VALMEX®structure to permanent architectures guideline Technical tensile 1 st Edition 2 Contents
The following information is intend- Our intention is to support architects, ed as a basic guide for architects engineers and generally all those who and engineers to assist in concept approach the technical and commer- design and in specifying materials, cial aspects of membrane structures in order to get enough preliminary solutions. background for planning activities.
General introduction 4
The Fabric – Material properties 6
Material types 7
General performances 10
Special materials application – Facades 12
Environment and sustainability 13
Design 14
Manufacture and installation 17
Maintenance 19
Frequently asked questions 21
3 Brief introduction to the tensile art of construction
Tensile architecture is probably fabric materials in modern architect- one of the oldest methods used ure can shape space, enabling to provide protection from adverse architects to sculpt 3-dimensional climatic conditions and against areas in a manner that is not possible predator attack. The humble ‘conic’ with any other type of material. This tent is the simplest form of tensile kind of architecture is offering much structure, and excelled where two more: the designer is able to play conditions prevailed: a shortage of with light and use this for natural building material and a need for illumination of the space, softening mobility. Evidence has been found it, fusing it, sharpening it or shaping Example of primordial tent which confirms that humans have it. This creates mood and ambience construction using animal skin. been making tents for at least 15,000 to reflect architectural intent, re- years, initially using animal skins, and sulting in an energy saving covering only 3000 years later, incorporating system, by approaching the element- woven fabrics. One of the first appli- ary need of being in touch with cations of tensile technology came nature. The dynamic shape and form at the very beginning by transferring of membranes allow new possibilities sailing principles. The spectators to become reality. at Roman amphitheatres (e.g. the Coliseum) were protected against the In no other sector of architecture do sun by retractable sheets of fabrics form and load distribution depend on roofs, supported by timber masts and each other as greatly as they do in cotton fibre ropes as operated by membrane construction. Hence, these sailors. Differing forms depended on represent the perfect marriage between different materials available at the architecture and engineering. time – for example the American In- dian Tepee, the Bedouin tents or the As in nature, the course of forces Mongolian Yurt. These forms have that are shown in the form and shape developed over time, using more can fascinate not only architects and advanced materials and construction engineers, but also the wider public methods into larger and more diverse as well, especially those who can structures such as the Canada Golf appreciate the equilibrium between Dome in Beijing, China. Modern aesthetics and functionality.
Example of modern tensile architecture
4 About Mehler Texnologies
The Company Mehler Texnologies − always „one of the first“ Mehler Texnologies is one of the Mehler Texnologies, as a pioneer in internationally leading companies this area started in 1944 with the 1944 on the market for coated fabrics. coating of PVC-Polyester membranes Start manufacturing of PVC-coated We produce in our facilities in Hückel- and were “one of the first” to im- fabrics hoven and Fulda in Germany as well prove the special PVDF lacquering 1954 as in Lomnice in Czech Republic and techniques, today synonymous with Technical coating of Polyester base distribute annually more than 50 long-term cleanability and added fabric million m² material under the brand long term UV protection. 1969 names VALMEX®, POLYMAR® and Mehler Texnologies has acquired a Lacquering of tarpaulins by means AIRTEX®. Our customers are found in wide range of expertise and experience of acryl top coat processing industries. More than 60 in the field of membrane architecture 1993 years of development and product- materials and is specialized in textile First coating based on Polyolefine ion experience are the basis for our products for particular uses. (PVC-free). Environmental recycling mature products. Continued research concept standards introduced and development improve existing Our capabilities at a glance: 1994 compound materials and open new First weldable PVDF-lacquer application areas. 50 million m² fabrics VALMEX® MEHATOP F comes into approx. 600 employees worldwide production A stable quality for all our products 3 production facilities 2004 is achieved by our state-of-the-art 9 sales companies Designed and produced new revolu- weaving and coating machines. 7 sales offices and sales partners tionary lightweight banner material Constant quality monitoring in our around the world for digital printing (AIRTEX® GT and laboratories, intense dialogues with Our goal, serve the specialized AIRTEX® magic) planners, manufactures and pro- customer. 2006 cessors in different market segments First coating of polyester base fabric and industry branches prove our Mehler Texnologies is your with temperature and chemical resis- close and trusting cooperation with specialist for coated fabrics and tant Fluorsynthetic base THV our customers. technical textile materials.
Biaxial strenght test Weaving loom (high speed)
Precision coating plant
Manufacturing of coated fabrics is committed to Tear strength test Spread the coating highest quality standards.
