Elevator

Consultant Project Main Contractor
King Khaled Airbase Yuksel
NAME OF PROJECT
King Khaled Airbase
METHOD STATEMENT
FOR
ELEVATORS
Main Contractor: YUKSEL
Sub-Contractor: ThyssenKrupp
TABLE OF CONTENTS
1.0 PURPOSE
2.0 SCOPE
3.0 REFERENCES
4.0 DEFINITIONS
5.0 RESPONSIBILITIES
6.0 COORDINATION WITH OTHER DISCIPLINES
7.0 EQUIPMENT & MATERIALS
8.0 PROCEDURE
9.0 HEALTH & SAFETY
10.0 QC INSPECTIONS
1.0 PURPOSE
The purpose of this Method Statement is to describe the procedure and explain the assembly process of the
ThyssenKrupp Elevators. This process is designed so that it can be assembled by a qualified team of
TECHNICIANS that organize their tasks in parallel. A summary with a description of the sequence of
stages is given in the following pages. Each stage is made up of one or various tasks.
2.0 SCOPE
The scope of this Method Statement covers the said activities at Project, and any such later requirement
incident to this project. The Method Statement shall be considered void for any other facility or installation
unless approval is acquired from the authority specific to that project.
3.0 REFERENCES
3.1 Approved ThyssenKrupp Shop Drawings
3.2 General Contract Documents including the final units specifications
4.0 DEFINITIONS
CONSULTANT :
CONTRACTOR : Yuksel
SUB- CONTRACTOR : THYSSENKRUPP ELEVATORS SAUDI LTD.
ITR : Inspection & Test Request
ITP : Inspection & Test Plan
HSE : Health, Safety & Environment
QC : Quality Control
QA : Quality Assurance
PM : Project Manager
IM : Installation Manager
5.0 RESPONSIBILITIES
5.1 The Project Manager is responsible for overall Site Management, Quality and Safety.
5.2 The Installation Manager is responsible for overall execution of this work; IM shall ensure that the
necessary resources are provided to implement the approved Method Statement and to ensure all
installation staff complies with consultant Quality, Health, Safety and Environmental Management
System requirements.
5.3 The QC Engineer is responsible for ensuring that the work is carried out as per the Method
statement approved by the consultant
5.5 The Site supervisor is responsible for ensuring that the work is carried out as per approved
Drawings and Method Statements.
5.6 The HSE Engineer is responsible for ensuring the activities are carried out as per Project Specific
Safety Rules and Regulations.
6.0 COORDINATION WITH OTHER DISCIPLINES
Daily coordination shall be made with Main Contractor to ensure that all works required for lifts
installation will be carried out according to the overall schedule of works.
Coordination will be made with other sub-contractors through the Main contractor for all MEP
requirements.
7.0 EQUIPMENTS and MATERIALS
Steps Prior to Starting the Assembly
TECHNICIANS must make sure that they have all the documentation, equipment and tools indicated
below. They must also to take into consideration all of the following safety instructions.
Documents
1. Assembly plans
2. Electrical/wiring diagrams
3. List of materials
4. Assembly instructions
Equipment & Tools
As work requires
Individual Safety Equipment
1. Basic safety equipment (overalls, helmets, safety boots, etc.)
2. Harness with fall arrest system
8.0 PROCEDURE
STAGE: 1
ARRIVAL AND ACCOMMODATION ON THE CONSTRUCTION SITE.
STAGE 1
STAGE 2
STAGE 3 At the arrival on site, an introductory meeting will be held with the supervisor or
STAGE 4
STAGE 5 person in charge, in order to establish the various conditions of the construction
STAGE 6
STAGE 7 site and the places where the equipment should be safely stored, as well as
STAGE 8
some of the materials that will be later used. Furthermore, the use of auxiliary
resources (crane, wheelbarrows, etc.) at later stages will also be discussed with
the person in charge.
SAFETY MEASURES
Access the site at the established points, that should be well lit
Obey safety signs
Check the material storage area conditions
Check the conditions and equipment for the unloading of materials
STAGE 2:
CHECKING THE STATE OF THE CONSTRUCTION SITE:
SAFETY PLANS AND MEASURES.
STAGE 1
STAGE 2
STAGE 3 Check that the site conditions correspond with those requested in the plans.
STAGE 4
STAGE 5 To do this, measure the machine room, shaft and pit. Also check the
STAGE 6
STAGE 7 following conditions:
STAGE 8
SHAFT CEILING AND UPPER LEVEL
Three-phase + neutral + earth (380V) power supply with their protections and Single Phase 220V
separate breaker. Hooks for suspending loads as indicated in assembly plan
SAFETY MEASURES
The accesses will be suitable for the weight and dimensions of the parts and shall be free
from obstacles
Check the shaft protections placing the Men at work in shaft sign.
Check the electricity supply protections and the action of the differential protection
SHAFT
Smooth inner walls that are completely level.
Metal bands at the necessary distance marked on the plans to mount the guide rail fastenings. If
greater, check that the metal profiling is in place for the intermediate fastenings.
The necessary dimensions to install the doors, leaving sufficient clearance at the sides and above.
Protection in all the doorways consisting of baseboard, intermediate bar and rails 1 metre above the
level of the finished floor.
Point given by the supervisor to show the level of the finished floor.
PIT
Depth as indicated on the assembly plan.
Waterproofed and clean
Plate perfectly level and smooth
MATERIALS CHECK
STAGE 1 Ensure you have all the elements described below, necessary to assemble the
STAGE 2
STAGE 3 mechanical parts.
STAGE 4
STAGE 5 Guide rails
STAGE 6
STAGE 7
STAGE 8
Fastenings
Machinery and bedplate
Speed regulator and cable
Tension pulley for the reducer
Drive cables
Cable attachments
Car support
Counterweight frame
Outer doors
Counterweights
Car floor
Start-up plate
NB: If anything is missing, immediately inform the person in charge of assembly for it to be replaced without
delay.
STAGE 3:
DISTRIBUTION OF MATERIALS, EQUIPMENT AND TOOLS.
STAGE 1
STAGE 2 Distribute the materials and equipment as follows:
STAGE 3
STAGE 4
STAGE 5
STAGE 6 AT THE UPPER LEVEL.
STAGE 7
STAGE 8
Materials:
Control panel
Two expansion plugs
Tools:
Hoist motor and chain differential
Safety ropes
Weights
Check equipment
Measuring tape
Safety sling
Pole
SAFETY MEASURES
Get as close as possible to the load

