Fabric Architecture Ltd.

The ‘Xtage’ tensile fabric structure is a 38 meters by 10 meters Bespoke Triple Conic suspended between two crossing arch booms. Steelwork has integrated lighting and speakers. The canopy covers an outdoor video screen and a performance stage for entertainers.

Manchester City Football Club fans are at the heart and soul of the club. The development of a covered Fan Pavilion outside the existing stadium was key to being able to offer a greater fan experience. The Fan Pavilion was to include a large, eye-catching canopy covering new bar and café areas. In addition, the Conic Canopy serves as a landmark entrance to the stadium, offering wayfinding and a dry place for fans to eat, drink and participate in pre- and post-match activities. An essential part of the brief was the ability to turn the project around within a very small time frame, ready for the start of the 2010-2011 season.

Our in-house structural engineers were able to reduce the amount of steel, allowing the structure to look light and almost float over the stage. The reduction in steel saved the client thousands of pounds. The entire structure is supported by two ‘x’ masts (one on each side of the structure). The framework, consisting of braces and ‘push up’ assemblies, supports the Triple Conics. The patterning was particularly complex, allowing us to reduce our off-cuts and create a structure that looks stunning when viewed from beneath the canopy.

The ‘Xtage’ has been a big hit for the Football Club, and in a short period of time it has generated excellent results for the club. Results include a greater fan experience, increased ticket sales, more families attending home matches, fan loyalty, increased revenue from food and beverage sales, increased revenue from merchandising and additional PR exposure. The Football Club was so pleased with the ‘Xtage’ that they have asked us to add two bespoke walkway canopies for a new outdoor food and beverage area, creating a fan pavilion. In addition, a canopy over the entrance to the metro, where fans will enter and exit from the rail system, is being installed in June 2011.

Project details

Location: Manchester, United Kingdom
Size: 380 sq.m
Fabrics: Type III Architectural Coated Polyester PVC
Architect: BDP

Cidelsa

Our project was to create a cover for the common area inside the District Department of Environment’s building. It was designed in order to cover the common and entertainment areas of the building, in addition to protect from the rain, as this area is often visited by staff working in the building. The client requested that the perimeter was fully covered, which was a challenge considering that the area to cover is irregular. They also requested that we place the least amount of the cover’s structural elements in the interior space so as not to interfere with circulation and in order to collect the rainwater through the roof.

This project was part of the first “green” building in the city, packed with enhancements that are at the forefront of comfort and environmental responsibility. The building, with terraces and green roofs, has features that promote efficient use of natural resources and, through the cover, correct use and reuse of rainwater. This will benefit the work environment and customer service. The membrane is no longer a simple cover, but it becomes an element with a high ecological and environmental responsibility, as its architecutral design allows the rainwater that falls on the cover to be carried through the two support columns into a tank for recirculation and reuse in Health 43, located within the irrigation of gardens and “green roofs” around the building. This project was very particular, but it also resulted in a very pleasant and comfortable environment within the covered space thanks to the three-story height of the three membranes that comprise the covering. This generates proper airflow and allows for an adequate and natural hot-air outlet. It is the only space within the building that does not need artificial elements for air circulation thanks to its good design and proper material handling.

The client was completely satisfied with the results of the project, as it complied with the request for a covering and gave added value thanks to the material’s multiple functions. We maintained aesthetic value and design, as well as providing proper functional and structural employment.

Project details

Location: Bogota, Colombia
Size: 75 sq.m
Fabrics: Precontraint 702 S from Serge Ferrari North America Inc
Subcontractor: Diseños & Fachadas

Fabritecture

We constructed 11 shade canopies in varying sizes for the Eagle Street Pier Waterfront Refurbishment. The 11 tensile fabric shade sails replaced the existing structures and provided new structures surrounding the Jade Buddha Restaurant and Bar, Coffee Club and main entrance area to Eagle Street Pier in Brisbane, Australia. Two tensile fabric canopies were installed at Eagle Street South, six at Eagle Street North, one at the Coffee Club and two at Jade Buddha Restaurant and Bar, for a total of 500 square meters of PTFE and 230 square meters of PVC. The main feature structure was a radiating conical for the Jade Buddha restaurant.

Eagle Street Pier is an idyllic dining precinct situated along the river in the heart of Brisbane City. The Pier offers matchless views of the Brisbane Story Bridge and River and is well known as one of Brisbane’s prime dining areas with various award-winning restaurants, casual dining spots and premium bars. Eagle Street Pier has continued with ‘business as usual’ despite being ravaged by the recent Queensland floods that saw the majority of Brisbane affected. The refurbishment of the waterfront area will be a boost to local businesses that are still feeling the effects of the floods and will breathe some new life into Brisbane as it continues to cope in the aftermath of such a devastating natural disaster.

Our aim was to install high quality, architecturally designed, contemporary shade sail fabric membranes to riverside metropolitan alfresco dining areas in order to improve the function of the restaurant precinct and create a visually attractive feature of Eagle Street Pier. The fabric structures were installed as part of a refurbishment project of Eagle Street Pier with a purpose of providing top quality alfresco dining environment consistent with the unique city waterfront location and high standing of the award-winning establishments.

Key requirements of the client brief included development complying with the corporate policies of the property owner, Stocklands, as well as agreements with high profile existing restaurateurs; ensuring no disruption to any of the existing restaurant operations or public pedestrian access and thoroughfare; integrating pre-existing and newly constructed frames; ensuring unobstructed views of the Brisbane River and Story Bridge for all restaurants while providing weather protection for patrons; materials and design to provide minimum of 15 years design life with minimal maintenance; design and installation of an extensive storm water management system which included water collection, drainage, electrical, lighting, etc., an important aspect of the overall design in light of the recent Queensland floods; and night work for all installation after the closing of the Eagle Street Pier businesses so that trade restrictions where not incurred.