5 The Fabric – Materials properties
A coated structural fabric usually increasing and perfecting those consists of a woven base cloth materials in each aspect. stabilized and protected by a coating on both sides. The base cloth consists There is a wide range of products of warp threads running the length which are very suitable for particu- of the roll and weft threads running lar uses, depending on the specific across the width. A mesh fabric is a project needs and the particular coated cloth with spacing between defined use (ex. façade shadowing the thread bundles. or roof covering, etc.). Regardless of Sometimes mesh fabric can also refer the fact that each material can be to a woven shade cloth where pre- used for textile roofing we suggest coated threads are woven into cloth. our customer contact the specialized industry and proceed to this choice For the engineering of tension struc- after particular analysis of all project tures, the most common choices are characteristics, in order to assure the PVC coated Polyester cloth materi- best possible decision taking into als. High quality low-wick treated account the aesthetics, the mecha- PVC-Polyester fabrics generally have nical/static load properties and the a structural lifespan in excess of 20 economical aspect of the project. years. On ordinary materials the plas- ticizers in the PVC migrate towards the surface over a period of time top coat making the surface harder to clean. primer The PVC coating contains additives main coat that include UV stabilisers, fire adhesion layer retardants, colouring and fungicidal base fabric agents. Mehler Texnologies quality adhesion layer materials under the brand name main coat VALMEX® MEHATOP are a choice of protective PVDF (Fluorinated Poly- primer mer) lacquers that enhance the top coat cleanability of the PVC membrane. Typical section of Mehler coated PVC-Polyester fabric To improve this and maintain trans- lucency, Mehler is offering a range of products including PVDF lacquer Conventional MEHATOP F on both material sides, perfectly immediatly weldable. The choice of a suitable after soiling after 1d material is dictated by many charac- at 70°C after 2d teristics, ranging from technical at 70°C and mechanical properties to the after 3d at 70°C aesthetical appearance, coming from after 7d physical material properties. at 70°C after 10d at 70°C
after 14d The textile industry is constantly at 70°C not improving the existing materials. cleaned Mehler Texnologies as a pioneer soiled cleaned Non low-wick base fabric absorbs liquids and properties. the membrane degenerate fabric producer is continuously a barrier to Low-wick base fabric generate of liquids assuring the original infiltration properties. membrane Comparison between low-wick and non low- wick base fabric
6 Materials types
In the architectural segment, mem- warp direction (length of the material textile architecture engineer or branes made by Mehler Texnologies roll) has less stretch to stabilize the specialized manufacturer. are multilayered composite materials elongation in this sense. The weft with special densely woven low-wick direction (the width side of the mater- This requires a certain kind of techni- yarns in base fabric. The double thread ial roll) has more stretch in order to cal information generated by com- woven fabric, commonly described absorb the orthogonal tension more puter analysis, simulation and testing as “Panama” weave, varies depending readily during the distensile install- processes, generated case by case for on the mechanical resistance reques- ation process* (see graphic below). each project. ted by the customers. The different membrane materials are graded by Professionals like to maneuver the Mehler Texnologies can provide to weight and strength, and an overview compensation ratio of the fabric the customer biaxial results for each of the standard types of materials is material during the patterning process produced batch of material. The tests listed below. in order to generate ad-hoc geo- are executed on client request to metries and unique smooth surfaces. external accredited laboratories based Mehler Texnologies materials are This process is generally considered on MSAJ/M-02-95 procedure. basically ”pre-stressed” with different “top secret” to most of them and is force grades in both directions. The also the core of the well qualified
Overview of Mehler Texnologies architecture PVDF-coated material types ® VALMEX FR 700 Type I FR 900 Type II FR 1000 Type III FR 1400 Type IV FR 1600 Type V Art. 7205 7211 7269 7270 7274 Finish PVDF-lacquer on both sides, protected against microbal and fungal attack, UV-protected, low-wick Total weight 700 g/m² 900 g/m² 1050 g/m² 1350 g/m² 1550 g/m² Tensile strength Warp/Weft 60/60 kN/m 84/80 kN/m 120/110 kN/m 150/130 kN/m 200/180 kN/m DIN EN ISO 1421/V1 3000/3000 N/50 mm 4200/4000 N/50 mm 6000/5500 N/50 mm 7500/6500 N/50 mm 10000/9000 N/50 mm Tear strength Warp/Weft 300/300 N 500/450 N 900/800 N 1200/1200 N 2000/2000 N DIN 53363 Light transmittance (approx.) 6 % 5 % 4 % 3 % 2 % Flame retardancy BS 7837 BS 7837 BS 7837 BS 7837 BS 7837 California T 19 California T 19 California T 19 DIN 4102: B1 DIN 4102: B1 DIN 4102: B1 DIN 4102: B1 Most common width 250 cm 250 cm 250 cm 250 cm 250 cm Welding weldable without grinding and with common welding equipment Higher strengths on request, program changes reserved. All technical data stated are based on laboratory tests at average results and are provided as a source of information and do not constitute a warranty. Applications suggested here do not release customer from testing material for its intended application. Colours are subject to slight variations. Always check the validity of fire certificate.VALMEX ® is recyclable. Manufactured by quality standards DIN EN ISO 9001:2000
* Attractive widths
fewer seams lower manufacturing costs
VARIO-STRETCH: less stretch Warp in warp direction than in weft direction lighter equipment Weft shorter assembly times lower erecting costs
very flexible easier handling high strength higher safety lacquered both sides more durable Example of asymmetrical curvature shapes with symmetrical high gloss attractive appearance primary structure, only generable by using VARIO-STRETCH no need to grind directly weldable fabric, properly compensated.