Keep your feet firmly on the floor. Find your balance.
Bend your knees.
Keep your back straight
Lid the load using your legs and straight arms.
Avoid twisting the torso.
Take advantage of the objects own weight and reaction.
AT ZERO LEVEL
Materials
Guide Rails: Transport the guide rails to the foot of the shaft and leave them facing it if there
is enough space.
Connections and nuts and bolts.
Fastenings and nuts and bolts.
Tension Pulley: Place it in the pit.
Car support: Take the upper and lower and side beams and put them so that they may later
be assembled on the ground.
Counterweight frame: Operate in the same way as with the car support.
Car floor: Place near the pit.
Fastenings and nuts and bolts: Take the boxes and bags to the pit.
Counterweights
Equipment:
Blockstop
Bevel
STAGE 4:
PREPARATIONS FOR GUIDE RAIL ASSEMBLY:
LEVEL ABOVE PIT
STAGE 1 DESCRIPTION OF THE STAGES:

STAGE 2
STAGE 3 Assemble life line
STAGE 4
STAGE 5
STAGE 6
Installation of the hoist motor
STAGE 7
STAGE 8
Install the electricity supply in the shaft
Installation of the test equipment
Taking measurements
Install the guide rails
Put counterweight frame into pit
Put car support into pit
Assemble car floor as assembly surface
Put guide rails into pit
Install the wedging system
Preparation for the support pull
SAFETY MEASURES
Ensure the portable electric tools are kept in perfect state and are protected.
Check the loading capacity in accordance with the sling configuration.
Do not stand underneath suspended loads.
Use each tool for the purpose for which it has been designed.
PREPARATIONS FOR GUIDE RAIL ASSEMBLY:

FROM PIT TO UPPER LEVEL
STAGE 1 DESCRIPTION OF THE STAGES:

STAGE 2
STAGE 3 Cut variable segments
STAGE 4
STAGE 5
STAGE 6
Assemble counterweight frame
STAGE 7
STAGE 8
Assemble car support
Install connections and guide rail fastenings on car guide rails
Prepare fastenings and take them to the 1st floor
ASSEMBLE LIFE LINE.

STAGE 1 Strap the safety rope hook to the end of the pole with insulating tape.
STAGE 2
STAGE 3
STAGE 4
Before hooking the rope, put on the harness and attach yourself to a
STAGE 5
STAGE 6
safe point in the vicinity of the shaft. If necessary, use the anchor point
STAGE 7
STAGE 8
following standard EN795A1.
Using the pole put it in the central slab of the hook.
With a small pull, unhook the hook from the pole.
Divert the rope to the front of the doors and attach with UNEX type belts
in order to have the rope close to the door to be able to easily grasp it.
INSTALLATION OF THE HOIST MOTOR

STAGE 1 With the same process used to hang the safety rope, hang the inverted chain
STAGE 2
STAGE 3 differential of the corresponding hook.
STAGE 4
STAGE 5
STAGE 6
STAGE 7 Suspend the hoist motor on the main fastening hook of the differential.
STAGE 8
Carry out the electrical installation of the hoist motor and

Check it functions correctly. Leave the safety sling positioned on the hoist motor
(see attached figure).
Operating the differential control chain, lift the whole unit as close as possible to
the hook. To facilitate the optimum functioning of the chain differential, it is
better to throw the machinery in the shaft and pull on the chain from the floor
just below.
Next fasten the safety sling to the door front hook.
INSTALL ELECTRICITY SUPPLY IN THE SHAFT
STAGE 1 From the electrical connections that have been prepared by the contractor at
STAGE 2
STAGE 3 the upper level, or failing this, on one of the floors, connect up 220 V, making
STAGE 4
STAGE 5 sure that the line is protected by a thermo magnetic and differential board. We
STAGE 6
STAGE 7
then throw the tubing carefully down the shaft to the pit without it touching the
STAGE 8 floor of the pit.
MEASUREMENT OF THE SHAFT RUN
STAGE 1 Here we measure the elevator run. For this take the finished floor levels of
STAGE 2
STAGE 3 the first and last stop of the elevator as reference. TECHNICIAN 1 throws
STAGE 4
STAGE 5 the measuring tape in the shaft from the last to the first stop.
STAGE 6
STAGE 7
STAGE 8
TECHNICIAN 2 (who works at zero level) will adjust the measuring tape to
the finished floor level of zero level.
This measurement will later be used to determine the variable segment.
TAKING MEASUREMENTS.
STAGE 1 Go along the shaft from the last stop to the pit taking the measurements
STAGE 2
STAGE 3 as per the GADs.
STAGE 4
STAGE 5
STAGE 6
STAGE 7
STAGE 8
GUIDE RAIL INSTALLATION.
STAGE 1 Check the pit support plate is perfectly level.

