mb design build 04 intro lowres

8/16/2019 Mb Design Build 04 Intro Lowres

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All projects designed, manufactured or installed byMoonBurst Structures staff

MoonBurst Structures Ltd, 320 Petre Street, Sheffield, S4 8LU, UK tel : + 44 (0) 114 22 1 8844 - fax : + 44 (0) 114 221 8866email : [email protected] - www.moonburststructures.comRegistered in England No. 4159716

AN INTRODUCTION TO PERMANENT AND

PORTABLE MEMBRANE STRUCTURES

SPECIAL STRUCTURES FOR SALE OR HIRE - WORLD WIDE


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We also provide a full event service, with the ability to supply aturnkey service for dealer support, roadshows, and to supplycomplete portable exhibition halls either as the main venue or asan addition to a traditional venue. Often experienced clientswish to manage the installation themselves. In thesecircumstances we work with the clients project team. Weoffer a full technical service in addition to specifications,drawings and downloads in PDF form (portable documentformat).

Design Life

Modern membrane materials are a complex mix of chemicalcompounds which perform well under a wide variety of environmentalconditions.

Typical life expectancy for a permanently installed membrane roof is inthe region of ten years depending on local conditions. Standard

membrane materials have a five year warranty, with extendedwarranties up to ten and fifteen years are available for suitable

fabric materials and coatings.

Most structural steelwork has the ability to last longer thanthe membrane roof, much like traditional roofing materialswhich do not generally last as long as the supportingframework and require replacement at intervals.

Whole Of Life Costs

In many cases the cost of a membrane can be further offset bysavings made over the life of the structure such as by reducedmaintainance or the electricity savings of a translucentroof.

Relocatable Buildings

It is possible to relocate a structure during its life withrepeatable results. These are available with Steel sidewalls and roller shutters for access. They can be boughtor leased for any period.

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DESIGN AND BUILDARCHITECTURAL MEMBRANES

MoonBurst specialist structures are state of the art, engineeredpermanent and portable building systems. We work witharchitects and engineers either as the prime contractoron stand alone contracts or as nominatedsubcontractors to supply the membraneelement of a project. We are fullyconversant with construction industrypractice and meet all on-site health andsafety requirements and CODAM. We use

qualified installation crew for rigging(IRATA), and skilled erectors for themembrane elements. We can meet all localbuilding codes specified.

Our architectural membranes are designed andinstalled to exacting quality levels. We provide a fullengineering service to clients for product design,installation, and maintenance. We can provide ten yearinsured warranties for all permanently installed structures.

PORTABLE STRUCTURES FOR PERFORMANCE

MoonBurst design and manufacture some of the largest mechanically tensioned portable structures in the world, includingthe ‘Kayam’ a revolutionary minimalist structure, the first version of which was built in 1991. Since then, these market leadingstructures have been used by most major music and cultural festivals in Europe,and in 2000 housed the performance of ‘Radiohead’ for their Europeantour, the first time that a market leading band had shunnedtraditional venues. The tour sold out, with more than150,000 people going to the performances. We alsodesign and manufacture the ‘Walt Disney On Ice’ 10,000seat portable structure to house the international iceshows in South America, the Middle East and inAsia.

In 1999 ‘Tensile 1’ (a version of his ‘Valhalla’structure) was erected in Don Valley athleticsstadium in the UK for Millennium Eave, with anoccupancy of 32,000 in the sole structure. This isbelieved to be the largest one night event of its kindin the world. Tensile 1 was awarded a Guinness WorldRecord for this incredible five acre portable venue whichis available for hire world-wide. MoonBurst have the solerights to manufacture the Kayam, Valhalla (Tensile 1) and ‘WaltDisney On Ice’ structures world wide.

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PORTABLE STRUCTURES FOR DISPLAY

MoonBurst have been used for many portableexhibitions over the years. Either as anexhibit at an agricultural show, or aroadshow for corporate clients, ourportable systems use state of the artstructures, flooring and wall systemswhich reflect the high standards theclients portray.

Smooth white glass fibre walls acceptbranding, logos and other graphics.