7 Advantages of weldable PVDF coated fabrics
Mehler Texnologies, a pioneer in This is the reason why our fabric is Many years ago the construction in- PVC-PES coatings, introduced more weldable, easy to manufacture and dustry in general, from construction than 14 years ago weldable PVDF stable (non-peeling). A properties to automotive, was using thicker, coated membrane. In our opinion, comparison with non-weldable PVDF heavy and in general oversized ma- the textile industry should provide coated materials follows. terials for different uses. With huge products to the market which can investments and precise objectives perform without the need to be Other material producers have this no longer applies, helping, and modified, ground or manipulated by recently offered a weldable version in many case improving, materials the fabricator. The industry should as well as a non-weldable PVDF. The performances in end use products assume in full the material properties performance of these weldable PVDF like those actually used in buildings responsibility, not delegate this to lacquers are affected by the thick- and cars. So, effective membrane additional substances, to manipula- ness of the lacquer, which for tensile materials have to perform with less tions of the surface, to the uncon- architecture where the absolute efforts and environmental impact; trolled machines operation capability concept of “less (weight, mass, membrane materials lacquering is or simply to human factor. emissions, etc.) is more”, increasing not a matter of quantity, but more It is wrongly assumed that the of the lacquer layer would be full about absolute quality. weldability of PVDF coated material in contradiction. The substrate of is given by the percentage of PVDF lacquering instead has to be thin as included into the top coat. possible to perform as protective sheet to the coating surface, be Mehler’s PVDF coated fabrics, flexible enough (image 3) to avoid incorporates a primer between the stiffness of the material and at the top coating lacquer and the PVC same time be stable, avoiding the so coating, completing 5 components call “peeling effect”(image 1), the in the building up of the product (s. release of the lacquer from the schematic picture at page 5). Other coating surface (image 2). manufacturers show 3 to maximum 4 components (base fabric, adhesion layer (some), coating, lacquer).
Image 3: Effect of stiffer surface due to thick lacquers. In some circum- Image 1: “peeling effect” due to Image 2: Lacquer adhesion problems stances the lacquer substrate can exaggerate lacquer thickness and in translucency. Where lacquer is not generate deep cracks to the PVC bad adhesion. performing the coating is directly coating. exposed to soiling and UV attack.
8 Comparison PVC/PES-Fabrics with weldable/ non-weldable PVDF coating
Comparison PVC/PES-Fabrics with weldable/ non-weldable PVDF coating Product PVC/PES-PVDF PVC/PES-PVDF non weldable Specification weldable MATERIAL PROPERTIES Basic fabric PES (Polyester) PES (Polyester) Type of coating PVC (Polyvinylchlorid) PVC (Polyvinylchloride) Top-coating Primer +blended PVDF Variable concentrated mixture of PVDF (polyvinylidene floride) variation (polyvinylidene floride) with other amalgamating lacquers compounds (Mehatop F) Total weight approx. 650 to 1550 [g/m²] approx. 750 to 1500 [g/m²] Tensile strength approx. 2500 to 9800 [N/5 cm] approx. 3000 to 9800 [N/5 cm] warp Tensile strength in approx. 3000 to 8300 [N/5 cm] approx. 3500 to 6500 [N/5 cm] fill Material roll width 250 cm (Standard) approx. 180 cm (Standard) Thickness up to 1,2 mm up to 1,2 mm Translucence up to 15 % up to 15 % Flammability Flame retardant according to Flame retardant according to DIN 4102, B1 DIN 4102, B1 as well as other classes as well as other classes Colour standard white, extensive standard white, extensive colour choice , no bleaching colour choice , no bleaching Manufacturing, Handling, Installation Manufacture Standard HF machine function Standard HF machine function tests. Grinding machine: devices preparation tests adjustment of the grinding parameters and replacement of grinding strip based on request. Preparing of grinding work area. Weldability Standard HF weldable without Top coat lacquer needs to be ground with abrasive machines. grinding the surface top Risk of damaging the basic fabric/ reducing depth of the PVC coating. Welding seams coating or insufficient removing of the top coat lacquer when strength and resistance are parameters or abrasive strip properties are changed. High risk of constant. inconsistent welding seams, strength and resistance. Foldability Standard comparable to PVC Not defined. Depending on the thickness of the lacquer may Acrylic coated materials. result to be difficult to high difficult, due to stiffer surface Based on Crack resistance conformation. Risk of abrasion on doubled folded areas and test DIN 53359 A+B ÈNo crack crack of the whole coating compound higher. @ 100.000 tours Manufacturing None Large area for folding operation is necessary. Grinding space to facility special be isolated and separated from manufacturing space. Grinding resources particle pollution contaminate working atmosphere. Patterns and pattern seams collect additional dirt. Human resource None Persons using grinding machine or working in the near proximity special resources need to wear minuscule particle masks and protective glasses. Seams and/or None Grinding seam lines to be sketched on and along the material welding areas surface. Membrane reinforcement area (cone top, corners, etc.) preparation