improve the appearance of buildings. Cladding can be made of any of a wide range of
materials including wood, metal, brick, vinyl, and composite materials that can include
aluminium, wood, blends of cement and recycled polystyrene, wheat/rice straw fibres.
Outside-glazed and inside-glazed
One of the factors that determines the cross-sectional shapes of mullions and rails is whether the
glass in the wall is to be installed from the outside or the inside of the building, referred to,
respectively, as
• Outside-glazed curtain walls
• Inside-glazed curtain walls

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Figure 4.1: Typical connection between rails and mullions of a stick-built glass curtain wall.
In an outside-glazed wall, the glass panes are installed from the outside of the building by
workers standing on a scaffold or staging. This method of installing glass is less efficient and
more expensive due to the cost of scaffolding or staging. It is generally used for low- to midrise
buildings. The glass in an outside-glazed wall can be secured in two ways:
• Pressure plate–captured glass (Figures4.2 to 4.6)
• Structural silicone sealant–adhered glass (Figure 4.7)
In an inside-glazed wall, the glass is installed by workers standing on the appropriate floor of the
building. The system is more efficient because it does not require scaffolding or staging. It is the
system of choice for high-rise buildings. However, the cross-sectional shapes of mullions and
rails for the inside-glazed system are more complex than the corresponding shapes for the
outside-glazed system.
Outside-Glazed Walls (Pressure Plate–Captured Glass)
In an outside-glazed curtain wall, the glass is held by horizontal and vertical pressure plates,
which are fastened to the mullions and rails with screws. A plastic insert is used between

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thepressure plate and the mullion (or the rail), which functions as a thermal separator. The
pressure plates are finally covered with Snap-on covers, Figure below.

FIGURE 4.2: (a) Anatomy of an outside-glazed glass curtain wall (pressure plate–captured
glass).

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Figure 4.3: (b) In fastening the pressure plates to curtain wall framing members, the glass is
temporarily held by small pressure plate members. After several glass panes are in position, the
temporary pressure plates are removed and replaced by full-length pressure plates.

Because the covers are the only externally visible part of the curtain wall frame, they have a
major influence on the curtain wall’s appearance. The covers can be profiled into various shapes,
Figure below.

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Figure 4.4: A custom cover and custom mullion for an outside-glazed glass curtain wall.

The exterior and interior gaskets should prevent water from leaking through the wall. However, a
curtain wall system typically includes accommodations for the drainage of water, should it
penetrate beyond the gaskets. This is accomplished through drainage weep holes in the pressure
plates and the covers. Thus, in a typical curtain wall, each glass-pane frame is drained
independently. Figure below shows typical sections through a pressure plate–captured outside-
glazed curtain wall.

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Figure 4.5: (a) typical details of an outside-glazed glass curtain wall (pressure plate–captured
glass). Aluminum sections used in the details are by Vistawall Architectural Products. Other
manufacturers provide similar sections.

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FIGURE 4.6: (b) Typical details of an outside-glazed glass curtain wall (pressure plate–captured
glass). Aluminum sections used in the details are by Vistawall Architectural Products. Other
manufacturers provide similar sections.
Outside-Glazed Walls (Structural Silicone Sealant–Adhered Glass)
Another version of an outside-glazed curtain wall is one in which the glass is held by structural
silicone sealant. In this type of system, the vertical edges of a glass pane are adhered to the
mullions with beads of structural silicone sealant. The mullions in this wall aresimilar to those of

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an outside-glazed wall without the mullion nose. The horizontal edges of the glass are supported
on rails and anchored to them through standard pressure plates.
Inside-Glazed Walls
In an inside-glazed wall, pressure plates are not used. Therefore, the aluminum curtain wall
sections are different from those used for the outside-glazed wall. These sections include glazing
pockets—in both mullions and the bottom rail—of an opening. The top rail of the opening is
open and has no glazing pocket. The openness allows the glass to be inserted in the opening.
After the glass is inserted, a glazing stop is snapped on the top rail of the opening from the
inside.

4.4. Cleaning

Cleaning aluminium window and door frames does require a bit of thought, because of the
powder coated finish that you don't want to damage with over vigorous cleaning. Even if
unpainted, you do not want to scratch the frames. That's why we recommend a simple, gentle and
regular cleaning method that avoids ingrained grime that you may want to scrub or scour.
4.4.1. Glass
This information is offered as a general guide only. Specific advice on the cleaning of glass
should always be sought from the glass manufacturer or professional window cleaner before any
glass cleaning is undertaken.
 To clean most glass, simply wipe over the surface with a few drops of methylated spirits
on a damp cloth and then polish the surface dry with a lint free cloth.
 Ensure that all the cleaning cloths are free of any abrasive substances.
 Avoid causing extreme temperature changes as this may lead to thermal fracture of the
glass (do not direct hot or cold water onto glass).
Some glass types, particularly Low-E varieties, may have special cleaning instructions. In these
cases, always follow the manufacturers’ recommended instructions to avoid any damage to the
glass surface.
NOTES