For some of the replacement shade sails PVC was being replaced with PTFE, more than 15 years after the original installation, thus necessitating complete, accurate 3D surveys of the existing structures. It was imperative that restaurants maintained trade throughout the refurbishments, therefore we carried out all installation of the sails at night so as not to cause disturbance to the surrounding businesses, as the fully operating dining precinct with large volumes of pedestrian traffic was required to be accessible to the public around the clock. There were no available storage areas for materials or equipment, therefore every night had to be planned in detail so that all requirements were delivered at the start of the shift and picked up at the end. This meant that project management had to be meticulously planned. In order to provide a solution that was both cost-effective and practical, membranes were selected based on location. For example, PTFE was used close to, or below, public areas where smoking may occur so no holes would be burned into the membrane. PVC was selected in areas that were out of the way where this would not be a risk. The project involved tensioning PVC and PTFE membrane fabric to a combination of pre-existing and newly constructed frames. As a result of the installations, we were able to provide seamless integration to the curved balcony structures, awnings and facades of the buildings.

The main structure was constructed at Jade Buddha Restaurant. This tensioned fabric membrane is a composite design of concentric curves with a central circular cone structure. The cone is positioned above the main fabric that allows natural ventilation with all-weather protection. The cone is supported by steel columns connected to a circular bale ring at the base of the cone and a central telescopic steel mast. The main fabric radiates out from the cone toward an external curved balcony facing the river. Internally, connection to the curved concrete upper balcony is a combination of rolled steel ‘U’ section, fixed with chemical anchors to the curved wall. This curved connection, approximately 30 meters in length, is weather-proofed by a patterned fabric, flash-welded to the roof membrane and clamp-plated to the curved wall. All other structures follow similar design attributes in relation to components, required 3D surveying, modelling and complexity, attachment detailing and combining the different tensioning requirements using both PTFE and PVC, all whilst being installed at night.

All structures were accepted by the client as fit for purpose, and the entire project was completed on time with no disruption to restaurants or public access. The completed sails provide an aesthetic and functional addition to the high traffic Eagle Street waterfront. The final results exceeded the client's expectations and met the intent of the design brief.

Project details

Location: The structures are now installed as a focal point of Eagle Street Pier along the Brisbane River in Brisbane City, Queensland, Australia.
Size: 312.8 sq.m
Fabrics: FGT 600 PTFE by Chukoh Chemical Industries Ltd. from Chukoh Chemical Industries Ltd., Precontraint 702 8604 S2 by Ferrari S.A. from Innova International Pty Ltd.
Engineer: Osborn Lane, Tracey Leiper
Design: Jethro Jones, Fabritecture
Architect: Powe Architects
Fabrication: Arch Perera and Graham Griffin, TSI International (PTFE and Fabric Shelter Systems, PVC)
Project Manager: David Schaefer, Fabritecture
Installation: Dean Peters, Ozrig

Oasis Tension Structures (Australia) Pty Ltd.

Conical structures are among the most popular form of coated fabric structure and examples can be seen in nearly every city of the world. However, the conical form we made for the Melbourne Girls Grammar School is not “typical.” It is inverted and the conical form has been pushed close to one edge of the Catenary cable.

The function of the structure is to provide critical protection for students from the elements during breaks in their school day, creating an outdoor leisure environment. It mixes native plants with modern aesthetic material technology, creating a space where the children could relax and briefly escape the physical confines of school. Even when it rains the children can retreat to this area and have their senses stimulated by the rain drumming on the tensioned fabric whilst the water is collected and pushed along the highly strung cables, creating a cylinder of rushing water.

Located in suburban Melbourne, the small portion of land was allocated for the final year students to relax for breaks and lunch in all seasons. The client requested a light-weight structure that would not heavily impact the delicate landscape. This was achieved through attachment to the main buildings and distributing most of the load into the ground through tensioned cables. The structure appears to float above the landscape, drawing your attention to the focal point of criss-crossing cables.

The most challenging thing about this structure was the form-finding process and analysis to literally “make it work” due to the constraints created by the off-set inverted cone. This structure and its environment were designed and constructed during one of the most devastating droughts Victoria has endured, where water and its conservation is paramount. In this project, the water is gathered in this giant funnel and collected in the enormous water tanks deep beneath the landscaped gardens. This water is then used to furnish the plants, ensuring the longevity of the native fauna. This light-weight inverted PVC fabric cone at Melbourne Girls Grammar literally hovers above the timber terraces and landscaped garden in its mix of steel and fabric. When it rains, the area turns into a spectacular performance space as all of the senses are enhanced by sight, sound and the atmosphere.

Project details

Location: Melbourne, Australia
Size: 360 sq.m
Fabrics: Precontraint 1002 T2 by Ferrari S.A. from Innova International (Australia) Pty Ltd
Engineer: Joseph Dean, Wade Design Engineers (Aust) Pty Ltd
Design: Chris Tattersall, SEMF (Aust) Pty Ltd
Architect: Shihab Kasmi, Sally Draper Architects (Aust) Pty Ltd
Fabrication: Chris Atkins, Atkins Fabrication (Aust) Pty Ltd
Subcontractor: Peter Bowie, Steelman (Aust) Pty Ltd
Project Manager and Installation: Dean Spencely, Oasis Tension Structures (Aust) Pty Ltd

FTL Design Engineering Studio

Located on the north lawn of the United Nations campus in New York City, the U.N. Interim Canopy is a Porte Cochere structure which sits adjacent to the U.N.’s new temporary General Assembly building. The design serves as an entrance pavilion and security screen for the General Assembly delegates. The structure is envisioned as a relocatable building which is intended to be moved to another part of the campus at the completion of the renovation.