needs to be ground by hand or using off-axis grinding machines. On site welding, Standard skill required: direct Special skill required: welding areas are to be ground off by repairs and welding to carry out by means means of off-axis grinding machines. Especially in case of close preparation of hot air welding machines flaps welding it may require additional working time and additional human safe harness equipment. Higher risk of main membrane damage. Higher risk of insufficient welding resistance performance. Higher risk of additional dirt collecting into the welding areas. Direct welding to carry out by means of hot air welding machines General Cost evaluative Low. Add factors, well Higher. Add factors, complicate by handling, quietly stiff, difficult (material/ foldable, easy welding and manufacture process and long term installation process in case processes) short installation. of site welding (close flaps, site joints, etc.). Recycling Full recycling possible Full recycling possible Expected lifetime > 25 years > 25 years Self- cleaning effect Good, where necessary Very good, where necessary during normal maintenance during normal maintenance cleanable with standard non-solvent cleaning agents cleanable with standard non- solvent cleaning agents Warranties Standard ¹ 10 years, can vary Standard ¹ 10 years, can vary depends from project depending on project requirements requirements Application field Standard systems, temporary Standard systems, temporary and permanent constructions and permanent constructions, mobile and foldable constructions
9 General performances
Wind Fire
A frequently asked question is if The fire performance of a membrane at lower temperature than PTFE membrane structures are suitable material depends on the base fabric material. This means that in case for permanent installation on windy and coating type. All membrane flames reach the material surface sites. The answer is usually „yes, materials will melt under higher tem- or the internal temperature reached as long as the project is properly peratures, even if at different grades. above approx.100° C, PVC membranes engineered”. Today it is possible to VALMEX® FR is difficult to ignite and help in exhausting smoke quickly generate computer analysis of the passes many national fire tests. The and reducing overburning effects. different load cases which show that speed of this process depends on PTFE on glass will melt at approx. the wind load is the major load case the type of coating, the temperature 300°C. In this case, all smoke and in any scenario. The detailing of the reached into the covered space in fire gases generated below the surface fittings and surrounding structure situations and the pretension in the will be captured within the buil- play an important role and needs membrane. The effect in a fire situa- ding which is a big health threat to to take into account the maximum tion is beneficial for the persons due the people, destroying a large part deflections of the membrane. Under to the fact that melted areas gene- of static construction materials. extreme circumstances the engineer- rate self-venting opening through a When the temperature reaches the ing and material choice has to be failed seam in the membrane surface PTFE melting point, welded seams carried out with particular attention. and consequently a natural smoke will open suddenly and give way Designing for permanent load cases reservoir (which may allow sufficient to a flash-point situation, with the (downloads are e. g. snow and sand, time for escape, when sufficiently conditions existing for the possibility uploads are generated by wind hot) will occur. There is no risk of of an explosion due to the emission suction) requires extreme care as burning droplets or fire propagation of oxygen (as example, material rips, there is a greater risk of form finding on the material surface. melting point or by opening a door). mistakes such as e.g. water pounding Additionally, the reduced mass avoids In case of fire PES/PVC melts where or sand build up (which can cause high weights falling down. Designers the flame reaches the membrane permanent uncontrolled stretching should consider smoke and collateral and lets the smoke escape. As a of the structure). In these circum- effects generated by the material consequence there is no flash-point stances, the fabric forms generally used. situation to fear about. need to be steeper, spans smaller, curvature greater and sometimes, The fire performances of materials In general, fire rating classifications intermediate cables needs to be are classified based on their perfor- are only defining the material introduced as fabric support. mances in case of fire dictated by performances (burning resistance, the material behaviour of the project smoke generation, droplet, ecc.) once requirements. As well know, PVC will exposed to fire sources. Is task of the melt with non-drops consequences user (architects, planner or special- ist) in evaluate and integrate those performances into the entire design concept, taking in account what DIN would be better and safer for people and support construction materials, and not for the material itself.
For high point structures critical steelwork should be supported by means of safety cables so that partial Mehler Texnologies fabrics easily pass the majority of quality tests at several failure of a damaged membrane roof institutes and independent testing laboratories in accordance with major will not cause collapse of the suspen- worldwide testing mandates. ded structure.