STAGE 2
STAGE 3
STAGE 4
STAGE 5 Put the guide rail start-up base on the support plate.
STAGE 6
STAGE 7
STAGE 8
Mark the car guide rail line with a pencil on the start-up base.
Gently tap with the hammer to move the start-up base sideward and make
it coincide with the previously marked line.
Adjust the start-up base in the other direction, analysing the minimum
measurement of the shaft on the wall on the side of the guide rails.
Once we have assembled the guide rail start-up base, carry out the first fastening level.
Put the variable segment of the car guide rail in its housing on the guide rail start-up base with the aid of the
hoist motor. If the variable segment was less than 1.5 metres, connect with a guide rail segment.
Use a chain to put the guide rail in the shaft making a double loop on the guide rail that will be provided with
a connection and a guide rail fastening on its upper part.
This system allows us to unroll the guide rail from below, as once it is supported, the chain will slide along
the guide rail when the hoist motor lowers, and we can access the snap ring to unhook it.
Keep the guide rail in a vertical position and connect its guide rail fastenings at the appropriate height.
Join guide rail fastenings and fastening using their nuts and bolts or clamps.
Do the same with the other car guide rail.
Position the bevel joining both guide rails to keep the distance between the guide rails.
Move the whole unit until positioning it with respect to the plumb.
Carry out the second fastening level from an auxiliary scaffold, wall scaffold or ladders resting in the pit. The
life line and fall arrest system is attached at all times as high as possible.
Put the counterweight guide rails and position them with respect to the car.
PUT COUNTERWEIGHT FRAME IN PIT.

STAGE 1
STAGE 2
STAGE 3 The counterweight chassis is assembled from the previous stages close to the Shaft.
STAGE 4
STAGE 5 Put a sling on the upper beam and hook the hoist motor to it.
STAGE 6
STAGE 7
STAGE 8
With the hoist motor control panel, lift and drag the frame along the floor until
It is hanging inside the shaft. Then, lower the chassis and position it until it is between the
guide rails and lower it onto the buffer.
Install the lower friction clamps from the pit, and the upper ones from a ladder, wall
scaffolds or tubular scaffolds.
Put the counterweights for the putting into operation and door installing.
PUT CAR SUPPORT IN PIT
STAGE 1 Move the car support to the shaft. Place a sling on the upper beam of the support,
STAGE 2
STAGE 3 Using the hoist motor buttons, alternate upwards movements with movements
STAGE 4
STAGE 5 dragging along the floor, making sure not to damage the wedging box during the
STAGE 6
STAGE 7 dragging movements.
STAGE 8
Before putting it in the shaft, screw two guide rail fastenings to the side rails of the
support on the bores provided for this. Then put the car floor on these guide rail
fastenings.
ASSEMBLE CAR FLOOR AS ASSEMBLY SURFACE
STAGE 1 Attach the car floor using an eyebolt screwed to the omega that is positioned on the side
STAGE 2
STAGE 3 opposite the machine.
STAGE 4
STAGE 5 Hook the hoist motor to the eyebolt and lift the floor until positioning it above the guide rail
STAGE 6
STAGE 7 fastenings installed on the side beams of the support. In this position, lower the floor until it rests
STAGE 8
on the guide rail fastenings. Lower the hoist motor using a rotation movement with respect to the
support of the guide rail fastenings, with the aim of leaving it in a horizontal position.
From the pit and without releasing the hoist motor from the eyebolt put the screws in the slots if
the side beam fastenings.
To fasten the floor on the opposite side, use two car columns.
Fasten the columns using two guide rail fastening plates.
PUT GUIDE RAILS IN PIT.
STAGE 1
STAGE 2
STAGE 3 Coil a chain around each section of guide rail and lift it with the hoist motor, as is described
STAGE 4
STAGE 5 in the section Guide rail installation and depositing tongues and grooves on each side, in
STAGE 6
STAGE 7 accordance with how the guide rails have been installed.
STAGE 8
INSTALL THE WEDGING SYSTEM.
STAGE 1 Place the jig casing in the Blockstop (only the original Tractel threaded screws supplied
STAGE 2
STAGE 3 with the jig can be used). Position two M10 screws with two nuts and a washer on the car
STAGE 4
STAGE 5 floor omega. Firmly tighten the screws until they come up against the base of the omega.
STAGE 6
STAGE 7 The separation between screws will be the same as that between the jig slots.
STAGE 8
Pressing the operating lever, we put the jig casing between the heads of the screws and
washers. We tighten the nuts and counter nuts so that the jig is guided but not joined to
the floor, i.e. it can move between the screws.
We put a sling on the lower beam of the support and using a shackle or a M16 screw we
attach it to the jig casing. The sling should be rolled so that it is free and tightens when the
jig separates about 20 cm from the assembly platform.
Attach the wedge lever to the wedging equipment with this at rest, by a cable and the tensioning grip.
Regulate the tension using the tensioner so that when it is wedged the jig does not come away from the car
floor screws and also so that the support does not remain hanging from the sling.
When the elevator descends without actuating the equipment lever, the Blockstop blocks on the cable and
actuates the car wedge lever. If the wedging does not occur or if there was sliding on the guide rails, the
support would remain hanging from the Blockstop via the sling.
STAGE 5:
PREPARING SUPPORT PULL
STAGE 1 Attach a 3 m sling to the rear beam of the lower part of the car support and
STAGE 2
STAGE 3 another on the front part of the support base. Join the eyes of said slings
STAGE 4
STAGE 5 by a shackle.
STAGE 6
STAGE 7
STAGE 8
To go up with an assembly surface through the shaft, hook the hoist motor in
the shackle that joins both slings, thus meaning the support will have a
central pull.
Once in the correct position to assemble the fastenings, wedge the support
and change the hoist motor hook only attaching it to the eye of the rear sling.
In this way and with gentle touches, we will manage to bring the car close to
the support and therefore the guide rails, with respect to the wall. This
operation makes moving the guide rails frontally easier and, therefore, their
positioning.
CUT VARIABLE SEGMENT
STAGE 1 CUTTING THE VARIABLE SEGMENT OF CAR GUIDE RAIL

STAGE 2
STAGE 3
STAGE 4
STAGE 5 We will have measured the distance between the last and first stop with
STAGE 6
STAGE 7 the measuring tape. If, to this level, we add the real height of the pit and
STAGE 8
the distance of the floor level from the last stop to the car guide rail end
marked on the plan, we will obtain the total length of the guide rails.
Determine the variable segment, subtracting the multiple less than 5 from
the total length of the guide rails:
Examples:
If the total length of guide rails was 12326 mm, the variable segment
would be 12326 10000 (5000 x 2) = 2326mm.
If the total length of guide rails was 29756 mm, the variable segment
would be 29756 250000 (5000 x 5) = 4756mm.
CUT VARIABLE SEGMENT OF COUNTERWEIGHT GUIDE RAILS

