Unitized facade modules arrive on site as finished assemblies: glass installed, seals in place, anchor hardware attached. The window between offload and installation is short, but that narrow span decides whether you find damage in time to remedy it or discover cracks and dimension mismatches only after hoisting begins. A disciplined incoming-inspection protocol protects schedule, cost, and the contract allocation of risk.
This guide covers offload sequencing, storage requirements, inspection checkpoints, hold-point documentation, and the conditions that should trigger an RFI before the first module leaves the ground.
Unitized modules typically ship on flatbed trailers or in sea containers, stacked vertically in A‑frame racks or crated with interlayer separators. The offload plan should be written into the method statement and reviewed during pre‑delivery coordination.
Crane and rigging
Use spreader beams or adjustable lifting beams to keep slings vertical and load-balanced. Modules are often 2.4–3.6 meters wide and weigh 300–800 kg; wind sail area is significant. Select a mobile crane with sufficient radius and capacity at the planned set-down zone, accounting for dynamic load during travel.
Soft-sling rules
Steel wire rope or chain must never contact finished aluminum, gaskets, or glass edges. Use wide synthetic web slings (minimum 75 mm width) or padded spreader-bar hooks. Sling contact points should align with factory-designated lift lugs or frame reinforcements shown on the shop drawings. Do not improvise sling paths around mullion caps or pressure plates.
Sequence and staging
Offload in reverse installation order when site storage is constrained—last-in, first-out. Mark each module's grid location on the A‑frame or crate before stacking. Avoid double-handling; the fewer times a module is moved, the lower the risk of edge impact and gasket displacement.
Weather and site access
Schedule delivery to avoid high wind (>12 m/s sustained) and heavy rain. Wet gaskets attract dust; wet timber dunnage promotes mold and moisture transfer to aluminum. Confirm that ground bearing capacity at the laydown area will support loaded truck weight plus crane outrigger loads.
Modules are designed to hang vertically in service; horizontal storage introduces frame twist and gasket compression that were not part of the assembly loading. Careless stacking accelerates damage.
Level bearing pads
Set modules on timber dunnage or rubber‑faced steel racks, oriented vertically in the same attitude they will occupy in the facade. The base must be level within ±3 mm over the module width; out‑of‑plane tilt loads corner brackets and distorts rectangularity. Use treated softwood dunnage, minimum 100 × 100 mm section, spaced at third‑points or at locations matching the internal transoms.
Stacking height
Do not exceed the manufacturer's stated stacking limit, typically three to five modules high for standard unitized construction. Higher stacks concentrate load on the bottom frame and risk progressive gasket set. If the manufacturer has not provided a stacking limit, adopt a conservative maximum of three units.
Cover and ventilation
Protect stored modules with breathable tarpaulin or shade cloth, not sealed polyethylene. Trapped moisture condenses on glass and accelerates corrosion of uncoated fasteners. Leave airspace at top and bottom to permit vapor escape. In high‑UV climates, opaque covers prevent premature weathering of structural silicone and EPDM gaskets.
Moisture and drainage
Ensure dunnage sits above grade on gravel or concrete pads; contact with wet soil wicks water into the timber and creates a differential humidity cell at the module base. Slope the laydown area to prevent ponding. Modules stored outdoors for more than two weeks should be inspected mid‑storage for water ingress, mold on gaskets, and discoloration of sealant.
Glass damage discovered after installation is expensive and slow to remedy. The incoming inspection is the last low‑cost checkpoint.
Edge and corner inspection
Remove corner protectors and inspect all four glass edges for chips longer than 6 mm or deeper than 3 mm. Small edge chips are common and usually acceptable if they do not penetrate the inner lite of an IGU; verify against the glass supplier's quality standard or ASTM C1036. Reject any module with corner spalls that expose the spacer bar or show delamination of the primary seal.
Surface scratches and coating damage
Inspect low‑E and spandrel coatings under oblique natural light; perpendicular viewing misses shallow scratches. Rub suspect areas with a damp cloth—residue that wipes away is safe; scratches that remain visible after cleaning are permanent. Record their location on a module elevation sketch. Scratches deeper than the coating thickness (typically 100–300 nm) will not polish out and require glass replacement.
Sealant bead continuity
Check the perimeter structural-silicone bead or wet‑glazed seal for voids, fish‑eyes, and dirt embedment. Run a gloved finger along the bead; incomplete adhesion feels spongy or shows air pockets. Wet sealant that has not cured indicates late factory glazing or humid shipping; do not install until the bead passes thumbnail‑press test (no permanent indentation).
Gasket seating and compression set
EPDM and silicone glazing gaskets should sit fully in their channels without twist or gaps at corners. Compression‑set gaskets (those that have been stored under load too long) remain flat when pressure is removed and will not recover to seal the glass. Pinch‑test a suspect gasket—it should spring back within two seconds.
Every module should arrive with a unique identifier—grid location, mark number, or serial code—matching the packing list and shop‑drawing elevation. Verification is straightforward but frequently skipped under schedule pressure.
Width, height, and diagonal
Measure module overall width and height at three points (top, middle, bottom for width; left, center, right for height). Tolerance is typically ±2 mm for unitized aluminum framing. Check both diagonals; a difference greater than 3 mm indicates out‑of‑square and will cause alignment trouble during install. Record measurements on the inspection sheet; do not rely on memory or verbal confirmation.
Anchor-bracket locations
Verify that cast‑in anchors, blind‑side fixings, or bracket bolt‑holes align with the as‑built structure dimensions. Measure from module datum (usually bottom frame centerline) to the center of each anchor point; compare to the shop drawing. Misalignment of more than 5 mm will require structural remediation or custom shim plates.