10 General performances
Sun, humidity and pollution Thermal insulation Lighting
Mehler Texnologies structural fabrics A single layer of VALMEX® FR 1000 Natural lighting is now a firmly es- incorporate UV stabilisers that pro- membrane with a of 1050 g/m2 has tablished concept in architecture, as tect colour and base cloth, slowing a U-value of approx. 5.7 W/m2K (DIN governmental institutions encourage the rate of degradation. 52611). In this respect it is very simi- energy saving processes. The most lar to glass. A twin skin with a 200 common PVC-PES fabrics available In areas of high humidity, regular mm air gap will give an approximate have visible light transmission of cleaning will reduce the risk of mould U-value of 2.7 W/m2K. between 5 and 16% (depending on growth on the surface of the fabric wavelength). However, predicting that may cause permanent staining. It is possible to get lower U-values actual light levels beneath a mem- Regular hosing down or effective than this by using additional material brane requires specialist advice. ventilation prevents mould build up layers to the fabric system. However, Factors such as the angle of the sun in the majority of cases. this needs to be designed for as it during the seasons, reflectance from will affect the performance of the surrounding structures and internal Wind, rain and running water carry entire enclosed space and also will finishes will all affect the light levels. small quantities of dust and other reduce the light transmittance levels. UV light transmission lost through polluting agents which are deposited membrane materials is usually less on the surface of the membrane. In certain environment conditions, than 10%. Generally rain, given that it is regular, high reflectance top coating or UV VALMEX® FR Solar light properties should remove most of these particles blocking materials can be of interest. - translucent - from the surface of the membrane. This can be a solution for example The progressive accumulation of in case of open air cinemas or circus Reflection (+/- 85 %)* small quantities of the particles will tents, where the light transmittance Radiation still occur. When it gets to the stage would disturb other lighting effects. that the majority of the particles Absorption (+/- 10 %)* remain on the surface and are easy Transmittance (+/- 5 %)*
02/2006 to perceive then the surface is * for standard white, method Mehler Texnologies - ASTM E 424, at 550 nm considered dirty. PVDF coating helps to impede soiling and facilitates cleaning.
Mehler materials grade of transmission is measured at 550nm, for humans the centre of the light spectrum visible part.
Colour A B C D E Solar transmission approx 5% 0% 0.5% 0% 12% A = translucent, standard white (at 550 nm) B = opaque white C = colour 141 pearlwhite Solar reflection approx 85% 85% 70% 40% 85% D = colour 852 sandstone (at 550 nm) E = highly translucent, white 919/008 Solar absorbtion approx 10% 15% 30% 60% 3% Thermal conductivity: approx 0,18 Watt/(meter x Kelvin) (at 550 nm) Heat transfer co-efficient: UV-transmission (<380 nm) 0% 0% 0% 0% 0% approx 5,7 Watt/(sqm x Kelvin)
11 Special materials application − Façades
Buildings able to adapt to changing temperature producing an effective The fabric has a low thickness of 0.45 climatic conditions are commonly working atmosphere. mm, has a low weight of 380 g/m² termed “intelligent buildings”. Since and has reliable roll up and unroll the term intelligent can be mislead- The use of energy-intensive air properties, enabling Flashguard® to ing when used in the context of conditioning equipment such as air be inserted in space-saving roll up buildings or façades, we will better conditioning systems, fans or air devices. Flashguard® use the term “adaptive façade” conditioning units is reduced and in • Contributes to reducing energy instead. Adaptation generally means many cases unnecessary. costs that buildings and façades adapt to • Generates pleasant room tempera- current weather conditions, espe- The open fabric structure of Flashguard® ture cially directed to the sun protection provides natural light. Dazzling • Re-create natural illumination functionality. sunlight, which has a detrimental • Avoids dazzling sunlight at compu- effect on health particularly at com- ter workstations, increases product- To meet this challenge Mehler puter work-stations, is prevented. In ivity by creating a pleasant work created the Flashguard® fabric which addition, the open fabric structure is atmosphere has been designed to meet the see-through from the inside, but not • Space-saving by low thickness and specific requirements of sun pro- from the outside, providing a high light weight tection systems and is suitable for level of privacy. It allows natural light • Easy roll-up and unroll properties both indoor and outdoor use. The to pass through. • Dirt-repellent and easy care exceptional material properties of • Flame-retardant Flashguard® reduce sunrays to create Flashguard® fabric uses 100% Polyes- • Keeps its appearance over a long a pleasant room climate. The use of ter. It is highly stable, weatherproof period sun protection fabrics negates the and extremely durable in long term • Light-, weather- and colour-fade need for expensive air conditioning, use. It is capable of withstanding resistant e.g. for maintaining productivity and temperatures between -30°C and Sun light Flashguard® Glazing protecting temperature sensitive +70°C. The special PVC coating makes devices. This helps to considerably the open fabric particularly dirt- reduce energy costs. repellent and easy care. It is flame- retardant according to test standard Sun protection fabrics contribute to CERF Category 1, NFPA 92507 M2, save energy by absorbing or reflec- DIN 4102 B1. Owing to the use of ting the main portion of energy high-quality colour pigments and contained in sunrays before these UV stabilizers, Flashguard® is ex- can heat the room. Particularly in the tremely light and weather-resistant hot summer months, sun protection and keeps its appearance over a long fabrics provide for a pleasant room period. R A T SA
