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PROJECT NAME: Te Hiku Sports Hub
APPLICATION OF PROJECT: Insulated Enclosure
PROJECT DESCRIPTION:
The Te Hiku Sports Hub in Kaitaia, New Zealand, is a state-of-the-art leisure and sports facility designed to cater to the diverse needs of the local community year-round. This innovative project consisted of two insulated wings connected by a central shared space, each tailored to specific functions.
The first wing, a 16.5m x 75m serpentine enclosure, is dedicated to gym spaces and administrative offices. This design not only maximizes the use of space but also ensures that the administrative functions are seamlessly integrated into the facility.
The second wing, measuring 27m x 57m, houses a comprehensive aquatic center, including a 25m swimming pool, two learn-to-swim/hydrotherapy pools, changing rooms, and an entrance lobby that serves as a junction between the two wings.
The Te Hiku Sports Hub aims to be a central hub for various clubs and community groups, promoting sport, recreation, and overall community health. The design emphasises a harmonious blend with the natural landscape, reducing the visual bulk and creating an inviting, user-friendly environment. The facility's construction incorporates innovative fabric architecture, using high-quality insulated PVC materials to ensure durability, thermal efficiency, and aesthetic appeal.
DESIGN / FABRICATION / INSTALLATION BRIEF
The client’s brief for the Te Hiku Sports Hub project was to create two insulated fabric structure enclosures that would allow the facilities within to be utilized by the community year-round. This project marked our first experience with insulated fabric structure enclosures, necessitating significant research and development within our factory. Our primary challenge was to determine an effective method for securing the insulation between two PVC membranes, forming the outer and inner roofs.
The two enclosures had distinct purposes: a dry structure for the gym and administration offices, and a wet structure for the pool complex and changing rooms. The design required one of the enclosures to be curved to accommodate a proposed oval running track. This design consideration ensured that both functionality and aesthetic integration with the existing sports infrastructure were achieved.
Future expansion and the potential inclusion of new partners were critical considerations for the project's economic sustainability. Consequently, the facility was designed to allow for easy expansion by adding extra bays to the structure, showcasing the inherent flexibility of tensile fabric architecture. This adaptability not only meets current community needs but also ensures the hub can evolve with future demands, supporting ongoing community engagement and usage.
STRUCTURAL SYSTEMS
The structural system of the Te Hiku Sports Hub was meticulously designed to integrate with conventional insulated wall cladding systems, such as Kingspan panels and double-glazed aluminium joinery, as per the client's requirements. This integration presented unique challenges at various stages of the project. During the design and engineering phases, careful consideration had to be given to the insulation's impact on patterning and additional loads, which required precise calculations and adjustments. In the fabrication stage, the production of the liner and outer membranes had to accommodate these design specifications, ensuring that the insulation and cladding systems were compatible.
The installation process on-site involved developing a new methodology to handle the insulation panels and membranes effectively. The insulation panels were initially suspended within the steel frame, which required temporary bracing to support them before the liner membrane was positioned. The liner membrane was then lifted into place and tensioned according to the design. Once the liner was secured, the temporary bracing supporting the insulation was removed, allowing the final alignment and installation of the insulation panels.
This approach ensured that the structural system met both aesthetic and functional requirements, providing the necessary insulation and maintaining the building's overall stability and performance.
MATERIALS
Choosing the right materials for the Te Hiku Sports Hub was a critical decision. We required a solution that was lightweight, provided excellent insulation, and accommodated unique structural forms. For this purpose, we selected a two-layer insulated finish specifically tailored to the project's needs.
The primary roof membrane was Serge Ferrari PVC 902S2, a high-performance fabric known for its robustness and flexibility. This material offers excellent resistance to weathering, UV radiation, and mechanical stress, making it ideal for outdoor applications. Its lightweight nature and durability ensure it meets the structural and aesthetic requirements of the project.
For the liner membrane, we used Serge Ferrari PVC 402N. This fabric complements the roof membrane by providing superior thermal insulation and enhanced acoustical properties. It also features a high resistance to abrasion and environmental elements, ensuring long-term performance and minimal maintenance.
In between these layers, Mammoth insulation was installed to provide exceptional thermal performance, enhancing the overall energy efficiency of the building.
Both fabrics were sourced directly from Serge Ferrari, ensuring that we utilized materials renowned for their quality, innovation, and suitability for complex tensile structures. This choice not only met but exceeded the client’s expectations for insulation, durability, and unique architectural forms.
FABRICATION
For the Te Hiku Sports Hub, the fabrication of fabric structures involved a precise and specialized process. High-performance fabrics, such as Serge Ferrari PVC 902S2 for the roof and PVC 402N for the liner, were selected for their durability and environmental resistance.
The fabrication began with accurate patterning using CAD software, followed by automated cutting of the fabric panels. Hot air welding was used to seam the panels, ensuring strong and weather-resistant joints. Steel frames were fabricated with tight tolerances to support the fabric structures.
On-site, the fabric panels were carefully suspended and aligned within the steel frame using temporary supports. They were then tensioned and secured to achieve the correct shape and stability. Maintaining tight tolerances was crucial, and advanced measuring tools ensured that the panels fit precisely and aligned perfectly.
COLLABORATION, CONSTRUCTION AND MAINTENANCE
For the Te Hiku Sports Hub project, our collaboration, construction methods, and maintenance program were designed to ensure efficiency and local engagement.
We prioritised collaboration with local suppliers to enhance the project's success and support the regional economy. FNR managed all civil works, including site preparation, excavation, and infrastructure development necessary for the subsequent construction. Their local expertise was essential for meeting the project’s requirements effectively. Arcline Architects in Kaitaia acted as our local design liaison, integrating architectural vision with practical engineering solutions and ensuring feasibility and innovation in the design. The fit-out was also completed by FNR, who handled the final installation phase and ensured the finish was to the highest quality standards.
To maintain the custom fabric structures, we recommended a yearly maintenance and cleaning program. This program aligns with the warranties provided by our fabric suppliers and includes routine inspections to identify and address any wear or damage. Annual cleaning is conducted to remove dirt, debris, and stains, ensuring the fabric remains in optimal condition, and the structure is checked for wear and tear. This approach ensures the longevity, functionality, and appearance of the Te Hiku Sports Hub.
COSTS
For the Te Hiku Sports Hub project, we meticulously budgeted the costs by breaking them down into separate Wet Wing and Dry Wing enclosures for more accurate financial planning.
Of the budget, approximately 7% of the budget was allocated to engineering and design efforts. This included conceptual and detailed design phases, ensuring that every aspect of the project met the client's specifications and structural requirements.
Steel supply, fabrication, and installation accounted for around 48% of the budget. This significant portion covered the cost of procuring the steel, fabricating it to the required specifications, and the installation of the steel frame, which was a major component of the construction process.
Fabric procurement and installation represented about 23% of the overall budget. This included the cost of sourcing high-quality architectural fabrics and the installation of these materials to create the custom enclosures. This detailed breakdown ensures a comprehensive understanding of the costs associated with each phase of the project, from initial design through to final installation, providing clarity and transparency for the client.
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