IDENTIFICATION NUMBER 5874
ENTRY CATEGORY (1-6) 5 Special Applications
ENTRANT ROLE: Fabricator
PROJECT NAME: Metro Sports Facility
APPLICATION OF PROJECT: Interior acoustic membrane
PROJECT DESCRIPTION:
Fabric Structures was instrumental in the development of the Metro Sports Facility in Christchurch, focusing on the design, engineering, procurement, and installation of a custom ceiling panel solution for the aquatic center. Our task was to create a ceiling system with dual functionalities: an acoustic layer on the underside facing the pools to absorb sound and reduce echo, and a solid membrane on the top side to support the plenum area above. We worked closely with architects and engineers to ensure the panels met both aesthetic and functional requirements. Our precise engineering and installation processes delivered a high-quality solution that enhanced the acoustic environment while maintaining structural integrity. This project showcases our capability to provide innovative fabric solutions tailored to complex needs, contributing significantly to the Metro Sports Facility’s role as a leading sports and recreation venue in Christchurch.
DESIGN / FABRICATION / INSTALLATION BRIEF
The project requirements for the Metro Sports Facility’s ceiling were clear: the ceiling could not sag or resemble a series of sails. Instead, the client desired a look and feel akin to rigid, rectangular panels, much like scaled-up versions of traditional acoustic office ceiling tiles. This approach led to the creation of approximately 150 uniform ceiling panels, varying in size up to a maximum of 5 meters by 9 meters. These panels were meticulously installed around a series of skylights to allow natural light into the pool areas.
Our response to the design brief involved extensive research and development to ensure the panels met the stringent aesthetic and functional criteria. This included procuring a unique custom panel tensioning system to maintain the rigidity and uniformity of the ceiling. The result is the first installation of its kind in New Zealand, featuring a rigid panel look and feel. This innovative solution successfully combined practicality with a sleek, modern appearance, addressing the client’s requirements and enhancing the facility's overall design.
STRUCTURAL SYSTEMS
The structural system used for the Metro Sports Facility in Christchurch required an innovative and customized approach due to the project's unique demands. To meet these needs, we designed, engineered, and sourced a bespoke dye for the panel extrusion system from China. This involved ordering approximately 4,000 linear meters of extrusion in 9-meter lengths.
The tensioning extrusion system was engineered to support two distinct PVC skins: an acoustic layer to control sound and a solid layer to ensure structural integrity. This dual-skin system was externally tensioned using a specially designed frame. The geometry of the panels needed to be precise, with each of the 150 panels varying in size up to 5 meters by 9 meters. These panels were installed around skylights to allow natural light into the pool areas, creating a bright and welcoming environment.
Another major condition we had to address was the possibility of SCC (stress corrosion cracking) within the humid environment of a heated pool facility such as Metro Sports. Potential structural failures occur to certain stainless steels under tension, when the cleaning chlorides react with human ammoniacal products and create volatile gasses which corrode and weaken the steel. To avoid any possible future issues, Fabric Structures specially designs our extrusion systems using high alloy austenitic steel 1.4529, which offers excellent resistance to SCC, ensuring structural integrity and safety in chlorine-rich environments.
On-site assembly was a significant challenge. Each panel had to be individually assembled and lifted into place up to 20 meters above ground level, using birdcage scaffolding. This meticulous process required precision and careful coordination to ensure the panels were installed correctly and safely.
Ground conditions and design loadings also played a crucial role in the project's structural considerations. The facility needed to withstand the unique environmental conditions of Christchurch, including potential seismic activity. This required robust engineering solutions to ensure the building's resilience and safety.
The project faced considerable program delays, some of which were due to the impact of COVID-19. These delays necessitated multiple departures and returns to the site, extending the overall project timeline to over four years. Despite these challenges, the project was completed successfully, resulting in a state-of-the-art facility that meets the client's high standards and enhances the community's recreational offerings.
MATERIALS
The Metro Sports Facility in Christchurch was constructed using carefully selected materials to ensure functionality, durability, and aesthetic appeal. For the fabric structures, we utilized Serge Ferrari Alphalia AW Acoustic PVC for its superior sound absorption, and Serge Ferrari 502 S2 PVC membrane for its durability and performance as a plenum barrier. Both fabrics, sourced directly from Serge Ferrari, ensured a high-quality finish.