The renovation of the historic U.N. buildings is scheduled as a five-year project. Due to the temporary nature of the interim buildings, the environmental impact and sustainability of the Porte Cochere was a prime interest for the U.N. and was considered at outset of the design process. Realizing these concerns, the design team introduced the concept of relocate-abilty. Why recycle parts when you can recycle an entire structure? The Porte Cochere may be relocated to another location on the U.N. campus or to any other site of the U.N.’s choosing. With this as a starting point, the design was developed to have minimal anchorage points and to be modular in nature, using prefabricated steel trusses allowing for quick installation, which minimizes the impact of construction crews on site. The high-tech textile membrane’s function is two-fold: it provides support as a working tensile element equally distributing structural loads and defuses sunlight to naturally illuminate the space below.

The client required visual privacy for the delegates and ventilation for idling cars under the structure. The structure uses two fabrics, a teflon coated glass fabric as the main fabric and a silicone coated glass fabric for greater translucency in the arches. Functionally, the canopy provides shelter for the motorcades as they load and unload delegates, requiring ventilation for the idling cars inside. The open facades and linear vents that run the entire length of the trusses allow fresh air to flow freely throughout the enclosure. In addition to the Venturi effect natural ventilation, exhaust fans are mounted in the trusses to remove fumes as required.

The client and its security teams, including the Secret Service, were very satisfied by the project as we were able to provide the necessary visual privacy, the passive and active ventilation and a sustainable approach to the design by using a design that is relocatable to other parts of the U.N. campus. The client called the structure a “functional work of art.” The Porte Cochere offers an elegant counter point to the rectilinear architectural elements which inhabit the site. This temporary addition to the long history of the site is at once a suggestion of ideas that speak not only of the present but look forward to the future possibilities of the United Nations, its mission and what humanity may achieve.

Project details

Location: United Nations Campus NYC, USA
Size: 9,000 sq. feet
Fabrics: Sheerfill II-HTSaint-Gobain Performance Plastics, Atex - 3000 TRLP-D Interglas Technologies
Engineer: Joe Schedlbauer (FTL), Erik Smith (FTl), Wayne Rendley, FTL Design Engineering Studio, Wayne Rendley PE
Design: N.Goldsmith, A.Soni, M. Hilyard, A. Perlas, FTL Design Engineering Studio
Architect: M. Barratt, M. Tegnell, HLW International
Fabrication: B. Dreiling, T. McFadden, Structurflex
Project Manager: M. Patterson, Skanska USA Building
Installation: R. Leu, Structureflex

Cidelsa

The client asked us to create textile roofs for three metro stations, Laguna Sur, Las Parcelas and Monte Tabor, to cover the platform of the stations to protect from the sun and rain water.

The project was initially based on a sequence of rectangular steel frames which formed an irregular profile along the platform. To develop the tensile surface we designed an ellipse structure over the rectangular frame and the sequence was generated by rotating them alternately in each of the existing frameworks.

The project had good results, with the client asking us to take on new projects. We designed, developed and built four stations for the same client in the same year.

Project details

Location: Santiago, Chile
Size: 2,279 sq.m
Fabrics: Precontraint 902 S by Ferrari S.A. from Ferrari S.A.
Architect: Burmeister Arquitectos Consultores
Subcontractor: Constructora Internacional

Carpas Y Lonas El Carrousel S.A. de C.V.

The historical center of downtown Mexico City is characterized by its colonial architecture, home to buildings over 300 years old. Many of these buildings have become museums, shops and offices, and it is the National Autonomous University of Mexico, together with the National Institute of Anthropology and History (INAH), that supervises and maintains the good condition of these buildings. The “El Palacio de Minería” (The Mine Palace) is one such bulding, an iconic piece of American neoclassicism built in 1792 by the Spanish architect Manuel Tolsá. It has great historical value to the country as a cultural and academic space. Known for hosting the International Book Fair, El Palacio de Minería is home to numerous academic and cultural events all year. For this reason the institution responsible for protecting the original essence of the building contracted out for the installation and dismantlement of a conventional membrane cover in the central patio (courtyard) for various events. Unfortunately this was not cost-effective and the membrane did not contribute to the aesthetics of the historical building.

The institution asked the architecture and engineering faculty to develop, design and show different project proposals to cover the central patio of the Palacio de Minería. A specialist’s group from the Laboratory of Structures at the National Autonomous University of Mexico was the winner with his proposal for a tensostructure cover with geometry based on a reverse double-curved surface and resistant to the wind, rain and hail so that it would protect the central patio with its design and prevent the greenhouse effect. Considering its particular characteristics, these covers would be an ideal solution as they are very light and, properly utilized, the support systems and anchorages do not damage the building. Nor are they dangerous in the case of an earthquake, making them ideal for historical sites and especially the Palacio de Minerí;a, which is sinking as a result of the characteristics of the ground in Mexico City.

The first cover, built by another company, had some faults in it, as water filtration, inadequate anchorages between membrane and building, too many cables and inadequate selection of membrane became issues. This year we were invited to build a new membrane; the project was a big challenge as we had to analyze the logistics of building the membrane in only one piece from our factory, disassemble the old membrane and install the new membrane without access in the building to any support machinery such as GENIE (articulated platform), a forklift, motor crane, etc. Everything had to be developed using manual tools and the force and skill of our workers.

The design of the membrane is spectacular; we obtained an organic view with the form of the patterns and lightness contrasting with the old majestic building and the modern tensostructure cover. All of our work, including the membrane-building accessories, disassembly of the old membrane and assembly of the new membrane, was supervised by the National Autonomous University of Mexico (UNAM) building department, National Institute of Anthropology and History (INAH), Laboratory of Structures of UNAM and Cultural Heritage Department of UNAM, and we had their full approval.