The length of the variable segment of the counterweight guide rail will be
the that of the car minus 70 mm.
ASSEMBLE COUNTERWEIGHT FRAME
STAGE 1 Assemble the counterweight on the ground floor landing. Position the two side
STAGE 2
STAGE 3 beams for their assembly.
STAGE 4
STAGE 5
STAGE 6
STAGE 7 Then introduce the upper beam and screw without completely tightening.
STAGE 8
Position the counterweight frame so that once the screws are in the guide rails
they have the head facing the shaft, i.e. the point of the screw and the nut
towards the wall.
Introduce the lower beam (where the supports go) and screw, check the
counterweight chassis positioning and tighten all the screws.
Leave the U-shaped counterweight frame supplements assembled to avoid the

first shortening of cables, so that the screws are accessed from the pit, i.e. with
the U facing outwards.
ASSEMBLE CAR SUPPORT
STAGE 1
STAGE 2
STAGE 3 Consult the documentation in the support nuts and bolts bag.
STAGE 4
STAGE 5
STAGE 6
STAGE 7 Assemble the car support on the ground floor landing. To do this put the two side
STAGE 8
beams in position for assembly.
Then place the upper beam and screw without fully tightening.
Place the lower beam and screw. Check the car support is square and tighten all
the screws.
INSTALL CONNECTIONS AND GUIDE RAIL FASTENINGS ON CAR GUIDE RAILS.
STAGE 1
STAGE 2
STAGE 3 Assemble a connection on the end of each guide rail with its four screws
STAGE 4
STAGE 5 and a guide rail fastening stuck thereto, well fastened. Take care to place
STAGE 6
STAGE 7 half of the connections on the tongue side and the other half on the groove
STAGE 8
side. Also bear in mind that the guide rail fastenings may be different on
both sides.
PREPARE FASTENINGS AND TAKE THEM TO THE 1ST FLOOR
STAGE 1 Take the screws, washers and nuts necessary to position the fastenings and
STAGE 2
STAGE 3 guide rail fastenings from the nuts and bolts bag and leave them mounted in their
STAGE 4
STAGE 5 slots.
STAGE 6
STAGE 7
STAGE 8
Take the fastenings and guide rail fastenings to the first floor.
ASSEMBLY OF GUIDE RAILS.
STAGE 1
STAGE 2 The guide rail assembly is divided in four sub-stages:
STAGE 3
STAGE 4 1. Guide rail elevation.
STAGE 5
STAGE 6 2. Guide rail connection
STAGE 7
STAGE 8 3. Guide rail fastening
4. Assembly of the last guide rail segment and bedplate support.
GUIDE RAIL ELEVATION.
STAGE 1 When the guide rails fit in the shaft, we will have them positioned with their
STAGE 2
STAGE 3 connections and their guide rail fastenings as is described in the Guide rail
STAGE 4
STAGE 5 assembly task.
STAGE 6
STAGE 7
STAGE 8
Put two fastenings on the side of the car floor door front. To do this we will use
two square nuts inserted in the lateral omega of the floor.
Go down with the support through the shaft until the platform is level with the
fastening attached to the guide rails gathered in the pit.
Attach the guide rails with their fastening to the guide rail fastening provided on
the car floor.
Lift the whole unit to the position where the connection is made.
NB. When there are 2 technicians in the same shaft, the system can be replaced by the traditional one, i.e. TECHNICIAN 2 hooks
the guide rail in the pit and TECHNICIAN 1 positioned in the assembly platform, takes it to its connection position.
SAFETY MEASURES
With the assembly surfaces stopped, in addition to activating the wedging, we will
have hooked the hoist motor or a safety sling
CONNECTING THE GUIDE RAILS.
STAGE 1 Once the guide rails are hoisted on the car floor, go up to a height in which the
STAGE 2
STAGE 3 guide rail connection is at shoulder height to the technician.
STAGE 4
STAGE 5
STAGE 6
STAGE 7 Wedge the support at the height indicated, tie a safety sling around the side beam
STAGE 8
of the guide rail car. Release the hoist motor from the car support, hook with a
chain to the upper part of the guide rail and release the latter from its fastening to
the car floor.
Lift the guide rail until the bottom is 10 cm above the assembled guide rail.
Use a scraper to clean the back of the guide rails in the connecting part, as well
as the joint and its cover.
Use the hoist motor to lower the guide rail so that the tongues and grooves of
both guide rails coincide.
Clamp a rule on so that the guide rails are aligned (see drawing on page 78).
Use a rule and spirit level to check that the guide rails are properly aligned
(frontally and laterally) in the place where they join before tightening the
connection plate.
Tighten the connection plate screws in successive diagonals and progressively

increase until completed.
FASTENING THE GUIDE RAILS.
STAGE 1 Check the distance between fastenings in the assembly plan and, on the working
STAGE 2
STAGE 3 platform mounted on the support, move to the position where the fastening level
STAGE 4
STAGE 5 will be.
STAGE 6
STAGE 7
STAGE 8
Move with the assembly platform throughout the shaft in the way described in the
Preparing the support pull task.
Then make the fastening level using the following sequence:
Mark (using the fastening support) the bores to make in the wall for the expansion
plugs, or preparation for welding if they were metal bands. The reference is the
plumb. Bear in mind that the fastening support is not level with the back of the car
guide rail, but approximately 1cm above it (no more than 1 cm).
Make bores to assemble the support. This should be level.
Join the guide rail fastenings to the car guide rail using staples.
Join the fastening and guide rail fastenings with their nuts and bolts without
definitively tightening them.
Perform the same operations with the other car guide rail.
Adjust the car guide rail bevel, joining the two guide rails and adjusting their
levelling. Use gentle taps on the fastening or on the flange of the guide rail made
with a heavy hammer or mallet to bring the unit to its final position. So that the
guide rails do not return to their original position, lightly tighten the fastening
screws to the support.
Install the counterweight guide rails, using those of the car as reference.
Once the unit is in its final position, definitively fix the guide rail flanges and the supports screws and then
remove the clamps from the fastening.
Check that:
The distance between guide rails does not exceed 1mm over the plan measurement.
The guide rails must be correctly aligned.
ASSEMBLING THE LAST SEGMENT OF THE GUIDE RAILS AND BEDPLATE SUPPORT.
STAGE 1 Remove the measuring templates and the plumbs.