STANDARD STRUCTURES

While standard structures can be hired orpurchased, they can also be modified orspecifically engineered for their purpose. We haveextensive experience of providing performance space intemporary and permanent membrane structures. Fortheme parks, leisure facilities, touring shows and music performance, our structures have provided many years of

accommodation for organisations wishing to stage events in cost effective and quickly installed structures.All structures can meet local building codes for permanent or temporary installations, or as a minimum, the accepted localstandards for marquees and tents. They meet, and many cases exceed, the technical standards of competitors products.

DESIGN AND MANUFACTURE

Our design and manufacturing staff have developedspecialised techniques for shape modelling, materialtesting procedures, structural analysis, cuttingpattern generation, membrane seaming machinery

and manufacturing techniques.Most quality control measures centre aroundchecking that the workshop has interpreted themanufacturing drawings correctly. This has beenresolved by eliminating a whole level ofmanufacturing which was traditionally the ‘black art’of tent making, i.e. the ‘cut’. The three dimensionalshape is turned into digital two dimensional cuttingpatterns and then exported into the cutter/plottersoftware, which automates the process, reducingpotential errors.

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INTRODUCTION TO MEMBRANES

Compared with traditional buildings, designers and architects must incorporate a surface form created (usually) in softwarewhich is not subject to artistic desire or whim. This requires the designer to work with the engineer earlier than would beexpected in the traditional building process. As the engineering requirements can not be ignored, both architects and buildingsthat push the boundaries of design will need input from engineers at an earlier stage.

Compared to traditional buildings, fabric structures present a unique set of design challenges, as the shapes of membranestructures cannot be chosen at random. The absence of bending resistance requires designers to work within the constraintsof feasible membrane equilibrium shapes, which can only be easily arrived at with the use of software. The structure can beconsidered in equilibrium when all forces and reactions balance each other out so that there is no net change.

Fabric membranes compare favourably with traditional roofing materials. In particular, flat membrane roofs are extensivelyused as part of current roofing systems. The significant difference to the flat roofing system is that while the flat roofing ismainly non load bearing, tension membranes accept all environmental loads.

Membrane forms are usually complex, doubly curved surfaces which must be pretensioned in such away as to resist applied environmental loading such as wind and snow. A tensile membranestructure is prestressed and stabilised by the counteracting tensions of opposingcurvatures of an anticlastic surface (two-directional curvature of opposite sign,as in a saddle surface), or the synclastic surface (two-directional curvatureof equal sign, as in a of a spheroid such as an inflated dome or

hemisphere).

Special non linear techniques arenecessary for the structural analysis of tension structures, since membranes undergo large shape changes under varying loadconditions and fabric materials exhibit complex stress-strain response. Finite element techniques can be used to solve thesenon-linear problems. FEA or finite element analysis breaks down the surface into finite elements or areas and analyses thereaction effects and inter relationships of the elements.

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ENGINEERED ROOFING FABRIC - THE ADVANTAGES

Engineering fabrics can be used to provide a roofing material which offers unique properties to the designer. They can betranslucent or blackout, single or double skinned for insulation, and are resistant to ultraviolet light degradation over periodsof many years, sometimes longer than a traditional roofing material. Engineered roof fabrics can be self coloured or have arange of translucencies yet retain those properties over the service life of the structure, often 15 to 20 years. All materialsused by MoonBurst Structures have guarantees of a minimum of five years with extended warranties available on allpermanently installed structures.

Most engineering fabrics use a base of high tenacity polyester or glass fibre with a high modulus to minimise extension underload. Both exhibit high tensile strength to weight ratios with resistance to tears and high shear strengths. Yarn stability isunaffected by changes in temperature and humidity which provides the dimensional stability that mechanically tensioned

structures require. Specially formulated coatings provide extended performance characteristics for specific installations suchas arctic or desert conditions. As well as resistance to chemical attack and the retention of flexibility in cold weather, the roofmaterials can be repaired in situ for economical maintainance.

Engineering fabrics have been extensively tested over a period of many years and meet building codes around the world. Wehave test results for flame resistance, colour fastness, fade resistance, flexibility and elongation under load.