Farbe Front / face 907 275 858 809 177 190 333 820 608 584 536 729 758 911* 911* 911* Colour Rück / reverse 901 275 858 809 177 190 333 820 608 584 536 729 758 911 907 275 Strahlungstransmission % T Solar transmission % 23 14 17 12 18 18 24 12 16 16 21 15 10 17 14 11 (DIN EN 410) Strahlungsreflexion % R Solar reflection % 66 64 57 47 60 54 40 8 30 34 27 54 20 47 58 55 (DIN EN 410) Strahlungsabsorption % A Solar absorption % 11 22 26 41 22 28 35 80 54 50 52 31 70 36 28 34 (DIN EN 410) Sonnenschutzfaktor innen Internal solar protection factor 0,51 0,52 0,57 0,63 0,55 0,59 0,68 0,88 0,74 0,72 0,76 0,59 0,80 0,63 0,56 0,57 (DIN EN 14501) Sonnenschutzfaktor außen SA External solar protection factor 0,25 0,17 0,22 0,16 0,21 0,22 0,32 0,26 0,23 0,26 0,31 0,19 0,22 0,24 0,17 0,15 (DIN EN 14501)
Sächsisches Textil Forschungsinstitut, Prüfbericht 0344/05 * Silber der Sonne zugewandt / Silver to the sun 12 Environment and sustainability
Mehler Texnologies and our emissions of CO2, in line with the ation with specialized partners, we label for Environment Engage- EU environment protection require- are effectively contributing to an in- ment ments. crease in the re-utilisation of tons of PVC components, to generate re-built Mehler Texnologies believes that the As a consequence of the optimiza- products via the EPCoat system. preservation of the environment is tion processes, Mehler is re-utilizing much more than “waste manage- production waste (like coating paste The membrane materials recycled ment” as may be the case of the sole and postproduction fabric waste) to via EPCoat system are mechanically recycling tasks. All activities have produce a so called E-Membrane, shredded and transformed into now been bundled under one all- designated to be used as a low- common use industrial products. This embracing label. quality product for several uses, from differs from other systems, as this can soil impermeability to temporary be applied as a reliable large scale coverings method, and in most cases locally, so there is no pollution produced during transportation of the materi- als. Also this does not use “additional Mehler, as one of the largest coaters solvents” to separate the compo- in the world, producing more than nents. In our opinion it doesn’t make 50Mil.m² fabric products per year, is sense to use chemicals to generate operating on a vast scale of activities, low-quality solvent-contaminated and has taken prevention activities chemical compounds which cannot on raw materials, the whole product- be used for producing high quality ion process, and lastly taking care of Mehler is additionally one of the fabrics. This is part of our way of the finished waste. active partners of Vinyl 2010 understanding “sustainability”. (http://www.vinyl2010.org), an or- Beside our own policy, and following ganization putting into practice the Those, and future activities, comprise the EU regulation on use of chemi- commitment of the European PVC the ”Mehler eco-care” statement. cals, Mehler has for many years sup- industry to Sustainable Development. Please find our new ”ECO-CARE“ bro- ported various EU-based associations Thanks to coordinated activities at chure for download on our website pro-actively, contributing in reduced all supply-chain steps and in cooper- http://www.mehler-texnologies.com emissions, thus helping to preserve the environment.
Our commitment to the environment starts with the raw materials select- Tarpaulins Post-consumer-waste Carrying ion. To do this, Mehler is selecting post-consumer-waste all chemical compounds based on the REACH (see attached statement) regulation. No one single additive rejected by the REACH rules is, or will be, utilized by our technicians to ful- fil any performance of our materials. Manufacturing technical textiles The production process is strongly EPCoat collects post-consumer-waste controlled and all machinery has been optimized to reduce energy Extrusion along the coating process; additio- nally, some years ago Mehler invested Shredding millions of Euros to reduce the New products
13 Design
Membrane constructions can be sub- This means, that either the form of A completely free invented design ject to tensile stress only due to the the membranes approaches the form form therefore must be compelled low compressive and bending rigidity of so called “minimum surfaces”, with the help of additional compres- of their surfaces. However, plane (following physical principles under sion and/or bending-stressed carrying surfaces react sensitively to defor- the condition of similar surface elements and at partly inadequately mation by external loads. They tend stresses within defined continuous high pre-loading and/or construction to flutter and to create snow and edge elements), or it is influenced by expenditure. water-traps, which in extreme cases changing the boundary conditions, can lead to failure of the construc- or by inserting additional supporting tion. The stabilization of plane areas elements (which can be linear, plane would require uneconomic high or supported at certain points) res- pre-stressing. Consequently, design pectively by different surface stress and draft follow completely different preconditions. This allows creating principles than other supporting either “anticlastic” saddle shape sur- structures, which are mainly bending faces or generating “synclastic” sur- or compressive stressed. In particular faces when using pneumatic internal the difference is that the process pressure like a balloon. Supporting of design of mainly tensile stressed media for producing internal pressure membrane constructions mostly can be air, gas, water or other liquids Geometry and forces defined inde- develops self-regulation. but also granulated materials. pendently of the materials used.