STAGE 2
STAGE 3
STAGE 4
STAGE 5 Assemble the last segment of guide rails using weights and level on the already
STAGE 6
STAGE 7 existing ones.
STAGE 8
Observe that the two last fastening levels are positioned in places that are
perfectly designed on the plan and checked from finished floor on the last floor.
Check that the end of the car guide has a length equal to that marked on the plan
on the finished floor level on the last floor. This measurement should be correctly
interpreted and in the case of discrepancies (due to error on calculating the run,
or in the cutting of the variable segment etc) take into consideration that:
The bedplate support plate has a double bore that permits regulation.
The really important measurement is that of the bedplate support
which should be at the height marked on the plan from the finished
floor level.
Both bedplate supports (each one on a car guide rail) have to be
noticeably at the same height.
On its upper part, fix it with the corresponding anchored fastening between guide
rails.
Screw the bedplate supports on both car guide rails.
Copy the 4 bores from the end of the counterweight guide, on the support plate
(this operation is comfortably performed without dismantling the car guide rail
bedplate) the bores should be made with a bit with diameter 11 (the screw is M-
10)
INSTALLING THE ANTI-VIBRATION KIT

STAGE 1
STAGE 2
STAGE 3 The joint of the bedplate support sign to the wall will be made using the rubber bushings
STAGE 4
STAGE 5 designed for this purpose and following the documentation attached to the material.
STAGE 6
STAGE 7
STAGE 8
The following will be done for the assembly of the anti-vibration kit on the last three levels.
First make the fastenings in the typical way without elastic plugs between fastenings and guide
rail fastenings.
Then dismantle the intermediate fastening of the last stop to place the elastic bushings according
to the documentation attached to the kit material.
This last operation is repeated with the upper and lower fastenings of the last stop, one by one,
i.e. releasing just one fastening.
STAGE 6:
ASSEMBLY OF MACHINERY
STAGE 1
STAGE 2
STAGE 3 Machinery assembly is divided in six sub-stages:
STAGE 4
STAGE 5
STAGE 6
STAGE 7 1. Preparation of slings and hoist motors
STAGE 8
2. Mount lifting jig of the machinery/bedplate.
3. Position bedplate on jig.
4. Elevation and assembly of the machinery/bedplate
5. Assemble the control panel and install the rescue system.

6. Install machinery area.
PREPARATION OF SLINGS AND HOIST MOTORS

STAGE 1
STAGE 2
STAGE 3 Remove the slings which have been used during the assembly of guide rails, and
STAGE 4
STAGE 5 replace them on he lower part of the car support, but this time on the beams
STAGE 6
STAGE 7 positioned on a door front and shaft bottom.
STAGE 8
Join the eyes of both slings by a shackle and hook the machine hook to this.
Ensure that the hoist motor hook is 1000 kg and that the lengths of the chains are
well assembled for this load.
SAFETY MEASURES
With the machinery on the support, it is compulsory to use the hoist motor with a 1000 kg
hook.
Whenever possible, work will be performed with no live parts, cutting off the power supply,
blocking in open position, checking there is no voltage and that there is a sign.
ASSEMBLE MACHINERY/BEDPLATE LIFTING JIG

STAGE 1
STAGE 2
STAGE 3 Place two bedplate support side beams with the supplement on the head
STAGE 4
STAGE 5 fastening housings, taking into consideration the precaution of leaving the
STAGE 6
STAGE 7 openings of the omega profiles outward. Assemble two brackets on the support
STAGE 8
side beams.
Ensure that the distance between the outer walls of the omegas is 620 to 630
mm.
Impregnate the two side beams with oil to facilitate the sliding of the bedplate.
POSITION BEDPLATE ON JIG

STAGE 1 Position the car support so that by actuating the safety lock it can rest on the fastening of the
STAGE 2
STAGE 3 floor level where the machinery is. Wedge the support and actuate the lock.
STAGE 4
STAGE 5
STAGE 6
STAGE 7 Positioning the machinery/bedplate in front of the doors, suspend the machinery with a sling
STAGE 8
hung around the motor casing attaching it by the lower part of the bedplate to secure it, put it in
the shaft above the jig. Next, rotate the machinery until it is in the correct position, i.e. the part
of the speed regulator towards the rear part of the shaft looking from the deck to the last stop.
Gently lower the machine until it rests on the jig, guiding it from outside the shaft. Fit in the
bedplate guiding strips outside the omegas.
Place the square nuts attaching the bedplate to the jig, taking care to leave it at a distance of 4
mm from the guide rail shaft so that it does not subsequently interfere with the bedplate
support.
Loosen the hoist motor in order to be able to unhook it from the machinery and positioning it in
the support slings.
From outside the shaft, bend back the safety lock and from outside the shaft lift the unit until the
machinery as high as possible with respect to the last stop that allows the operator to access
the platform.
ELEVATION AND ASSEMBLY OF THE MACHINERY/BEDPLATE