Mullion alignment and stack‑joint offset
For stack‑joint systems, check that the horizontal joint aligns with the floor slab edge or spandrel line. A 10 mm vertical offset between adjacent modules cascades into a visible step that cannot be concealed by joint covers. Measure offset between male and female joint components when modules are stood side‑by‑side.
Glass thickness and makeup
Confirm the IGU makeup against the specification: glass thicknesses, low‑E surface position, argon fill (if verifiable with a field gauge), and spacer type. Common errors include reversed low‑E orientation (coating on surface 3 instead of surface 2) and wrong tint. Verify with the factory datasheet or laser marking on the glass edge.
An Inspection and Test Plan (ITP) defines mandatory hold points at which work may not proceed until the supervising engineer, facade consultant, or owner's representative has witnessed and released the checkpoint. For incoming modules, hold points typically include offload completion, initial storage setup, and first‑module dimensional verification.
Witness vs. review vs. record‑only
Witness (W) points require the inspector to be present; no work proceeds without sign‑off. Review (R) points permit work to continue but require submission of records within 24 hours. Record‑only (S for "surveillance") points are documented by the contractor and filed for audit. Incoming inspection is usually an R or W point for the first ten modules, then S for remainder of the shipment once the process is stable.
Photo evidence requirements
Capture wide shots showing the full offload area, stacking arrangement, and weather protection. For each inspected module, photograph the identification label, all four corners of the glass, anchor brackets, and any damage or non‑conformance. Images must include a scale reference (tape measure or dimensional call‑out card) and be date/time stamped. Store photos in a shared project folder organized by module mark and date received.
Sign‑off and traceability
The incoming‑inspection checklist must be signed by the site foreman and the receiving inspector (GC or facade subcontractor QA/QC lead). Retain one hard copy on site and upload a scanned or native digital copy to the project document‑control system within 48 hours. If a module is later found damaged during installation, traceable records determine liability.
Not every defect stops work, but some conditions exceed field authority and require formal design‑team input. Issue an RFI when:
Dimension exceeds tolerance and affects adjacent trades
A module 8 mm taller than specified may clash with a suspended ceiling grid or conflict with slab‑edge fire stopping. Do not trim, grind, or force‑fit; request engineering review and approval of shimming, revised flashing details, or module return to factory.
Glass breakage affects structural integrity or thermal performance
A cracked outer lite in a non‑structural IGU might be acceptable as temporary weather protection if the inner lite is intact and the building is not yet occupied. A cracked inner lite compromises insulation and requires immediate replacement. Consult the facade engineer and glazing subcontractor; document the decision in writing.
Sealant or gasket non‑conformance is systemic
One module with a gasket gap is a workmanship defect; ten modules with the same issue indicates a factory process failure. Stop offloading, quarantine affected units, and issue an RFI describing the pattern, supported by photos. The manufacturer may need to send a field‑service team to rectify on site or arrange return shipment.
Anchor hardware does not match structure as‑built
If cast‑in anchors were poured at the wrong elevation or laterally misaligned beyond adjustment range, the module cannot be installed safely. Do not attempt field modification of structural connection points without an engineer's sealed revision. Escalate immediately; the fix may involve post‑installed anchors, steel brackets, or module rework.
Missing or incorrect certification marking
Some jurisdictions require product compliance marks (CE, Certified Product, or project‑specific test‑report reference numbers) to be visible on the module label. If the marking is absent, illegible, or refers to the wrong test standard, notify the authority having jurisdiction and request clarification before proceeding.
Customize this field template to the project ITP. Use one copy per module for first-article inspection, then one per truck or container for the balance.
| **Item** | **Check** | **Tolerance / Criterion** | **Pass / Fail** | **Notes / Photo Ref.** |
|---|---|---|---|---|
| Module mark matches packing list | Visual | Exact match | ☐ | |
| Overall width (top, mid, bottom) | Tape measure | ±2 mm | ☐ | |
| Overall height (left, center, right) | Tape measure | ±2 mm | ☐ | |
| Diagonal A, Diagonal B | Tape measure | Difference ≤3 mm | ☐ | |
| Anchor bracket location vs. shop dwg | Tape measure from datum | ±5 mm | ☐ | |
| Glass edges — chips, spalls | Visual + finger test | No edge damage >6 mm | ☐ | |
| Glass surface — scratches, coating defects | Oblique light inspection | No visible scratch after wipe | ☐ | |
| IGU makeup vs. spec (thickness, low‑E, tint) | Laser marking or datasheet | Matches specification | ☐ | |
| Structural silicone bead continuity | Visual + finger press | No voids, fully cured | ☐ | |
| Gasket seating and compression set | Visual + pinch test | No gaps, springs back <2 sec | ☐ | |
| Frame finish — scratches, dents, corrosion | Visual | No defects >25 mm length | ☐ | |
| Weather seals and joint gaskets in place | Visual | Fully seated, no missing sections | ☐ | |
| Lifting lugs and temporary bracing intact | Visual | All present, no damage | ☐ | |
| Module stored on level dunnage | Spirit level | ±3 mm over width | ☐ | |
| Weather protection (tarp, cover) in place | Visual | Covers glass, breathable material | ☐ | |
| ITP hold point sign-off (if required) | Witness signature | Signature and date | ☐ | |
| Photos uploaded (ID label, corners, damage) | File check | Minimum 6 images per module | ☐ |
Inspector name: ____________________ Date: __________ Signature: ____________________
Foreman / receiving party: ____________________ Signature: ____________________
Use the checklist above as a hold point before any module leaves laydown for the hoist. Modules that fail dimensional, glass, or sealant checks should be quarantined, photographed, and logged—do not install them. Align who signs the ITP and how RFIs are issued when marks or glass do not match approved shop drawings.
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