IDENTIFICATION NUMBER 3214 Hamilton Workingman’s Club Canopy
PROJECT DESCRIPTION:
Hamilton Workingmen's Club was established in 1955, and in the last two decades has experienced significant growth with more than 7000 members, to become one of the Premier Clubs in New Zealand. Infrastructure development is important to both the club and community, and over the years the club has invested in maintaining and elevating their amenities. Fabric Structures was engaged to design, fabricate, and install a new partial enclosure over the green at the Hamilton Workingmen's Club. This project aimed to provide a versatile, weather-resistant space for club members and visitors, enhancing the usability of the green throughout the year.
DESIGN / FABRICATION / INSTALLATION BRIEF
The project involved designing, engineering, and building a fabric structure over a bowling green, incorporating two walls along two sides. The remaining sides were adjacent to the clubhouse and a large concrete boundary wall, providing sufficient shelter and thus eliminating the need for additional walls on these sides. The client required that the wall running alongside the neighboring green be operable, which led to the installation of a custom curtain on this side, while the second wall remained fixed.
To meet the client's needs, we focused on creating a sheltered environment over the bowling green that seamlessly integrated with the existing clubhouse and boundary wall. Durability, aesthetic appeal, and functionality were key considerations, particularly in ensuring the operable wall could accommodate various needs. We collaborated closely with structural engineers to develop a robust and visually appealing fabric structure, selecting materials that could withstand various weather conditions and ensure longevity.
The operable wall featured a custom curtain mechanism, allowing easy opening and closing to adapt to different situations and events. Throughout the design process, we made sure the new structure harmonized with the existing clubhouse and concrete boundary wall, paying careful attention to aesthetics to ensure the design complemented the overall look and feel of the area.
The installation was meticulously planned to minimize disruption to the bowling green's activities, coordinating closely with the client to ensure all requirements were met and the project was completed within the agreed timeline. The seamless integration with the existing structures met the client's expectations, leading to a high-quality and satisfactory installation.
STRUCTURAL SYSTEMS
The geotechnical report revealed that the site presented significant challenges, ruling out the feasibility of a traditional pile design. A blade pile system was chosen to address these complexities. This alternative approach introduced substantial intricacies in both the foundation design and the construction phase.
Given the difficult ground conditions, the blade pile system was essential for providing the necessary stability and support. Blade piles are designed to cut through challenging soil layers, making them suitable for sites where conventional piles would be ineffective or impractical. The decision to use blade piles required careful consideration of the unique loading conditions and the specific geometry of the site.
To arrive at the final solution and geometric form, we conducted a thorough analysis of the geotechnical data and collaborated closely with third-party engineers. The design process involved advanced modeling techniques to simulate the load distribution and ensure the structural integrity of the foundation. Special attention was given to the dynamic forces and potential ground movements that could affect the stability of the structure.
During the construction phase, the implementation of the blade pile system necessitated precise coordination and specialized equipment. The installation process was meticulously planned to accommodate the complex foundation design, ensuring that each blade pile was correctly positioned and anchored.
MATERIALS
To meet the client's goal of maximizing light transmission within the closed-site environment, we selected the Hiraoka HG212 HT PVC membrane. This fabric was chosen for its ability to balance effective light ingress with necessary structural durability.
The Hiraoka HG212 HT fabric features a light transmission rate of 21%, allowing a significant amount of natural light to filter through and illuminate the internal structure, whilst still being lightweight. This enhances the interior environment, creating a bright and inviting space, which is crucial given the site's limited natural light exposure.
Constructed from high-quality PVC, the HG212 HT membrane offers excellent resistance to weathering and UV exposure. This ensures that the fabric maintains its appearance and functionality over time, even under various environmental conditions. The fabric's strength and flexibility make it well-suited for fabric structures that require durability and the ability to conform to complex geometric forms. It can handle structural loads and resists tearing or stretching, which is essential for preserving the integrity of the build.
Additionally, the PVC material provides superior resistance to moisture and temperature fluctuations, making the fabric effective in protecting the bowling green from rain, wind, and temperature extremes. Its smooth, clean finish contributes to the structure's aesthetic appeal, offering a translucent quality that enhances the visual connection between the indoor and outdoor environments.