STAGE 1
STAGE 2
STAGE 3
STAGE 4 Put a sling between the upper beam of the support and the last fastening with sufficient
STAGE 5
STAGE 6 clearance to permit the support reaching a height where the bedplate is above the bedplate
STAGE 7
STAGE 8 support.
With the support wedged, the technician accesses the assembly platform and moves with this
until the bedplate is 2 to 3 cm above the support.
Loosen the safety nuts, without removing them and push the bedplate until it is on the vertical
of the bedplate supports.
Put the screws joining the bedplate to the supports and tune the nuts.
Descend with the support until the bedplate is totally supported.
Remove the 4 safety nuts of the jig omegas and definitively tighten the bedplate. We then go
down to the level of the last stop to dismantle the equipment.
The situation may arise where the elevator is wedged and cannot move upwards until the
wedges are released. We should then dismantle the jig before going down to the level of the
last stop to give the support its upwards run and the wedges may be released.
ASSEMBLE THE CONTROL PANEL AND INSTALL RESCUE SYSTEM

STAGE 1
STAGE 2
STAGE 3
STAGE 4 Provisionally assemble the control panel on the last floor according to the following sequence:
STAGE 5
STAGE 6
STAGE 7
STAGE 8 Position the panel in the approximate position with the lower anchor assembled
under its legs.
Mark the position for the expansion plug, of the lower anchor
Make a bore and fix the lower anchoring.
Regulate the height using the lower anchor nuts.
PERFORM INSTALLATION IN MACHINERY AREA

STAGE 1
STAGE 2
STAGE 3 Before putting the pulleys into operation, use the working surface to install the
STAGE 4
STAGE 5 chute and make the electrical connections corresponding to the upper part of
STAGE 6
STAGE 7 the shaft, i.e.:
STAGE 8
Motor
Brake and PTC
Electrical contact of the rescue system
Speed regulator contact
Speed regular remote control reel
Leave sufficient length so that they reach the planned position of the control
panel (on the last stop landing door).
Bear in mind that when we remove the platform we will no longer have access
to the upper part until the car is assembled.
The hoses should be provided with the upper part of the cables.
STAGE 7:
PUTTING THE PULLEYS INTO OPERATION
STAGE 1
STAGE 2
STAGE 3
STAGE 4 The following should be taken into consideration before starting
STAGE 5
STAGE 6
STAGE 7
this assembly phase:
STAGE 8
When the putting the pulleys into operation has concluded, the machinery
cannot be moved unless electrically or by the rescue system. The control
panel will be necessary for both operations.
When the putting the pulleys into operation had concluded and the assembly
surface has been dismantled, there will be no access to the machinery area,
until the car is mounted (from the roof thereof).
If the mechanical execution is done incorrectly there could be serious

problems. Effectively, since if the cables at the end are longer than planned it
may arise that the elevator does not correctly cover the last stop. If, by
contrast, they were too short, there is the risk that the car or counterweight
impact against the bedplate (as the elevator runs to the end floors) creating a
situation of risk.
This circumstance makes it necessary to check the measurements, not just when
concluding to put the pulleys into operation but only assembling the car, loading
counterweight, etc and on concluding the work.
SAFETY MEASURES
The bolts for tightening the clips must be on the long stretch of the cable that is the
one that works by traction.
The bolt tightening must be gradual and alternative without excessive force.
From the assembly surface on the car support, pass the drive cables to the side of the car through the inside
of the separator. From the pit place the cables in the tensioner knots, and them in their support housing. The
remaining cable is deposited in ordered fashion on the assembly surface. Move until the upper part of the
shaft, and throw the drive cables through the drive pulley, starting with that closest to the machinery.
Separate the cables with dividers to avoid them from crossing.
Position the support so that the car floor remains in its final position once assembled, 12 to 15 cm above the
finished floor level of the last stop.
Go down to the pit, and with the aid of ladders or tubular scaffolding, join the drive cables to the cable
attachments of the counterweight (with spring). To do this, put the cable in the tensioner knot, on the
attachment plate of the counterweight frame and mark with insulating tape in the place whereby this bends
around the tear of the tensioner knot.
Bend the drive cable by hand, at the place indicated. Put the cable through the tensioner knot and make the
signal coincide with the curve of the tensioner knot tear.
Assemble the tensioner on its attachment plate and tighten it by hand.
Repeat the operation with the other drive cables. Do not cut the drive cables.
Assemble the cable positioner in the cables that fall towards the counterweight. Do not tighten it, so that the
cables easily slide inside it. This cable positioner does not trap the drive cables, it just guides them. To avoid
it rising up the cables, a clasp is placed on one of the cables.
STAGE 8:
ASSEMBLING THE DOORS.
DOOR DISTRIBUTION
STAGE 1 Once they have been unpacked, the doors are taken to the foot of the shaft to
STAGE 2
STAGE 3 begin their proper assembly, for which we will follow the sequence below:
STAGE 4
STAGE 5
STAGE 6
STAGE 7 1. Assemble and adjust the floor of the car until it is in its final position.
STAGE 8
2. Put the door onto the floor of the car and use the elevator to take it to the
relevant floor. (Before doing this put weights in the counterweight, bearing in
mind the weight of a person and a door that the car-counterweight balance is
suitable for the load and, if necessary, correct it).
3. Mark the reference of the centre of the doorway on the car floor so that it
coincides with the centre marked on each of the landing doors.
4. Situate the floor of the car approximately at the same level as the finished floor
on which it is to be assembled.
5. Bring it up to the marks in the centre and put it right up to the plugs that mark
the separation between levels (usually 30 mm).
6. Using screws for regulating the height or supplement (according to the type of
doors), raise the door on the landing until it coincides with the level of the finished
floor.
7. Check the level of the floor and that it is straight and then assemble the lower
fastenings provisionally
8. Move the floor of the car up to the top of the landing door and with the
separation plugs and the doors centre mark, fix the position (also provisionally) of
the top of the door.
9. Before fixing it definitively, check once again that it is:

Centred.
Aligned.
Level.
Frontally and laterally plumb.
(Error +/ - 1 mm.)
SAFETY MEASURES
Follow the safety rules to handle materials while assembling the doors.
Use safety goggles when eliminating the scale from the weld bead.
NB 1. Start assembling the doors by the door on the top level.
NB 2. Once the door is definitively placed, extend the lateral anchor plates, so that they are later received by the
construction site.
9.0 HEALTH & SAFETY
Basic Work Safety Rules
1. For your own safety follow the established accident prevention and protection instructions.
2. Bear in mind the steps to take in the event of an accident or when faced with an emergency
situation.
3. Dont forget that your safety and that of others depends on you.
4. You must always remember that a job well done is a safe job.
Collective Safety
1. Collective safety always takes precedence to individual safety.
2. Collective safety measures are aimed at protecting all workers from risks.
3. They will be installed prior to any work which requires their assembly.
4. You must keep the collective protection in the planned, assembled use position.
Personal Protection Equipment (PPE)
1. The personal protection equipment is not uncomfortable, it is compulsory.
2. Use PPE required for the risk to be protected against at all times and keep it in good working
order.
3. Remember that PPE protects you from a risk or reduces it. It does not totally eliminate it.
4. After using it, you should store it according to the manufacturers instructions.
5. Immediately inform your superior of any imperfection or irregularity in the equipment and
request its replacement.
Tools
The working tools and equipment must be suitable for this type of work and they must be kept in a
good state of repair. Each tool must be used for the purpose for which it was designed, avoiding
exceeding its design limitations and carrying out disproportionate efforts when using it.
Environmental Procedures
In order to comply with the environmental policy of ThyssenKrupp Elevator Saudi Ltd.
The following must be taken into account:
1. Inert residues: wood, cardboard, plastic, metal.
They will be collected at the end of assembly and separated by type of waste. Their
subsequent recycling is to be considered a priority (placed in their specific bins, provided by
the construction site or council). If this is not possible they should be put in a bin to be sent to
a waste management site. Empty unused oil cans will be considered inert residues
2. Spillages and contamination of the soil
Do not tip hazardous wastes, oils, solvents, paint in drains or on non-asphalted areas (unused
oil should be taken to the factory or representative)
3. Energy saving
Use water and electrical energy sensibly.
2. Emissions into the atmosphere
Do not produce polluting emissions by burning oil, paint, plastics etc.
3. Noise, odours and dust
Avoid unloading or movements that produce noise or dust. Keep urban wastes or any
compounds that produce odors in sealed containers.
4. Environmental Procedures
In the event of an environmental accident (spillage of hazardous wastes in drains, on soil etc.)
the site manager must be told as well as the environmental department of the council or regional
government
10.0 QC INSPECTIONS:
As per our Standard Checklist & procedures the QC team will inspect & confirm for the compliance of
EN81-1 standards and the quality procedures of the ThyssenKrupp Elevators.
ACTIVITY HAZARD ANALYSIS ( AHA )
Project: KKAB F-15 Fleet Modernization Programme, Royal Saudi
Overall Risk Assessment Code (RAC) (Use highest code) M
Air Force , Khamis Mushait, KSA
Contract Number : Risk Assessment Code (RAC) Matrix
Date Prepared : 22.07.2016 E = Extremely High Risk
Probability
Prepared By : Osman alar Demir , HSE Engineer H = High Risk
Reviewed By : M = Moderate Risk Frequent Likely Occasional Seldom Unlikely
S
Job : Elevator e Catastrophic E E H H M
v
e Critical E H H M L
r
Recommended Protective Clothing & Equipment : i Marginal H M M L L
t
Hard Hats y Negligible M L L L L
Safety Glasses Step 1: Review each Hazard with identified safety Controls and determine RAC (See above)
Gloves Probability is the likelihood to cause an incident, near miss, or accident and
RAC Chart
Steel-Toe Boots identified as: Frequent, Likely, Occasional, Seldom or Unlikely.
Coverall Severity is the outcome/degree if an incident, near miss, or accident did E = Extremely High Risk
Full Body Harness occur and identified as: Catastrophic, Critical, Marginal, or Negligible H = High Risk
Fire Extinguisher Step 2: Identify the RAC (Probability/Severity) as E, H, M, or L for each M = Moderate Risk
Ladders Hazard on AHA. Annotate the overall highest RAC at the top of AHA L = Low Risk
JOB STEPS HAZARDS ACTIONS TO ELIMINATE OR MINIMIZE HAZARDS RAC
1. Ensure that all the persons taking part in the activity are inducted
1. Training 1. Various injuries and illnesses. and trained for the activity. Conduct toolbox talk before starting the L
activity.
2. General Housekeeping, keeps area free of debris. Before work starts,
2. Housekeeping 2. Slips, trips and fall. L
clean up area so there are no tripping hazards. Clean up trash daily.
3. Provide safe access, egress route. Adequate sign boards. The area
3. Safe Access/Egress 3.Slips, trips and falls; abrasions must be isolated /enclosed with warning tape to prevent people from M
entering the job sites. Store materials properly.
4. Use proper method for lifting of materials. Get as close as possible to