Project details

Location: Downtown Mexico City
Size: 1,700 sq.m
Fabrics: Precontraint 1002 T2 by Ferrari S.A. from Ferrari S.A., Soltis 86 by Ferrari S.A. from Ferrari S.A.
Engineer: Ismael Ortiz
Design: Dr. Juan Gerardo Oliva, Laboratorio De Estructuras De La Unam
Architect: Cos Ontiveros Hernandez, Laboratorio De Estructuras De La Unam
Fabrication and Installation: Hector Mendoza Uribe, Carpas Y Lonas El Carrusel, S.A De C.V.
Subcontractor: M. En I. Xavier Palomas Molina, DIRECCION GENERAL DE OBRAS DE LA UNAM
Project Manager: Victor Hugo Mendoza Uribe, Carpas Y Lonas El Carrusel, S.A De C.V.

Taiyo Europe GmbH

The project specification was a retractable roof with a total surface of 2,800 square meters.The fabric panels are supported by arches and the retractable fabric and the steel structure system move along the steel trusses. The light transmittance of the fabric is 19 percent.

The purpose of the project was to create a changing atmosphere inside a shopping mall with a retractable roof. If the roof is closed it will provide a shadow system to protect people from the sun light and delivers a charming and comfortable light situation. The second type of atmosphere involves the roof being open. In suitable weather conditions the roof will be opened to provide an outside shopping atmosphere. The client requested a retractable roof to create a changing atmosphere inside the shopping mall.

The complex aspect of the roof of the Metro Mall was that the complete fabric roof of 2,800 square meters was to be retractable with a controlled driving mechanism. Each single fabric panel is fully controlled and can be moved independently from the others. Furthermore, the fabric and steel arches are retractable and there is a 3D shape in the retractable roof.

Both the client and patrons of the shopping mall are very happy about the outcome of this roof and conversations with the client about further projects are in progress.

Project details

Location: Athens, Greece
Size: 2,800 sq.m
Fabrics: Gore Tenara Fabric 4T20HF by W.L. Gore & Associates Inc. from Sefar AG Architecture
Engineer and Design: Massimo Ing. Maffeis Engineering and Consulting
Architect: Archicon Ltd.
Project Manager: Jens Post, Taiyo Europe GmbH

Beijing N&L Fabric Technology Co., Ltd.

Xi’erqi Subway Station membrane structure comprises the main body and passageway; the structural style is a ridge-valleyed tensile system. Triangular and fusiform air exhausting shutters are arranged respectively on the east facade and west facade. D axis is the dividing line between Changping Line and Line 13. There is a full gutter in D axis and with inner fabric as its bottom cover. The total coverage area of this project is about 7,300 square meters and the expanded area of external fabric is about 13,250 square meters (including 207 square meters of shutters on the west facade); the expanded area of inner fabric is about 2,000 square meters (456 square meters of shutters on the east facade). The main body of the membrane structure is rectangle. Steel cables (ridge cable, valley cable or outboard guy) and rigid members (ridge or lower link ) are enclosed in a series of accordion-like wrinkles. From far away they look like a plump windbox. The length of the main body from north to south is 120 meters and there are 36 ridge-valleyed fabric units; the length from east to west is 54.5 meters and there are two spans. A rocking steel column is arranged in the middle. The roof in the middle of the two spans are ridge-valleyed form which are membranes supported by ridge cable and valley cable.

Beijing Xi’erqi Subway Station Membrane Structure Project is located in the northwest Beijing City (Hai Dian district). It is the terminus of subway Changping Line and the transfer station between Changping Line and Line 13. The first floor of the station is semi-underground, the second and third floors are on the ground, which are in the frame of four poles and three spans. Changping Line is the overhead side platform and lies in the west part of the station; Line 13 is the ground side platform and lies in the east part of the station.

The adoption of ridge-valleyed tensile system makes this project no large-span steel structure members so the architectural image looks simple and generous without un-orderly steel structure framework both inside and outside of the building. All these consolidate the construction and structure form perfectly. It is running well and the client and the people of the city like it.

Project details

Location: Beijing, China
Size: 20,000 sq.m
Fabrics: SkyTop FGT 800 by Chukoh Chemical Industries Ltd. from Chukoh Chemical Industries Ltd.
Architect: Xing-Gang Li, CADG, China

Cidelsa

Del Sol Station is an intermodal station, which means interconnection between the subway and bus system, determined by the thirteen bus stops. We designed a cover that protects the users while leaving the bus at the entrance of the station.

The challenge was to adjust the shape of the roof into the existing architectural plan which shows an irregular platform design. We also had to achieve a good ratio between the height and the length of the transverse arches of the irregular architectural plan; meanwhile we wanted to have as few supports as possible to achieve more free space. In the pictures you can see how we set up the structure: reinforced concrete supports were placed every 20 meters, the arcs ranged between five and 30 meters.

It had good results, with the client asking us to work on new projects. We designed, developed and built four stations for the same client at the same time during the year.

Project details

Location: Santiago, Chile
Size: 3,224 sq.m
Fabrics: Precontraint 902 S by Ferrari S.A. from Ferrari S.A.
Architect: Burmeister Arquitectos Consultores
Subcontractor: Constructora Internacional

Covertex Membranes (Shanghai) Co., Ltd.

Our company created a two-story walkable exhibition area of 330 square metrs for the World Exhibition in Shanghai. The first floor is used for sample display, while the second layer is for conversation and a coffee house. The innovative art building is eight meters high, 25 meters wide and 10 meters deep, made to a great extent of bamboo canes and laminates. PVDF material is used for the roof area, and a folded pattern was designed to add a sense of leisure to the entire building; clear ETFE membrane is used for the façade. The good light transmittance performance of the membrane greatly meet the client requirements for daylight and openness. All these are to let the visitors feel more relaxed when enjoying their coffee and the displays. The architect created an impressive symbiosis of nature and high-tech design through his combination of the natural material bamboo for the load-bearing structure and modern synthetic materials (ETFE & PVC) for the facade and roof.