The Hiraoka HG212 HT fabric is also designed to be easy to clean and maintain. Its resistance to dirt and stains helps preserve its appearance and performance with minimal effort, ensuring that the structure remains in excellent condition over time.
FABRICATION
The fabrication of the fabric structure required precise techniques and equipment to ensure accuracy and durability. Key fabrication techniques included advanced cutting, welding, and assembly processes, each requiring specific equipment and adherence to tight tolerances.
The initial step involved detailed measurements and cutting of the Hiraoka HG212 HT PVC membrane. Precision cutting tools, such as computerized cutting machines, were employed to achieve the exact dimensions needed. This equipment ensures that each piece of fabric is cut with high accuracy, which is critical for maintaining structural integrity and achieving the desired geometric form.
Following cutting, the next stage was welding the fabric panel together. High-frequency welding machines were used to fabricate the material into a single 1600sqm panel. The welding process must be executed with precision to avoid weak points or inconsistencies in the fabric, ensuring the overall strength and durability of the structure.
Special methods were employed to address the complexity of the design, including custom fittings and structural reinforcements. For instance, specialised fixtures and jigs were used to hold the fabric in place during welding and assembly, ensuring that all components aligned correctly. These fixtures were essential for maintaining the precise geometric form of the structure and adhering to the required tolerances.
During the assembly phase, careful attention was given to the alignment and integration of the fabric with the supporting framework. The fabrication team used laser measurement tools and alignment systems to ensure that all components were installed with high accuracy. This was particularly important for the operable wall section, which required precise alignment of the custom curtain system to function correctly.
The level of tolerance required was stringent, as even minor deviations could affect the overall performance and appearance of the structure. Tolerances were closely monitored throughout the fabrication process to ensure that the final installation met all design specifications and quality standards.
COLLABORATION, CONSTRUCTION AND MAINTENANCE
The project's construction faced significant challenges due to the site's constrained access, which was bordered by other businesses. Effective collaboration and strategic planning were crucial in overcoming these obstacles and ensuring the successful completion of the project.
Close coordination among various teams was essential from the outset. We conducted regular meetings with all stakeholders, including the client, engineers, and subcontractors, to address site-specific challenges and align on project goals. Detailed planning sessions were held to develop a comprehensive construction schedule that accounted for the tight access and potential logistical issues.
We employed digital tools for project management and communication, allowing real-time updates and efficient sharing of information. This approach facilitated quick decision-making and adjustments, ensuring that all parties remained informed and responsive to any changes or complications.
Due to the restricted access of the site due to other tenancies, the construction method required innovative solutions. Once the steel framework was in place, the limited access around the boundary posed additional challenges. To address these, the installation of the PVC fabric and gutters had to be executed from inside the bowling green. This required careful planning and coordination to minimize disruption and ensure that the installation was completed with precision despite the constrained working environment.
A tailored maintenance program was implemented to ensure the fabric structure's long-term performance and appearance. A once-yearly fabric cleaning was recommended to remove dirt and preserve light transmission without causing damage and aligned with the fabric manufacturers warranties. The maintenance program also suggested periodic checks of the steel framework and gutter systems, as well as regular servicing of the operable curtain to ensure smooth operation. This comprehensive approach addressed site-specific challenges and contributed to a durable, high-quality result.
COSTS
The project budget was allocated as follows: Engineering, design, and consent costs made up approximately 7.5% of the total budget, covering both the conceptual and detailed design phases, as well as necessary approvals. Project management accounted for 1.5%, reflecting the oversight and coordination throughout the project's lifecycle. Steel costs, sourced from MacWeld in South Auckland, constituted about 42.5% of the budget, encompassing supply, fabrication, coating, and installation. Fabric supply and fabrication represented 9% of the total, with an additional 5% for the installation of the fabric and tensioning equipment. The full LED lighting system, including all electrical works and control systems provided by Feisst Electrical, amounted to 4% of the budget. This allocation underscores the substantial investment in steel and fabric, alongside costs for design, project management, and additional features like lighting.
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