4.Strains and sprains; injuries such as
4. Manual Handling the load, keep your feet firmly on the floor, bend your knees, keep your M
back damage.
back straight, lift the load using your legs and straight arms.
5a. Keep tools in good condition. Inspect tools before use. Tools shall
be carried in a safe and proper manner. Defective tools shall be tagged
5a. Cuts, pinches, smashes, punctures,
5. Using of hand & power tools immediately and removed from service. Tools shall be used correctly M
severing of fingers. Lacerations
and only for their intended purpose. Wear safety glasses. Work away
from yourself.
5b. Inspect cord and tools before use. Keep power cord away from
5b. Electric shock; electrocution work area. Plug tools into GFCI-protected outlets. Do not use electric M
tools if work area is wet.
5c. Tripping over or cutting power 5c. Keep power cords away from work area or rise them over head level
M
cord inside work area.
5d. Wear safety glasses, and optionally a dust mask, gloves, long-sleeve
shirt and/or coveralls. Wear full face shield over safety glasses when
5d. Injury from flying bits of material. M
working with grinder machine. Provide all protective guards for hand
and power tools.
6a. Check all the connection ropes, chains, bolts and nuts prior to
6. Falling Down of the materials,
6. Installation of the Elevator installing them. Make sure that they fastened safely and tightened well. M
elevators, personnels, injury or death.
6b. While working at height over the shaft, provide anchor points to fix
M
personnel himself to safe point with full body harness.
6c. Before putting the pulleys into operation, use the working surface
to install the chute and make the electrical connections corresponding
M
to the : Motor, Brake and PTC, Electrical contact of the rescue system,
Speed regulator contact, Speed regular remote control reel
6d. Check the loading capacities in accordance with the sling
configurations. M
Do not stand underneath suspended loads
6e. Check the mechanical executions are done correctly. Check all
M
measurements step by step.
7a. Ensure that All scaffolding used on site are checked before start any
7a. Lack of Training/ activity at height and tagged. All scaffold persons must be suitably
7. Mobile Scaffolding M
Information trained and experienced. Scaffold must be designed and erected as per
load capacity.
7b. Follow Fall Protection rules. Harness must be visually inspected by
the user and safety officer for damage prior to use. Persons who is
7b. Fall from height working in scaffolding must be tied of to a suitable anchorage point M
when they work over 1.8 meters height. When modify requires for
scaffolding , get permit from safety team.
7c. Avoid storing tools and equipment on scaffold platforms. Always be
aware of people below. Barricade area below keeping people away
7c. Falling from scaffolding. Signs and barriers should be erected as required. M
Equipment/Materials Materials can only be lifted using suitably rated and inspected lifting
equipment (gin-wheels, ropes, attaching devices, etc).
7d. Ensure that a competent and qualified person has erected all access
platforms. Visually inspect scaffold for completeness, suitability and
7d. Integrity of Scaffold ensure signed scaffolding tag / inspection tag. Use green tag for safe M
scaffolding. Red tagged scaffolding means not safe to use.
7e. Ensure adequate lighting is provided. Wear appropriate footwear

7e. Slips/trips/falls (non-slip). Do not lean out beyond scaffold handrails. Do not alter M
scaffolds
7f. Ensure scaffold is adequately protected against damage from work
operations (I.e. fire, chemicals, vehicles, plant, materials etc.) Remove
7f. Damage to Scaffold M
Scaffolding tag and report damage immediately to supervision.
Equipment to be Used Training Requirements/Competent or Qualified Personnel name(s) Inspection Requirements

PPEs Safety induction Training Inspection of PPEs , Tools, Work area, Hand and
Hand and Power Tools Working at height training power tools, Fire extinguishers, Scaffolds
Slings, Chains, bolts, Nuts AHA Training
Temporary barriers, Scaffolds
Fire Extinguisher
Activity Hazard Analysis Review
By signing below, I agree to the following:
I agree to follow the work steps and implement the controls as written.
I agree to stop work when conditions or hazards change or when I encounter unexpected conditions during the execution of work, or when work cannot be performed as
written, or instructions become unclear during execution.
I am qualified and fit to perform the work.
Worker ( Name Surname , Date, Signature ) Worker ( Name Surname , Date, Signature )

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Consultant Project Main Contractor

King Khaled Airbase Yuksel

King Khaled Airbase

Main Contractor: YUKSEL

King Khaled Airbase Yuksel

6.0 COORDINATION WITH OTHER DISCIPLINES

7.0 EQUIPMENT & MATERIALS

9.0 HEALTH & SAFETY

Main Contractor: YUKSEL

King Khaled Airbase Yuksel

3.1 Approved ThyssenKrupp Shop Drawings

3.2 General Contract Documents including the final units specifications

SUB- CONTRACTOR : THYSSENKRUPP ELEVATORS SAUDI LTD.

ITR : Inspection & Test Request

ITP : Inspection & Test Plan

HSE : Health, Safety & Environment

Main Contractor: YUKSEL

King Khaled Airbase Yuksel

6.0 COORDINATION WITH OTHER DISCIPLINES

Main Contractor: YUKSEL

King Khaled Airbase Yuksel

7.0 EQUIPMENTS and MATERIALS

Steps Prior to Starting the Assembly

Equipment & Tools

1. Basic safety equipment (overalls, helmets, safety boots, etc.)

2. Harness with fall arrest system

Main Contractor: YUKSEL

King Khaled Airbase Yuksel

SAFETY PLANS AND MEASURES.

SHAFT CEILING AND UPPER LEVEL

Main Contractor: YUKSEL

King Khaled Airbase Yuksel

Main Contractor: YUKSEL

King Khaled Airbase Yuksel

Get as close as possible to the load

Main Contractor: YUKSEL

King Khaled Airbase Yuksel

LEVEL ABOVE PIT

STAGE 1 DESCRIPTION OF THE STAGES:

Main Contractor: YUKSEL

King Khaled Airbase Yuksel

PREPARATIONS FOR GUIDE RAIL ASSEMBLY:

STAGE 1 DESCRIPTION OF THE STAGES:

ASSEMBLE LIFE LINE.

INSTALLATION OF THE HOIST MOTOR

Carry out the electrical installation of the hoist motor and

Next fasten the safety sling to the door front hook.

Main Contractor: YUKSEL

King Khaled Airbase Yuksel

INSTALL ELECTRICITY SUPPLY IN THE SHAFT

MEASUREMENT OF THE SHAFT RUN

This measurement will later be used to determine the variable segment.

GUIDE RAIL INSTALLATION.

STAGE 1 Check the pit support plate is perfectly level.

Main Contractor: YUKSEL

King Khaled Airbase Yuksel

it coincide with the previously marked line.

Do the same with the other car guide rail.

Main Contractor: YUKSEL

King Khaled Airbase Yuksel

PUT COUNTERWEIGHT FRAME IN PIT.

PUT CAR SUPPORT IN PIT

Main Contractor: YUKSEL

King Khaled Airbase Yuksel