The campaign “Germany and China - Moving Ahead Together” during the 2010 World Exposition in Shanghai provided an architectural highlight: the German-Chinese House, an example of a building for the future. Conceptually, the architect’s goal was to design a “future-oriented” building that used materials from nature - in this case bamboo - and create a high-tech structure that fulfilled the mandates of being sustainable and environmentally friendly. This building, located in the expo zone, incorporated the expo theme of “better city, better life” and advocated a new construction idea, which is “green” and environmentally friendly.

The pavilion is a self-supporting, two-story construction made from giant bamboo. The load-bearing structure consists of 8-meter long bamboo canes from southern China with a diameter of up to 23 centimeters. Inside the building beams up to six meters long, made from glued laminated bamboo, support the upper floor without the need for any intermediate columns. The roof surface, 264 square meters, consists of a special PVC membrane that spans across the load-bearing structure without folds or creases. It ensures good illumination and its lightness characterizes the atmosphere inside. On the façades, the bamboo is combined with a single layer of ETFE film. It is the high transparency of this film that is responsible for the open and diaphanous look of the building. White sun-shading panels are spanned between the façade members in a regular pattern to lend the building a particular dynamic. The use of a fabric, or transparent membrane, gave the pavilion a luminous, almost futuristic quality. Its translucency gave the building a friendly touch from the inside and out.

The pavilion was erected in just one month. Its modular design and lightweight materials mean that the entire construction can be dismantled after the Expo and re-erected on another site. That makes the German-Chinese House the most sustainable pavilion of the entire World Exposition. Its innovative design, sustainable materials and accessibility symbolized the two countries’ cooperative spirit in the fields of culture, tourism, education, environment and trade. A perfect blend of bamboo and fabric, inside and out, the German-Chinese House expresses both high-tech structure and raw nature.

Project details

Location: Shanghai, China
Size: PVDF material 264 Square Meters and ETFE material 443 sq.m
PVDF by Serge Ferrari North America Inc. from Ferrari China Shanghai
ETFEAGC by Chemicals Trading Shanghai Co., Ltd. from AGC Chemicals Trading Shanghai Co., Ltd.
Engineer and Design: Munich Urban Design International (MUDI)
Architect: Mr. Markus Heinsdorff

Hightex Group PLC

The project consists of an essentially transparent roof to the Main Concourse of the new railway station at Esch-sur-Alzette in Luxembourg. It is a part of the redevelopment of the former main steel production region and is the second largest railway station in the country.

It was wished to achieve a light and airy concourse space to the main railway station building, but at the same time it had to meet the internal climatization requirements and therefore not to have a very high solar gain on days of high solar insulation.

We designed a solution that met the clients requirements by having a “movable’ middle layer to the three-layer ETFE pillows that form the roof covering. The upper and middle layers of the pillow were printed with a “checkerboard’ pattern, the pattern being the opposite in each layer. Thus, when the layers are separated the the cushions allow a high amount of daylight and solar energy to enter the building, giving excellent light levels and a good daytime solar gain in the winter months. However, in the summer months the system can be used to reduce the sunlight entering the building through the roof which would otherwise cause it to overheat or put excessive demand on the internal conditioning system. Hence, by varying the distance between the upper and middle layers, the light transmission and the heat gain can be regulated.

The end result was that the Main Concourse of the building could achieve the desired open, light-filled space by the novel use of ETFE pillows. Each with a width of about four meters and spanning the full width of the building, it gives the effect of a very lightweight filigree roof structure, whilst having the capability of controlling the solar heat gain during the hotter months of the year.

Project details

Location: Esch-sur-Alzette, Luxembourg
Size: 2,300 sq.m
Fabrics: ETFE Film by Saint-Gobain Performance Plastics from Saint-Gobain Performance Plastics
Engineer: Augustin Bizmana, MST Consult
Design and Architect: Jim Clemens, Atelier Clemens
Project Manager: Julian Bose, Hightex GmbH
Installation: Julian Bose, Hightex GmbH

FabriTec Structures

The project is a custom bandshell in a park environment. The general purpose of the structure is to accommodate outdoor performances by musical groups and outdoor presentations. Due to the intricate surrounding landscape, the architect wanted to design a unique shape and form that could be illuminated at night. Translucency was key.

This was one of the most complicated and challenging patterning jobs developed by our design and engineering teams. The complications were compounded by the ever-changing radii of the compound curves and having to create seams that followed the numerous and different meridians. Prior to any of the patterns being completed, the structural frame needed to be assembled off site so that a 3D survey could be developed to determine the exact shape and form. The installation complications came from tensioning each panel into place and minimizing any wrinkling.

This project was a job well done and very much to the client’s satisfaction. All participants developed an enormous appreciation of the complexities of the design, from the structural steel to the membrane patterning and installation.

Project details

Location: Playa Vista, California
Size: 9,200 sq. feet
Fabrics: Sheerfill V by Saint-Gobain Performance Plastics
Engineer: Arup
Design: Michael Maltzan / Steve Neidig, Michael Maltzan Architecture/Arup/FabriTec
Architect: Michael Maltzan, Michael Maltzan Architecture Inc.
Subcontractor: Structural Steel: Plas-Tal
Project Manager: Claude Centner, FabriTec Structures
Installation: Deon Kleynhans, FabriTec Structures

Lindstrand Technologies

Our company was approached by Oresund Dry Docks in Landskrona, Sweden to design and manufacture an inflatable hangar to house their AS-350 helicopter on board the Ice-breaker ship Oden. We were given the dimensions of the helicopter pad and the extreme weather parameters that the hangar must be designed to withstand.

The purpose of the hangar was to protect the AS-350 helicopter from the extreme weather conditions that Oden would encounter en-route to either the Arctic circle or Antarctica. The client requested that the hangar had to operate in temperatures as low as -30 degrees Celsius and withstand wind speeds up to 80 knots.