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 Glass should be cleaned using onlycleaning materials that are free ofgrit and debris (to
avoid scratchingand marking of the glass surface).
 Only detergents and cleaningsolutions that are recommended forcleaning glass should be
used.
 Extra care is required where highperformance reflective glass isinstalled. The coated
surface can besusceptible to stains and scratchesand therefore requires vigilanceduring
the entire constructionprocess.
 Glass installations which areadjacent to concrete (for example,concrete slab floors)
require extracare and cleaning due to theabrasive nature of concrete dust.
 The cleaning of toughened glassrequires special care. The glasssurface opposite the
standardscompliance stamp may, as aconsequence of the manufacturingprocess, have
‘pickup’ on thesurface. ‘Pickup’ is a deposit ofvery small particles of glass whichare
fused to the glass surface. Acleaning method which does notdislodge these particles
should beemployed otherwise scratching ofthe glass surface may result. Bladesor
scrapers have been known todislodge ‘pickup’ from the glasssurface. A soft cloth should
beused.
 Do not use cleaners that contain hydrofluoric or phosphoric acid as they are corrosive to
the glass surface.
 Do not clean the glass when the glass is hot or in direct sunlight.
 Do not allow cleaning solutions to contact the edges of laminated glass, Insulating Glass
Units or mirrors.
 Do not store or place other material in contact with the glass. (This can damage the glass
or create a heat trap leading to thermal breakage).
 Abrasive cleaners, powder based cleaners, scouring pads or other harsh materials should
not be used to clean windows or other glass products.
 Some tapes or adhesives can stain or damage glass surfaces. Avoid using these materials
unless they are known to be easily removed.

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 4.4.2. Frames
It’s natural for windows and doors to gather dirt and dust over time, even aluminium ones!
Though aluminium frames are relatively low maintenance and longer lasting than other
materials, it’s essential to keep them clean to avoid any damage or need for repair. But it’s also
important to follow the right steps to clean your doors and windows without causing any
damage.
The methods you use to clean your aluminium windows could differ depending on how old they
are and their exact finish. Aluminum frame windows that are newer won’t need as vigorous a
clean as older aluminium windows that haven’t been painted.
Do you have an aluminium window with a powder coated finish? This is a great finish for
windows as it is long lasting and doesn’t corrode easily. It also doesn’t require very frequent
cleaning, saving you lots of time and effort in the long run.
If your aluminium window has a finish that is powder coated, it is best to clean it at least once
every 3-4 months to keep it looking as good as new. The best way to clean it is as below:
 Start your cleaning from the top and work your way down to the bottom of the window.
This will help prevent any dirt spilling down into areas you’ve already cleaned.
 To wash the aluminum frames, simply use soapy and warm water. There is no need to use
cleaning agents laden with chemicals, as the harshness of such products could potentially
damage the finish of your windows.
 Dip a soft cloth, ideally made of a microfibre material, into the soapy water, and start the
cleaning process.
 Perform a slightly more intense cleaning action on any areas with stubborn dirt or marks,
but there is no need to be too vigorous as aluminium windows are generally easy to clean.
 Remember to clean any hidden spots and hard to reach places. Dirt and debris can often
build up over time in all the little nooks and crannies of windows, making window
drainage a little more difficult.
 Once you’re satisfied that you’ve given your aluminium windows a thorough clean, dry
them using a soft clean cloth for a sparkling finish.

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When cleaning aluminium windows that are older, the cleaning process needs to be a little more
intense and more frequent. The lack of powder coated finish on older aluminium windows means
that they’re exposed and vulnerable to weather elements, and more prone to wear and tear. You
may even find some areas that need repair while you’re cleaning, so it is a good time to
thoroughly inspect your windows for any leaks or damage.

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Self-Check – 4
Part I: Choose the correct answer
1. In a stick-built glass curtain wall, the mullions are erected first and the rails are inserted
between them.
A. True B. False
2. A glass curtain wall in which the glass is pressure plate captured is glazed from the
A. Building’s interior. C. Either (a) or (b).
B. Building’s exterior.
3. As shown in this text, a glass curtain wall in which the glass is structural silicone adhered is
glazed from the
A. Building’s interior. C. (A) or (B).
B. Building’s exterior.
4. In a glass curtain wall with pressure plate–captured glass, there are
A. No covers. D. Covers only in the vertical direction.
B. Covers in both horizontal and vertical
directions.
C. Covers only in the horizontal direction.
5. As shown in the text, a glass curtain wall with structural silicone–adhered glass
A. Has no exterior covers.
B. Has exterior covers in both horizontal and vertical directions.
C. Has exterior covers only in the horizontal direction.
D. Has exterior covers only in the vertical direction.
6. A typical glass curtain wall is provided with weep holes to draininfiltrating water even
though it is sealed from both the inside andthe outside with gaskets or tapes.
A. True B. False

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Part II: Fill in the blank space
1. __________________ is the application of one material over another to provide a skin or
layer.
2. __________________ is a material for bonding and sealing various glasses with other
substrates.
3. In __________________, the glass is installed by workers standing on the appropriate
floor of the building.