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MEMBRANES - THE DESIGN PROCESS

Engineering of fabric membranes requires expertise in two primary areas; in the conceptual design and analysis of stressedskin structures, and in the use of advanced geometry manipulation in the manufacture of the built form. In order to realise thecomplex three dimensional forms, it is necessary to use predominantly computer modelling techniques. Complex threedimensional shapes can be generated in special software suites which simulate applied environmental loads such as wind andsnow. The software can compensate for different loads and component properties such as fabric stiffness and cable forces. Ateach stage of the design and analysis process the geometry can be checked for suitability for manufacture. The software canoutput not only technical information such as readouts of forces at node level to assist in specifying supports, but design aidessuch as graphic output of deflections and contours, in addition to membrane, cable, and vector forces. Cutting patterns areoutput from the three dimensional form to ensure the design information is optimised.

Compared to traditional buildings, fabric structures present a unique set of design challenges, as the shapes of membranestructures cannot be chosen at random. The absence of bending resistance requires designers to work within the constraintsof feasible membrane equilibrium shapes, which can only be easily arrived at with the use of software. The structure can beconsidered in equilibrium when all forces and reactions balance each other out so that there is no net change. Membraneforms are usually complex, doubly curved surfaces which must be pretensioned in such a way as to resist appliedenvironmental loading such as wind and snow. A tensile membrane structure is prestressed and stabilised by thecounteracting tensions of opposing curvatures of an anticlastic surface (two-directional curvature of opposite sign, as in asaddle surface), or the synclastic surface (two-directional curvature of equal sign, as in a of a spheroid such as an inflateddome or hemisphere).

With a wealth of information at hand, every performance characteristic can be assessed. The post analysis form can beexported to visualisation packages to create photo realistic visuals and animated fly-through’s which provide an unparalleledopportunity for a potential client to assess the project.

This design loop of feasibility study, cost analysis, structural analysis, design for code provision, manufacturing detailing, andtransport and erection documentation forms a specialised branch of engineering which is practiced by a select few engineersin the world. A simple example that can be shown is that a typical membrane has single and multi layered fabric, reinforcingbelts, and steel wire rope cables all bound together in a complex interaction of forces. These materials all exhibit differentstretch characteristics which have to be allowed for in the manufacturing geometry. The materials have to be tested in thelaboratory and the compensations included in the production drawings so that when the structure is installed all componentsin their loaded state arrive at the correct point in three dimensional space.

An important part of the design process is final certification of the project. Certification and insurance are required for thesafe use and operation of leading edge buildings and rely upon a high standard of engineering. As all potential performanceparameters can be assessed, most project information can be extracted.

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MEMBRANES - ANALYSIS

The development of tensioned fabric membranes has gone from the use of early stocking models and ‘soap bubble’ tests tothe current use of multi programme software suites. Special non linear techniques are necessary for the structural analysis oftension structures, since membranes undergo large shape changes under varying load conditions and fabric materials exhibitcomplex stress-strain response. Finite element techniques can be used to solve these non-linear problems. FEA or finiteelement analysis breaks down the surface into finite elements or areas and analyses the reaction effects and interrelationships of the elements. The main processes that generally need to be undertaken are as follows;

Simulated application of loads

Even with a rectilinear building it is difficult to asses the loads that may be imposed due to the variables of weather and in

particular wind, which can exhibit unpredictable eddies and turbulence. When the force calculation is made more difficult dueto the three dimensional form of a membrane there are only three ways to assess the potential forces. One is to apply anoverall pressure co-efficient (uniform load) which makes allowance for most conditions. While factors of safety are a vital partof engineering, over engineering can be detrimental to a project and not just on the grounds of cost. We use softwareapplications which break down the surface of the membrane, sector by sector and apply a simulated load determined bydirection of force and angle of approach. This provides a more accurate method of determining potential force.

Validation of fabric properties

To provide accurate analysis of membrane structures, it is necessary to accurately asses the performance characteristics ofthe engineering fabric chosen, within the software. Once the chosen fabric exhibits the same performance characteristics insoftware as the physical tests, analysis can begin.