This hangar is the first of its kind to be mounted on a ship destined for two of the world’s most extreme weather regions (Arctic and Antarctic). The hangar has a complex control system which allows it to be operated in temperature ranging from -30 C to +60 C without having to change any components or system parameters.

In May 2010, the ship with the hangar on board was deployed to Antarctica for a three month ice-breaking expedition. During this expedition the hangar was exposed to 64 Knot winds and temperatures down to -26 C. That ship is due for redeployment to the Arctic Circle in July 2011 with the hangar on board.

Project details

Location: Worldwide
Size: 12.6 m by 7 m
Fabrics: Precontraint 402, IvoryFerrari S.A.Milton
Design and Project Manager: Liam Hope, Lindstrand Technologies

Air Structures American Technologies Inc.

The client’s request was to have a multi-sport dome to be used for football, soccer and lacrosse, surrounded by a four-lane running track, which can be used year-round if needed. We created this air-supported structure to provide the teams with an all-weather facility, with tedlar coated translucent outer fabric, allowing the participants to practice in natural lighting during daylight hours. The interior of the dome is heated by the forced hot air heating system with automatic controls to maintain 70-degree temperatures within the structure when outside temperatures are as low as zero degrees. Our lighting system provides 60-foot candles of indirect, glare-free sports lighting over all of the playing areas. This structure can easily be taken down in the summer and reinstalled in the winter.

Our patented bias cable net system allows the structure to be inflated to wsp, required for providing the structural stability needed for resisting 120 mph winds and supporting 35 pounds of snow load per square foot without over-stressing of the fabric envelope. The structure also includes field junction seam joints, a revolving door, an emergency exit door and an anchorage system. The overall focus is on heating and pressurization as well as engineering and fabrication.

The result of the project is a state-of-the-art clearspan turnkey enclosed air-supported structure that represents an exciting opportunity for a year-round facility regardless of weather, under natural or interior lighting.

Project details

Location: Livingston Campus, Piscataway, N.J.
Size: 230 feet wide by 430 feet long by 96 ft high
Fabrics: Seaman Corporation
Engineer: Kevin Miley, Hillman & Miley Consulting Eng. White Plains, N.Y.
Subcontractor: Epic Management, Inc. Piscataway, N.J.
Graphics: Magic Vinyl Printing, Westfield, Mass.
Project Manager: Paul Sabo, Our Company
Installation: Miquel Disla, MDCourts, Inc Fabric Structure Services & Products, Closter, N.J.

Carroll Awning Co.

The project was to make a custom manufactured fabric canopy that connects a parking garage to an office building. The frame is constructed of completely welded galvanized steel “Gatorshield” tubing. The fabric is “Coastline Plus” vinyl laminated fabric by Herculite Products. The canopy, which is anchored to concrete footings below grade, is supported by 6-inch pipe uprights. The support columns near the garage penetrate through the lower canopy and attach to the upper canopy. There is an aluminum drip edge attached to the outer edge perimiter so rain water does not run inward on employees.

The purpose of this canopy is to protect employees walking to and from the parking garage and the office building. Employees can walk between the garage and building and be protected from the sun, rain and snow.The client wanted something that fit with the building and was unique in design. The client wanted a lower-portion canopy at the entrance to the garage to provide more protection for employees.

The odd design, angles, size and design criteria made this canopy complex. The office building was askew to the parking garage, making the design more intricate. The sloped valance design makes this canopy unique and different from ordinary designed canopies. The canopy portion over the driveway had to have a 15-foot clearance for emergency vehicles to pass under. The span between uprights over the driveway is 30 feet so the internal trussing had to be designed to support the canopy and the loads from wind and snow.There is a lower canopy that is at the entrance to the garage that has 6-inch support posts protruding through it and up to the higher canopy. Transitioning between the canopy and office building made for a unique design that also functions and fits with the architecture of the building.

The results were very nice. The client was very satisfied and the employees could pass from the garage to work and have protection from the elements. The general contractor was satisfied that there were no delays and now has confidence in our company to complete difficult and complex awning and canopy projects.

Project details

Location: Reston, Va.
Size: 1,150 sq. feet
Fabrics: Coastline Plus by Herculite Products Inc. from Tri Vantage LLC
Engineer: Quinton Worrell
Design: Ivory Butler IV, Carroll Awning Company
Architect: Hickok Cole
Fabrication: Mark Jarrett, Carroll Awning Company
Project Manager: Brian Nussbaum, James G. Davis Construction Corporation
Installation: Mike Fritter Sr., Carroll Awning Company

Camel Custom Canvas Shop

This is a 47-foot awning made of aluminum framing and covered in canvas with painted graphics. The client needed to replace an old awning and was game for something a little different.

This unique wave design serves great purpose in that it is very eye catching and like nothing we’ve done before. We built prototypes to get the best curve, practiced covering and came up with what you see.

This project resulted in a very satisfied customer and a new learning “curve” for us, along with a great product for our portfolio.

Project details

Fabrics: Sunbrella by Glen Raven Custom Fabrics LLC from Tri Vantage LLC
Design and Project Manager: Christian Cain, Camel
Fabrication: Mark Silor, Camel
Graphics: Debbie Fettig, Camel

Miami Awning Co.

This project is a 60 feet by 15 feet alternating curved designed frame and awning installed on existing supports. The fabric used on these curved frames is Ferrari Precontraint 502. This covers one of two outdoor patio areas that are used by the restaurant.

Bongos Latin Café is a classic Cuban Supper club that is part of the vibrant venue of The Seminole Hard Rock Hotel and Casino in Hollywood, Fla. The interior of the restaurant is multi-layered in appearance and the client wanted to protect the outdoor patio area from rain. Combining the client’s tastes with their needs, a “multi-layered” awning canopy was designed to keep the theme of the restaurant, “Where the rhythm is gonna get you.”