Examples of design by construction, rendering and model making: First price of Mehler Texnologies‘ VALMEX® Structure Award 2007 by Architect Sra. Eliana Ferreira Nunes from Brazil.
14 Design
Design process
The stress demands put on the After arriving at a stable configura- membrane surface will determine tion, the structure is analyzed under the construction and the patterning various load cases using large deflec- of the edges, tension elements and tion finite-element method analysis anchors. Determination of the form, software. (the cutting patterns as well as the Figure 1: hyperbolic paraboloid preconditions for the load-sensitive These programs permit the inclusion demands of the surfaces as a basis of of tension-only membrane elements, the static-dynamic computations) was as well as cables, struts and beam determined a few decades ago in elements in a three-dimensional order to simulate a full scale repre- computer model resulting in rapid, sentation of a natural structure. accurate member analysis and sizing. Today‘s engineering achievements Each batch of fabric is tested in make use of proven computer biaxial (both direction) mode, to generated methods for the accurate measure the stretch in both thread construction unit dimensioning and directions at load ratios derived Figure 2: the conical form automated cutting. from the form generation computer model. These figures are then used The structural analysis must be com- as “compensation percentages” that pletely integrated into the architec- are factored into the patterning tural design. The geometry of the software. The fabric is deliberately membrane is established through a manufactured undersize so that „shape generation‘‘ (form finding) when installed to its final dimensions Figure 3: the arch supported or barrel technique in order to ensure static it tensions out correctly. form equilibrium of the system. Stress analysis must incorporate „large Mehler Texnologies vario-stretched deformation‘‘ techniques in order to materials properties have been produce accurate results. perfected to meet the engineers’ requirement in equilibrate and be The geometry of a tensioned mem- reactive to force distortions gene- brane system cannot be precisely rated by orthogonal loads reaction. Figure 4: filled synclastic form defined before analysis. First, a shape generation technique must be used to establish the natural “equilibrium shape”.
The equilibrium shape is the geo- metric configuration which induces in static equilibrium with its own internal pre-stress forces.
Integration of 3-D models in architectural design
15 Form finding and pretensioning
Permanent tensile membrane struc- tension under any design load case. Proper material compensation and tures are designed to resist the same Imposed loads are resisted by redis- fine-tuning application of the bi- basic loading criteria as conventional tribution of the stresses within the axial values (as well as material high buildings. Imposed minimum live membrane system. If this results in quality mechanical properties) are loads and wind pressures are derived any area going into compression then here highly demanded. Those factors from the requirements of the local creases will appear and in critical when properly evaluated are avoiding building code or the model code cases generate form distortions until “relaxing” of the membrane surface having jurisdiction. structure collapse. and consequent re-tensioning needs. Mehler Texnologies materials are This architecture needs a symbiosis Similarly, if the pretension is not commonly performing in the time (s. of live forces in each situation. The properly distributed or not high FAQ section this guideline, at point 3. force generating those forms is the enough then substantial movement What consideration should we allow tension transmitted and governed by of the structure could occur with for the membrane material service the material. Pretension is defined as consequent destabilization of the life?), with proven and excellent the tensile forces in the fabric after whole tensile structure. values. erection but prior to external loads being applied.
The ratio of pre-stress in the principle curvature directions, which dictates the shape, is initially established in the computer form generation process. The absolute values of pre- stress are calculated to be sufficient to keep all parts of the membrane in Computerized load analysis on the Higher stress concentration in weft membrane material in warp direction. direction. Note the different loads distribution on both directions of the membrane surface. Detailing
Once analyzed form and material These generally consist of a cable Use of complicated devices and properties will be necessary to carry sitting in a pocket at the edge of the non-standardized forms will seriously out a preliminary statistical analysis. membrane. In some structures, webb- affect the design and the commercial ing belts can be added parallel to the aspect of the project. As part of the preliminary design edge to take out the shear loads. process a provisional load analysis derived from a computer model will Membrane edges can also be linearly give typical load directions and figures fixed. Usually there is a rope edge of the design loads to be transferred also called “keder” formed by sealing to the supporting structure. By des- a flexible PVC rod in a small pocket. cribing the supporting structure, the This can then be trapped behind an type of connections and all accessory aluminium clamp plate bolted direct- Example of corner fitting plate device parts like the perimetral links, anchor ly onto the structural steel work or plates and corner devices are to be slid into an aluminium track extrusion. dimensioned properly. A properly designed fabric structure The boundary of the membrane usu- should take account of these elements ally falls into one of two categories: as well as all other particulars to curved and scalloped edges. minimise membrane material waste.