Finite element analysis

Typical membrane structures defy classical analysis. Modern engineers use sophisticated software tools to generate virtualmodels which can represent the real world project. Every part of the virtual model can have properties simulated torepresent forces and structural components in software. The model can then have surface pressures defined from projectedwind and snow patterns as above and assigned. The analysis provides output forces and geometry. The output forces are usedin the design of supports.

Cutting pattern generation

The form has geodesic lines generated on the surface in the position of the seam lines. This positioning is configurable tomeet production requirements and to match fabric roll widths. Seam lines are the jointed edges of the individual panels thatmake up a membrane section. The geometric information is used to provide 2D cutting patterns. The 3 dimensional form isbroken down into fields divided by the geodesics. These fields are then split into triangles which are opened up along theircommon edges and unfolded flat in software. The node points are then treated as co-ordinates for manual marking or todrive an automated cutter/plotter.

Building code compliance

Most structures around the world need to meet some form of local authority standards. The manufactured design must bechecked for compliance.

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MEMBRANES - MANUFACTURE

The use of computers in membrane architecture extends to manufacturing the built structure. We use large scale x-y cutterplotters for the creation of the cutting patterns, and predominantly laser cut parts for structural steel components, for whichthe information is generated by our in house specialist software.

Fabric structures rely on their geometry to work structurally. The difficulty in manufacturing the membrane is to translate thethree dimensional geometry of the finished and installed shape to the flat workshop floor, or in reality the other way round.The workshop is presented with a series of instructions which are not always clear, which is understandable when you thinkhow difficult it is to represent overlapping layers of cloth in acomplex layout. Fabric manufacturers and assemblers tend to useavailable production materials (apart from special mixes ofcolour) as the warranties could be an issue with special weavesand finishes.

The making of parts and components (sometimes with the help ofrobots), is usually considered a subspecialty of mechanicalengineering. Fabric workshops increasingly use automatedmachinery for the assembly of materials.

The knowledge of 3D CAD-CAM, engineering design, fluidmechanics, structuralcomputation, machine design,controls, robotics, operations,maintenance, and logistics are allinvolved in a project. All parts aredesigned with the aid ofcomputer graphics. The computercarries out all the technicalcomputations needed to make apart meet performancerequirements. This aspect ofcomputer-aided design (CAD) isfrequently coupled withcomputer-aided manufacture(CAM) to produce partsautomatically.

Although many differing computer aided manufacturing techniques are used, two examples can be shown;

1./ Using traditional woodworking practises, laser cutters can be used to create metal parts that not only allow complexshapes not easily attainable, such as slots or compound curves, but to ensure a perfect fit to the co-components. Lugs andgrooves are used to register the parts together, in a way not possible with normal fabrication techniques. These shapes aretransmitted to the laser cutter by MODEM or disk to provide geometrical information without traditional paperdimensioning.

2./ The two dimensional co-ordinates of the tents are passed to a large scale X-Y plotter, (some as large as 3 metres by 25metres, {10 feet by 80 feet}), which draws and marks or cuts by knife-edge or by laser, the fabric panels for seaming. These areregistered by marks down the seams to ensure perfect seam match on every panel. The marks identify the panel, (panelnumber, orientation, left hand, right hand etc.) to avoid confusion. These panels are obviously easily scaled down to allow the

manufacture of a model for wind tunnel analysis, thereby completing the circle from design to manufacture.

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STRUCTURES FOR HIRE

The MoonBurst Hire Structures

Our hire products have been used for most high profile events in the UK and some events overseas. We provide a full serviceto predominantly corporate clients although we have provided structures for private functions such as the private hospitalityat the Hyde Park hotel for the after concert party for the Pavarrotti performance which housed princes and princesses aswell as Prime Ministers, cabinet ministers and a host of celebrities. The structure has been used for many Royal and nationalevents.

The MoonBurst provides a most attractive and comfortable venue for hospitality as well as a spectacular housing forcorporate displays. The structure has been used at some of the top sporting events for hospitality such as the British GrandPrix, the Open Golf, Royal Ascot, Cheltenham, Burghley, the Derby, Lords and Old Trafford. It has also been used for air showsand many other events. The roofing system also covers stages and seating grandstands.