What made this project unique was that it was contracted, designed, permitted, fabricated and installed in less than one month. The awnings were designed to fit existing framework that supports lighting. Precise measurements and attention to detail were needed to integrate all of the components and features of the various units to be installed. Ferrari fabric was chosen to give the awnings a clean look that reflects the lighting that is used at night to create an exciting atmosphere below.

These multi-layered canopies create an exciting atmosphere that was desired by Gloria and Emilio Estefan for their restaurant, the Bongos Latin Café. We were able to design and complete what they were looking for by the deadline that they had given. The white palette of the canopy and framework make it possible to integrate any lighting and colors that they want to use for various occasions and events throughout the year. These arched and convex multi-layered awnings provide the Estefans with extra seating for dining under the stars and a view of the lake for the water shows that are featured throughout the year.

Project details

Location: Hollywood, Fla.
Fabrics: Precontraint 502 by Serge Ferrari North America Inc. from Tri Vantage LLC
Engineer: Rodrigo Ariza, P.E., A & G Advance Engineering
Design and Project Manager: Gus Rotella, Miami Awning Company

TensionStructures.com, a division of Eide Industries Inc.

In September 2010, we completed the fabrication and installation of an inviting entrance canopy for the Friendly Baptist Church in Tyler, Texas.

This project is a great example of how, in the early phases of design development, we can take a simple concept from an architect to produce 3D visual models and budgetary estimates. We created a 32-foot by 17-foot canopy that covers approximately 550 square feet. We used white Ferrari Precontraint 502 Textile Fabric. We framed the canopy with eight 5/8-inch diameter upright columns and four 1/2-inch upper frames, with 2-foot, 16-inch diameter footings that are six feet deep.

We worked closely with the architect within the budget constraints to help refine the tensile structure design to fit the financial allowance.

Project details

Location: Tyler, Texas
Size: 550 sq. feet
Fabrics: Precontraint 502 by Serge Ferrari North America Inc. from Tri Vantage LLC
Engineer: Wayne Rendely PE, Wayne Rendely Engineering
Design: Erik Jarvie, Eide Industries Inc.
Architect: Jennifer K. New, BWR Corporation
Fabrication: Eide Industries Inc.
Subcontractor: Randy Reynolds - General Contractors, HGR General Contractors
Project Manager: Roger Fuller, Eide Industries Inc.
Installation: Albert Soto, Eide Industries Inc.

Canfab Products Ltd.

To attract clients to the customer’s business in a nondescript building, we created an illuminated handbag that immediately and vividly informs the public exactly what the client supplies. The customer was happy with the outcome, and the installation of the handbag has increased walk-in traffic.

Project details

Fabrics: Awnmax by Hiraoka & Co. Ltd. from WRI Supply

Carroll Awning Co.

This project involved a custom-manufactured fabric canopy that contours to the irregular-shaped concrete parking garage to protect the driveway ramp from snow and ice during the winter months. The size of the canopy is 26 feet wide and 140 feet long. The frame is constructed of completely welded galvanized steel Gatorshield framework and the fabric is vinyl Patio 500 515 Buff.

The purpose of this canopy is to cover and protect a fourth floor sloped driveway in a parking garage. The snow and ice during the winter months made it difficult to drive and the custom fit canopy was the solution. The building engineer was constantly dealing with clearing snow and ice from the ramp, occupying a lot of time and manpower.

The difficulty factor was high on this project because of the complexity of following the irregular curves of the existing structure and the location on the fourth floor of a parking garage. The site was too difficult to measure with traditional methods, so a surveyor was brought in to shoot points and transfer to a CAD file from which we could produce accurate shop drawings. Full-size line drawings were plotted at our company and laid out in our frame shop to accurately reproduce the more difficult areas. We manufactured the frame in sections and then cut it into transportable sizes. The frame sections were welded back together on the field into larger sections that were, in turn, lifted by crane into place and anchored to the building.

The results on this project were very good. The client was very happy that the canopy met the needs of protecting the driveway while conforming to the building and surrounding architecture. The customer has purchased multiple canopies from us in the past and is interested in more. With the completion of this parking garage canopy the client has complete confidence in our company and our ability to complete even the most complex awnings and canopies.

Project details

Location: Towson, Md.
Size: 3,600 sq. feet
Fabrics: Patio 500 by Tri Vantage LLC from Tri Vantage LLC
Engineer: Quinton Worrell
Design: Christopher Carroll, Carroll Awning Company
Project Manager: Tim Carroll, Carroll Awning Company

MakMax Australia

This project was essentially a weather cover over a public space. However, during discussions with our sales team at the tendering stage it was clear that the project also had an element of environmental consideration. For this reason we developed a custom design that worked to these constraints.

The purpose of this project was to create an inviting public area intended as a cafeteria or outdoor dining space. Suters Architects specified a tensile membrane roof in order to cover the area while allowing natural light to enter the space. The environmental consideration included low maintenance requirements and long life span, design for disassembly, as well as efficiency in material use. Our sales team quickly realized that polytetraflouroethylene fabric with a self-cleaning titanium dioxide coating would fulfill all these requirements.

The most unusual detail of this project was the fabric used. Polytetraflouroethylene fabric with a self-cleaning titanium dioxide coating (PTFE with Ti02) is a product available only through the Taiyo Group. The development of this revolutionary self-cleaning fabric was realized through our research and development department. This is the first time this fabric has been used by our company within Australia. Because this fabric is new to our company’s Australian manufacturing, a slightly altered manufacturing technique was implemented in order to yield the best result. This was a big learning curve for the Australian factory, however, we are all pleased with the result.

As per our client’s needs, the membrane roof delivers on all fronts. Natural light is able to pass through the fabric to the area below. We have been able to offer a green alternative in our own fabric, and the overall construction is light-weight and on budget. The use of polytetraflouroethylene fabric with a self-cleaning titanium dioxide coating is now tested and proven in Australia.