The steel framework, sourced from reputable steel suppliers, provided the necessary strength and flexibility to withstand seismic activity, supporting the tensile fabric panels and ensuring structural integrity. A custom-designed extrusion system from China was used to carry the dual PVC skins and maintain a flat, uniform appearance without sagging.
Birdcage scaffolding from local suppliers facilitated the precise installation of ceiling panels at heights up to 20 meters. The selected materials and construction methods reflect our commitment to excellence and innovation, resulting in a state-of-the-art facility that meets the highest standards of design and functionality.
FABRICATION
For the Metro Sports Facility’s interior acoustic ceiling, we undertook the design, engineering, procurement, and installation of a 5,000 sqm rigid custom panel ceiling system, essentially a scaled-up version of traditional office acoustic ceiling tiles, with maximum panel sizes reaching 5m x 9m. This ambitious project required innovative fabrication techniques and specialized equipment to achieve the desired outcomes.
The fabrication process began with the precise engineering and creation of the panel extrusion system. A unique dye for the panel extrusions was designed and manufactured in China, allowing us to produce approximately 4,000 linear meters of extrusion in 9m lengths. This extrusion system was engineered to carry two layers: the bottom layer composed of Serge Ferrari Alphalia AW Acoustic PVC for sound absorption, and the top layer using Serge Ferrari 502 S2 PVC membrane to serve as a plenum.
The custom panel tensioning system was a critical component, ensuring the panels remained rigid and uniform without sagging. This system involved the use of a frame that externally tensioned the PVC skins. Maintaining precise tension was essential to achieving the flat, clean look specified in the design brief.
The design and fabrication process also included considerable research and development to address the unique requirements of this project. The combination of acoustic and solid PVC membranes created a dual-purpose system that controlled sound within the aquatic center while also providing a robust structural component.
Throughout the project, maintaining tight tolerances was crucial. The precision required in cutting, fitting, and tensioning the panels ensured that the final installation was both aesthetically pleasing and functionally effective.
COLLABORATION, CONSTRUCTION AND MAINTENANCE
On-site assembly presented its own set of challenges with the ceiling installation. Each of the 150 panels had to be individually assembled and lifted into place, up to 20 meters above ground level. This process was facilitated by birdcage scaffolding, which provided a stable and secure platform for workers. The installation required meticulous alignment and tensioning of the panels, with tolerances held to within millimeters to ensure a seamless finish. Despite challenges such as COVID-19-related delays, the project was successfully completed, resulting in a state-of-the-art acoustic ceiling that enhances the Metro Sports Facility’s environment.
Our custom fabric structures come with a recommended yearly maintenance cleaning program, aligning with the warranties provided by our fabric suppliers. Regular inspections and cleaning will maintain the acoustic properties and structural integrity of the ceiling panels. The maintenance plan includes checking the tensioning system to ensure no sagging or misalignment occurs over time and addressing any wear and tear promptly. By adhering to this maintenance schedule, the Metro Sports Facility will continue to provide a high-quality environment for its users, preserving the aesthetic and functional benefits of the acoustic ceiling panels.
COSTS
Due to the complex nature of the Metro Sports Facility project and the delays encountered, including time variations with the main contractor and significant cost increases driven by inflation, the final cost distribution reflects these challenges. Engineering and design fees accounted for approximately 4% of the total budget. This portion covered the comprehensive planning, detailed design, and engineering solutions necessary to meet the project's unique requirements.
Fabric supply was a significant portion of the budget, representing around 20%. This cost encompassed the procurement of high-quality Serge Ferrari PVC materials, including both the acoustic and plenum membranes required for the custom ceiling panels.
Installation costs were the largest expense, comprising about 50% of the total budget. This figure includes the on-site assembly and precise installation of the 150 panels, the use of birdcage scaffolding, and the specialized tensioning systems necessary to achieve the project’s high standards.
The remaining 26% of the budget was allocated to other aspects of the project, including fabrication, additional materials, and completion costs. These covered the manufacturing of the custom panels and extrusions, additional steel framework, and final adjustments and inspections.
Overall, the project’s budget distribution reflects the extensive effort and resources dedicated to overcoming the challenges posed by delays and inflation, ensuring the successful completion of the Metro Sports Facility with the required quality and functionality.
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