Our hire equipment has features not availablewith traditional marquees. Self levellingfloors, hard walls, glass and aluminiumsides, modern lighting. All contributeto a truly modern and uniquestructure fit for any occasion.Our venues reflect the highstandards that discerningclients require. Corporatebranding, high classinteriors, white fibre glasshard walls, slam proofhydraulic doors, and flexiblelayouts all provide featureswhich impress clients. Forover ten years the MoonBursthas been used at the top corporateevents. Tailored packages for any eventcan be quoted for.

We can tailor our standard structures for hire ordesign and build structures to clients specifications. Corporate graphics can be applied to almost any surface of ourstructures. Solid glass fibre walls (normally white) can be sprayed or have printed vinyl applied. We are able to map imagesonto the 3 dimensional surfaces of the roofs, including photographs, as can be seen in these images.

STORAGEBuildings for long term storage and maintenance can be supplied with personnel and roller shutter doors and plastic coatedsteel sides up to any size. All structures are capable of being tailored for most installations. High side walls, extreme snowload capabilities and industrial storage solutions such as roller shutters and personnel doors are among the many possibilities.We will consider any form or size of structure. We are able to provide solutions to most short or long term installations. Wecan provide a solution from the ground up, or include below ground works if needed. Structural calculations for all localitiescan be provided. (Maximum site wind speed to suit your specification). MoonBurst Structures Ltd can provide a turnkeyfacility for all kinds of project. Long or short term storage facilities can be provided for sale, hire, or lease withquick installation times. The structures can be supplied with security features such as steel side walls and roller shutters. Sidewall heights up to 5 metre high are normal with higher sides with custom build.

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MOONBURST MARQUEE

The MoonBurst was designed in 1990 by Rudi Enos to provide solutions better than the more traditional flat roofed frametents. Despite being innovative in design, the MoonBurst takes little longer to erect than similar frame structures. Thepretensioned roof membrane provides more stability in uncertain weather and reduces the noise of the framework. Webelieve there is no finer structure in the world today.

The MoonBurst has proved it’s worth at many events such as: The Royal Show, The British Grand Prix, Royal Ascot, TheOpen Golf, Corporate Roadshows, Hyde Park Pavarotti Hospitality, Burghley International Trials, Ebbw Vale Garden Festival.

MoonBurst is a visually stunning and unique fabric structure. Designedand manufactured in the UK to exacting standards, it combines thepracticality of a well proven extruded aluminium frame togetherwith a superb flowing roof which sweeps towards theground, giving a dramatic sense of style tocompliment any occasion.

The unit is based on modularframework which allows almost anyconfiguration and size to be achieved.Clear span widths of 12.5 metre to25 metres (40 ft to 80 ft) can bebuilt on in multiples of 5 metres (16ft), to create unique structures fromthe small party to large exhibition andHospitality Villages. The MoonBurst ismanufactured to exacting standards. Onthe MoonBurst for example, the 15metre span frame work is taken from a25 metre span system. This allows forthe structure to be more stable, tosuspend higher weights and to reducethe inevitable deflection of the aluminiummembers at the larger span, much desired whenused for exhibition or road show purposes.

The modularity of the structure also defines the size of the membrane sections being deployed. The main consideration is theability to connect the membrane sections together structurally (and in a leak proof manner), which determines the time toassemble the membrane. If the sections are too large, then the folding and unfolding requires greater manpower and takeslonger. If the sections are smaller the joining process may effectively wipe out any productivity gains of moving a smallersection. Only experience can determine these ratios, as they require the interactivity of the installation crew to prove. Ourcrews have many years of experience in the movement of portable structures and have refined our ability to predict thecorrect ratios.

MUSIC

The MoonBurst is ideal for staging music performance. Different versions have high side walls and load carrying capability tosuspend light and sound equipment. By adding modules, the capacity of the structure can be extended to accommodate over4,000 people in festival form. The structure is suitable for fashion shows or other performance.

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