Project details

Location: New South Wales, Australia
Size: 300 sq.m
Fabrics: Skytop FGT 600 Ti02 by Chukoh Chemical Industries Ltd. from Chukoh Chemical Industries Ltd.
Engineer: Robert McDonald, MakMax Australia
Design and Architect: Suters Architecture
Project Manager: Alberto Del Arco, MakMax Australia
Installation: SydRig

Port Douglas Sailmakers Pty Ltd.

This project consisted of the supply and installation of a waterproof membrane over an outdoor restaurant area at the departures lounge of an airport.

The design parameters for this Domestic and International Airport redevelopment called for all on-site building structures, including fabric, to be rated to the highest wind code specifications of 205 kph. The client required a freestanding fabric awning covering a large outdoor restaurant area adjacent to the departures lounge of the facility. The brief was to design a structure that was compliant with the site building codes, was striking in appearance and offered protection from the elements, incorporated a fire-rated premium quality translucent membrane roof to allow natural light while still complying with Australian Civil Aviation Authority (CASA) standards regarding reflection of light above during night operations, was not attached structurally to existing buildings and using minimum support posts so not to interfere with entrance doorways or emergency exits, was completely waterproof on existing building sides, allowed for all water runoff to site storm water system and included fans, lighting and security cameras.

These requirements presented several challenges for our design team, including the need to control sway effect on the structure during heavy winds; meeting CASA night time landing standards relating to light transmition above, water runoff requirements, sealing between structure and existing building and a separating mast design to enhance the visual effect. We first produced several concept designs and, using a modelling program, eliminated one by one any non-compliant components. Using the height of the rear wall of the existing building as a starting point, we designed a curved frame that projected just above the roofline to ensure maximum weather protection on that side. We then carried this line through to the lower outside perimeter columns and counter levered the fame beyond them by one meter. The rear support columns were set at a vertical angle. However, to enhance the visual appearance of the design, the front columns were set with a lean towards the exterior of the design and with a mast-type protrusion above roof level for added effect. These protrusions were created using matching top and bottom attachment plates, though bolted after the membrane was fitted to give the appearance of a continuous post without having to cut the skin around a complete section. The fabric tensioning system comprised a track system of robust aluminium extrusion on all perimeter edges. The tracks were linked to the steel frame with adjustable bolts spaced every 250 millimeters to achieve an extremely tensioned membrane finish. To seal between the side of the project and the existing building a separate fabric pelmet was designed that did not restrict independent movement of the two structures. A custom gutter system was added to the front section and positioned to catch all the water runoff and channel to the site storm water system.

Initial modelling showed significant sway during maximum design wind load conditions which may have caused collision between the structure and the existing side wall. Due to the need to keep the area below free of any separate bracing or cables we were unable to use this method for bracing. We solved the issue by designing a tapered column section with heavy duty base plates incorporating over-sized gussets and footings to strengthen the design and reduce any sway. To prevent trip hazards, the base plates and gussets were finished below floor level and a secondary slab was installed around them to give an unimpeded finish to the base of column. A lighting technician was engaged to assess the light penetration above the membrane at night. Using the light transmission figures relevant to the selected fabric we were able calculate the illumination of light above and then design and position lighting in a way to comply with the CASA standards without reducing the overall lighting requirement for the area below. Along with the lighting fixtures we also were required to allow for overhead fans and security cameras with access cables inside the frame.

The whole structure above footing level was fabricated off site and fully installed in only three days. It has been a great success, meeting all of the client’s requirements as well as the CASA standards. It is now a very popular venue for departing passengers as well as being used for many corporate functions. It has already been tested in several severe weather events and the entire structure performed to specification.

Project details

Location: Cairns Airport
Size: 180 sq.m
Fabrics: Precontraint 902 by Ferrari S.A. from Innova International Pty Ltd.
Engineer: Trevor Wright, Port Douglas Sailmakers
Design and Graphics: John Rebbechi, Port Douglas Sailmakers
Fabrication, Project Manager and Installation: Mal Richardson, Port Douglas Sailmakers

Awnings of Hollywood, Inc.

This project was an installation of three awnings around an outdoor patio/BBQ dining area with curtains that can drop when needed, as the original roof area did not offer enough coverage. The client wanted to extend the roof line so that diners have shade overhead. He also wanted roll curtains to keep out inclement weather, however they could not be visually obtrusive when not in use.

First of all, the house is a corner house on the Inter-coastal Waterway in South Florida. It has sea water on two sides (very high salt environment). The frame is made of aluminum with a powder coated finish to delay corrosion as long as possible. The designer and client came up with the outward curved design for the awnings on the three sides, which was very pretty and added a nice element to an otherwise square property. On the rear there is a balcony that projects out very close to where the awning would have been from the house, so that frame has a double curve as a result. The end curtain under the short awning is positioned between two posts so we were able to use a completely enclosed unit with side track. When it is up it is virtually invisible. The long curtain on the water side would have been over the bar had we tried to position it between the posts, so instead it is tensioned to cables on the sides about a foot in front of the posts.

The awnings are stunning and the client is extremely happy and has referred us to his neighbors.

Project details

Location: Ft. Lauderdale, Fla.
Size: 248 sq. feet
Fabrics: Sunbrella by Glen Raven Custom Fabrics LLC from Innovative Industrial Solutions
Engineer: Victor Ceron, PE
Design: Christopher Thompson, Awnings of Hollywood, Inc.

House of Canvas

The frame was constructed of welded Gator Shield steel, primed and painted black. The canopy top was fabricated with Sunbrella woven acrylic. Due to the height and extensive projection, all rafters required trusses. The curved outer perimeter of the canopy has a 22-foot radius.

Project details

Fabrics: Sunbrella by Glen Raven Custom Fabrics LLC from Trican Corp.
Design: Arturo de la Torre Palma and John Conroy, House of Canvas
Project Manager: John Conroy, House of Canvas