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Tensile Fabric Shades Fabrication and Installation Methodology

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Below is a precise method statement that covers the fabrication and installation of fabric components of the tensile fabric shades that includes:

This procedure shall be read in conjunction with project specifications wherever applicable.

Below is the equipment required for fabrication and installation of fabric shades.

The capacity / size of the above equipment shall be judged in accordance with site conditions, requirements, and availability at the time of execution.

STEEL STRUCTURE FABRICATION FOR SHADES

Engineering department will issued approved client drawing for fabrication to quality and fabrication department.

Fabrication team shall prepare cutting list as per approved fabrication drawings.

Fabrication engineer will take material from store as per cutting lists.

QA/QC engineer will check layout before cutting as per the cutting lists.

Fabricator will make fit-up as per approved drawings.

QA/QC Engineer will inspect fit-up as per approved drawings.

Fabrication supervisor will assign certified welders for welding of the structural elements.

QA/QC Engineer will inspect welding joints as per specified and applicable standard.

Fabrication engineer/supervisor will supervise final cleaning and finishing.

QA/QC engineer will make final inspection and release for blasting & painting.

Blasting and painting foreman will blast and paint the material as per approved painting specifications.

QA/QC engineer will make final inspection as per client specifications.

FABRICATION OF FABRIC FOR SHADES

QA/QC Engineer will inspect all the materials to make sure these comply with the contract specifications.

Fabric rolls are supplied only by recognized international manufacturers of architectural fabrics.

Factory supervisors shall be responsible for full implementation of quality and safety procedures.

The factory area shall be clean and dry, inspection of the factory floor surface shall be done on regular basis to avoid damages to the fabric.

Fabrication area has polished timber floors and anyone entering the factory area must remove footwear.

The plotter operator shall inspect each panel of the material over the plotter table for any faults or marks which might cause rejection.

Any faults during fabric visual checking or due to any other reasons are to be reported immediately to supervisor for inspection and clarification of its use.

Prior to commencing, the plotter operator shall check that all cutting patterns are within cutting area of table and do not overlap each other.

Any queries that arise must be answered before marking and cutting begins.

All patterns are to be cut by the plotter unless otherwise discussed.

After plotting, a final check of panels will be performed by the plotter operator.

Operator will check that panel numbers, fold lines etc. are present on all panels.

All panel marks shall be made with a GREEN pen only which can be removed with white spirit and clean cloth.

When plotting is complete the operator shall complete plotting sheet and sign off his work.

A properly performed high frequency weld shall be defined as one which when peeled apart, removes the Teflon or PVC coating from one or both sides completely. This is referred to as “delamination” test.

All weld surfaces must be clean and free of obstruction prior to welding.

Ensure the welder bottom plate is covered with barrier paper prior the welding.

All test welds are to be welded out of the fabric being used for the project.

The test weld samples for the completed job shall be labeled and placed with project detail sheets. These samples will be stored for future reference.

Any errors in welding shall be immediately reported to production supervisor

Overlapping panels must be properly lined up and even tension placed on either panel.

Uneven tension will cause wrinkling in the fabric once it has been welded and this will not be acceptable.

Use the maximum size welding bar suitable for the project as to minimize the amount of welds required.

The welding bar should be checked for surface quality and straightness before use.

Report any faults to Supervisor.

Test welds to be performed before commencing welding on project fabric.

Welds should have no excessive PTFE / PVC visible outside the weld width.

When welding is complete the operator will complete fabrication worksheet and the supervisor will check and sign off this work.

Doublers are to be welded with small plates “Floaters” using the size that minimizes the amount of welds per doubler according to the size of doubler.

All hardware including cables, membrane plates, nuts and bolts etc. shall be made as per the project specifications and design details.

Holes in fabric for membrane plates must be punched in the factory using the membrane plate itself as template, provided this will not pose any risk to the safe packing and transport of fabric panels to site, membrane plates are to be fitted in the factory to avoid any misfits on installation site.

As far as is practicable, also bale rings are to be fitted inside the factory to ensure no misfit problems on site.

Fabric Supervisor Worksheet shall always show record of the date work was performed, the operator who performed the work and the supervisor who checked the work.

Fabric inspection shall cover below details:

The above record sheets are provided to factory staff prior to commencement of each project.

Plotting sheet and fabrication worksheet must be filled throughout each process and must be kept in the project file during fabrication.

These records are to be kept in the appropriate project file and archived for future reference on project completion.

INSTALLATION OF SHADES

Supervisor engineer shall ensure that material submittals and subcontractor are approved by the client/consultant.

Ensure that shop drawings showing details of fabrication, assembly, installation and fixing of specific items or components are submitted and approved by the client/consultant.

Installation should be done as per the manufacturer recommendations.

Check that all necessary clearances and permits are available.

The work areas must be barricaded with warning tapes before start of work.

Work areas must be clear from unwanted material and other obstructions.

Make sure that all the survey and setting out works are complete and inspected by the consultant.

All levels / locations for base plates and/or other fixings are correct as per approved shop drawings.

A typical installation sequence shall be as follows:

The anchor bolts that hold the steel structure will be done first.

These are either cast-in RCC footings or site-fixed into RCC walls/slabs/columns using HILTI chemicals.

Structural steel framing (columns and beams) shall be then fixed and made plumb / square. All bolts will be tightened up.

The factory-packed fabric panels will be positioned on a clean surface area over a clean ground sheet.

Each fabric panel will be carefully opened and its accessories (viz. membrane plates) bolted to it.

Fabric panels will be carefully lifted up and connected in position as per the sequence.

Extreme care shall be exerted to avoid any damage to the fabric during installation.

Fabric panels will be then tensioned as per approved procedures to the shape intended.

Finally, the completed structure will be cleaned up and any paint scratches shall be touched up up to the client satisfactions.

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