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Operation sheet –4.1: Exterior Wall cladding
Operation Title: Exterior cladding

Purpose:To perform Aluminum cladding

Conditions or situations for the operations:

 Safe working area
 Properly operated tools and equipment
 Appropriate working cloths fit with the body
Tools required
 Aluminum Cladding Rivets
 Corner Braces
 Work Procedure
 Clips for Supporting Aluminum Cladding Systems
 J-starters and Trims
 Collet Holders
 Different Aluminum Extrusions
Aluminum cladding procedures
1. Use appropriate screws and ensure that the head does not exceed the fixing area
2. Aluminium expands and contracts with temperature changes, therefore it is essential that
fixings are in the centre of the pre-slotted slots.
3. When cutting board, starters or trims, always allow for a 5mm clearance under the
adjacent trim for expansion and contraction.
4. When installing on to steel support sub frames, ensure to use a non-compressible
separation tape between the dissimilar metals.
5. Use appropriate cutting saws suitable for aluminium and ensure they are sharp to reduce
the chance of burrs.

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6. To avoid damaging the finish, always use care and a piece of timber with a rubber mallet
to guide the profiles together, if required.
7. Ensure you are using the correct starter by choosing either the horizontal or the vertical
starter dependent on the board orientation.
8. Level and screw off the starter using the pre-slots at a maximum of 450mm centres in the
centre of the slot.
9. Position the first board into the Starter and ensure that the board is completely seated
prior to fixing it off, again using the pre-slots at a maximum of 450mm centres in the
centre of the slot.
10. Continue the installation whilst ensuring that each board is completely seated into each
other prior to fixing them using the pre-slots at a maximum of 450mm centres in the
centre of the slot.

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LAP test – 4.1

Given all the necessary materials and preform the following task

Task 1: perform Aluminum cladding

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Unit five: Completion
This learning unit is developed to provide the trainees the necessary information regarding the
following content coverage and topics:
 check up
 Documentation

This unit will also assist you to attain the learning outcomes stated in the cover page.
Specifically, upon completion of this learning guide, you will be able to:
 Perform check up
 Perform Documentation

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 5.1. Check Up

As a final check of ultimate sealant adhesion, the following field adhesion test should be
conducted by the glazier:
 Visual inspection of structural glazing system and structural silicone sealants. Observe any
indication of sealant adhesion loss or sealant physical property change.
 Hand pressure on accessible sealant joints to verify sealant adhesion
 Depending on the sealant used, let cure for 14 to 21 days and then conduct hand peel test.
 Make a knife cut horizontally from one side of the joint to the other.
 Make two vertical cuts approximately two inches long at the sides of the joint meeting the
horizontal cut at the top of the two-inch cuts.
 Grasp the two-inch piece of sealant firmly between the fingers and pull down at a 90° angle
or more and try to pull the uncut sealant out of the joint.
 If adhesion is good, sealant should tear cohesively or be difficult to remove adhesively
from the substrate.
 Sealant may be replaced by applying additional sealant in the same manner it was
originally installed.

5.2. Documentation

The sealant user is responsible for developing proper quality control documentation for their
project.
Traceability documentation which allows each production unit to be precisely correlated to a
specific date, time and location of production. All production units must be numbered so that
they can be specifically linked to the quality control logs. The position of each panel on the
building should be marked on the elevation drawing so that it can be easily identified if required.
This traceability documentation is critical in the event that a problem needsto be investigated on
a project.

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Documentation needs to be accurate and free from errors. Wrong documentation is often worse
than no documentation. Documentation needs to be correct over time, reflecting changes
performed upon code, infrastructure or interfaces of the system. Documentation needs to be
understood by the target audience.
The following overview of documentation requirements
Correct: Technical documentation absolutely needs to be correct, “free of mistakes or errors and
strictly adhere to fact and truth.”
Current:Change is normal: Development teams have to implement new features or
optimize/fix/change existing ones. They have to adjust the system to cope with changes in
infrastructure, updates in frameworks or 3rd-party products. Teams have to update their systems
to reflect changes in external infrastructure, data formats or a plethora of other aspects that might
change during the lifetime of any software system.
Understandable: Although understand-ability seems like a trivial and basic requirement for
technical documentation, it is pretty hard to achieve and really easy to get wrong.
Relevant: Documentation shall serve the purposes of its target audience. They have specific
goals or tasks that can be enabled or supported by technical documentation.
Referenceable: Referenceable elements can be uniquely identified in the context of your
documentation. Instead of writing “see the diagram below” or “the table above”, you should
strive for “see diagram 5.2” or “the table 3.1”. You can chose any numbering or referencing
scheme you like, but you should use it consistently.
Proper language: Your target audience shall have no reason to complain about spelling or
grammar mistakes, but shall instead focus on content. Proper language will also improve
readability and understandability.
Maintainable: The structure and organization of technical documentation should be optimized
for maintainability - so that keeping the documentation current despite frequent changes becomes
as easy as possible.
As already mentioned above, many aspects of systems change - requirements, source code,
configuration, deployment, operations, external interfaces, etc. These changes shall be easy to

