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Large frame awnings and fabric structures are what most of us in the industry want, or at least a few of them per year. They usually take substantial labor hours and material, and as such, can be very profitable and keep your staff busy. For the customer they solve big problems, or allow previously unusable outdoor areas to be utilized.
All this is great for the both parties, but what are some things that you as the fabricator need to consider?
Most every portion of the country will have environmental concerns like snow loads or, perhaps, extreme winds. As such, building these structures will require careful consideration of materials and engineering.
The first step will always be identifying the size and scope of the structure that will meet the customers needs. Step two is coordinating with local government offices to make sure such a structure will be possible. You don’t want to get too far ahead of yourself if the structure will not be possible because of occupancy permits, fire suppression, or property lines that limit how much area you can cover.
Let us presume the local governments have no issue with the preliminary site plan, and any permits are obtainable. What’s next? Time to sketch out how the structure might be built and with what components. From that you can generally price the structure accurately.
If you have done something like this before, you will have an idea what materials and construction methods will most likely be used. With your preliminary plans in hand, you can bet that consulting with a local structural engineer is next on your list. They will want your plans, along with a set of plans for the site or building you will be attaching to/along. Don’t be alarmed if the engineer says you need more of one thing or less of another. You should have wiggle room in your pricing to account for such things. Pay careful attention to specific needs such as how many dining tables can or will fit under the new cover. Each project will have requirements to make it financially feasible.
Now it’s time to fabricate. Your local building codes and input from your engineer will stipulate many things such as proper welding techniques, hardware and mechanical attachment methods. These need to be followed since great liability rests on you and your engineers’ shoulders. You want a durable, long-lasting structure that performs safely in the environment it was meant for.
As a professional in this industry, you have some additional things to consider. We know that modern outdoor fabrics are wonderful and durable, but they do have a limited lifespan and accidents do happen. As such, your structure should be built in a manner that it can be serviced with limited disruption to the customer and as easy/cheaply as possible. If you have to remove the whole thing just to fix something small or simple, perhaps go back to the drawing board. Consider this before you start welding. Nobody wants follow-up work on something that was made harder than it needed to be. This could be fabric repairs or replacement, water leaks, or areas that prematurely wear out.
You have the structure built according to the approved engineer’s plans, the permits have been approved, and it’s time to install. Inform the customer and block off the construction area well in advance.
Time to consider safety measures. Large structures transport more difficultly, so have a plan in place that will get it to the site safely, legally and undamaged. You might need lifts, cranes or tools that you don’t normally need. Make sure your staff is trained in safely utilizing these things or anything else required by local law.
The structure is up and looks great. The customer loves it and it solves their problem. Be sure to make routine site visits in the coming weeks to inspect and observe what you created!
These are just some of the things that might go into your large fabric structure. Take your time, follow the local laws and adhere to the approved plans. Don’t guess how something should be done, rather, consult with professionals that share in the liability to make sure it’s done correctly.
I am not an engineer or an architect, but I do have many years of experience working with those professionals in the construction of large frame fabric structures. I have made mistakes and learned from them. The goal here is to lay out the series of events and workload that we have observed for successful construction in a way that is less intimidating and hopefully, proves profitable and advances the validity of large fabric structures for many years to come.
Scott Neville is the owner of Welhener – H.B. Wall Awning and Kansas City Tent & Awning Co., and vice chairman of the Professional Awning Manufacturers Association advisory board.