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incorporate into the technical documentation, therefore maintainability is an important
requirement.
Easy to find: Finding information is essential. The organization, retrievability, and visual
effectiveness of information contribute most to whether users can find the information that they
need.
Version controlled: As there will be several people actively contributing to technical
documentation, you should version-control its artifacts similar to source code.
Use appropriate tools: You need a toolchain that satisfies a number of requirements.
Continuously updated: Deferring documentation to later is like procrastination, or saying “I’ll
start healthy living next week.” Start right now, in small chunks.

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Self-Check – 5
Part I: Say true or false

1. Visual inspection is not final check of ultimate sealant adhesion of structural

glazing system and structural silicone sealants.
2. Hand pressure is on accessible sealant joints to verify sealant adhesion for final
check.
3. If adhesion is good, sealant should tear cohesively or be difficult to remove
adhesively from the substrate.
4. Sealant may be replaced by applying additional sealant in the same manner it was
originally installed.
5. Sealant user is responsible for developing proper quality control documentation.
Part II: match part column “B” column “A”

Column “A” Column “B”

A. Improve readability and
1. Correct
understandability
2. Current
B. Technical documentation
3. Relevant
absolutely needs to be correct
4. Referenceable
C. Update their systems to
5. Proper language
reflect changes in external
6. Maintainable
infrastructure, data formats
D. Documentation should be
optimized for maintainability
E. Documentation shall serve
the purposes of its target audience
F. Referenceable elements can
be uniquely identified in the context
of your documentation

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Reference

Edward Allen, Joseph Iano - Fundamentals of Building Construction Materials and Methods-
Wiley (2008)
Eva Kultermann, William P. Spence - Construction Materials, Methods, and Techniques_
Building for a Sustainable Future-Cengage Learning (2021)
G.C. Sahu_ Joygopal Jena - Building Materials and Construction-MC GRAW HILL INDIA
(2015)
https://civil4m.com/threads/work-procedure-of-structural-glazing.1245/
https://klaasmerk.ee/en/guides/post-glazing-defects/
https://www.ggrglass.co.uk/blog/glass-lifting-equipment-you-need-to-lift-
glass/#:~:text=For%20lifting%20and%20lowering%20much,cords%20to%20help%20them%20
operate.
https://www.ggrglass.co.uk/blog/how-to-transport-and-install-
glass/#:~:text=Moving%20Glass%20Safely&text=The%20best%20way%20to%20transport,still
%20proceed%20with%20your%20project.
https://www.innoq.com/en/articles/2022/01/principles-of-technical-documentation/
Medan L Mehta Ph.D., Walter L Scarborough, Diane L Armpriest - Building Construction_
Principles, Materials, & Systems (2nd Edition)-Pearson (2012)
Michael S. Mamlouk, Jogn P. Zaniewski - Materials for Civil and Construction Engineers-
Pearson Canada (2016)
O'Regan, C - Structural use of glass in buildings-Institution of Structural Engineers (2014)
Patterson, Mic - Structural Glass Facades and Enclosures _ a Vocabulary of Transparency-John
Wiley & Sons (2011)
Sidney Levy - Construction Databook Construction Materials and Equipment-McGraw-Hill
Professional (2010)

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 Developers Profile
N Name Qualification Field of Study Organization/ Mobile E-mail
o (Level) Institution number
1 WAKWEYA TOLERA A Industrial Wolisso PTC 0911752444 [email protected]
engineering
2 MUSTEFA AMAN A Manufacturing Bishoftu PTC 0911364645 [email protected]
engineering
3 JEMAL YIMER A Manufacturing Harar 0912848457 [email protected]
Technology
Management
4 MICHAEL CHALI A Manufacturing Ambo PTC 0911956577 [email protected]
technology
management

Page 74 of 74 Ministry of Labor and Glazing Aluminum Joinery Products Version -1

Skills October, 2023
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Page 75 of 74 Ministry of Labor and Glazing Aluminum Joinery Products Version -1
Skills October, 2023
Author/Copyright