16 Manufacture
The fabrication of the membrane The production itself can be sub- High frequency fabrics is a specialist activity and re- divided into four phases: delivery and welding process quires experienced personnel, special quality inspection of the material, materials and facilities adapted for cutting, welding and packing. Welding is effected by conducting the works. Experienced manufac- electrical energy in the form of a turers secure a QA manager to over- In case of non weldable Top coat radio frequency field to the two see the quality aspect of the fabrica- lacquer, this needs to be ground with surfaces that are to be joined to- tion and conduct the final inspection abrasive machines. Risk of damage gether. This stimulates the molecules and acceptance of the finished mem- to the base fabric/ reduces the depth in the material to move at a speed brane. of the PVC coating or insufficient re- of approx. 25 million times a second. moving of the top coat lacquer when The friction that arises between the The cutting patterns are generated parameters or abrasive strip proper- molecules generates the heat that is using 3D computer models of the ties change needs to be minimized required to fuse together the mater- structure and taking into account by paying particular attention. High ial. A weld seam is thereby created the required compensations for the risk of inconsistent welding seams which has the similar strength as the individual production weave batches strength and resistance can occur. surrounding material. of membrane material and the edge Persons using grinding machine or The electrical field is conducted to corrections for welding seams and working in close proximity need to the material through a metal tool, edge details. These electronic cutting wear minuscule particle masks and an electrode. Welding performances patterns are then transferred by a protective glasses. The work area de- need to be tested at each machine computer into a controlled cutter/ signated to grind needs to be isolated adjustment, new start or malfunc- plotter. from the rest of the facility. tion. Normally, the welded seam resistance should be at least 70% of The joining or assembly process of During the production process, the material resistance. the single membrane area (patterns) records are made of all the work for the PVC-coated fabrics is normally steps to guarantee state-of-the-art per high frequency induction. To this workmanship. The manufacture pro- end the main tools for fabrication cess of fabric membranes does not are purpose built welding machines. bear any significant environmental Periodical measurement of the main risks. All waste materials are disposed parameters, like the output tempera- of in accordance to governmental ture or the executed pressure level regulations. of the machines will be carried out by common external gauges. The hand-held welding process by means of hot-gun tools are used to do the detail work at corner etc.
High frequency welding
Cutting the patterns Final check
17 Installation
The installation of the fabric systems The installation of tensile systems is a highly specialized area of work requires reasonably clement weather requiring experienced personnel and conditions. The lightweight of the special access equipment. However fabric materials, coupled with the the tools and other equipment are large areas of exposure, means that standard items used in conventional work can only precede at wind construction rigging. speeds of less than 5 m/s. At higher wind speeds certain lifting opera- Most of the roofing materials, i.e. tions must be suspended. Installation membrane fabric, cables, etc. are should be stopped at temperatures relatively lightweight, but access below 10° Celsius. Working at heights Areas below open-height working has to be provided for most of the is a high-risk activity. All personnel shall be cordoned off and warning construction area. shall be familiar with a safety induc- signs should be placed advising of tion course and be briefed on safe the danger of falling objects. The One of the biggest advantages of working procedures and require- crane(s) and other lifting equipment membrane structure is the easy, clean ments. All men working at height shall only be operated by trained per- and quick installation and adjust- should have a full safety harness sonnel. Crane lifts shall be controlled ment process. Because of its light- with two safety lines, one of which by the crane operator and rigger / weight no heavy hoisting equipment must always be attached to the fixed banksman shall be present at all lifts. is required to get it in place and life-lines. When working at heights Safety procedures at the start of specialist riggers can install them in operatives must always be secured each shift shall include a ‘buddy- most cases practically by hand. with a fall stop device. All lifting system’ check of all PPE for each equipment shall be pre-checked and worker at height. The main functions of the installa- sufficient for the loads to be raised. tion of the fabric roof are verifying the tolerances of the main structure, installment of the temporary works, securing of the primary structures, and the quality and safety control process of the installation.
Installation phase for a high point concept. Therefore only in tensile shaped membrane roof. This process structures it is possible to cover requires to be integrated into 2000m² surface within 5 full days planning phase and must be carefully installation time. synchronized in the whole installation
18 Maintenance
The Mehler Texnologies membrane A continuing awareness of the con- Depending on the project location material is weather resistant and dition of the membrane is essential. (and the maintenance dedicated should provide many years of trouble Throughout the life of the structure to the membrane covering) small free service life. there shall be visual inspections con- quantities of dust and other pollut- However, the fabric can be cut ducted to spot any obvious damage ing agents could deposits itself on or torn, and damaged by a sharp or deficiencies. If any are found they the surface, degenerating the natural impact; it can be crushed if sub- shall be further investigated and beauty. Generally rain removes most jected to high localised ‘pinching’ action taken to repair or correct as of these particles but when it gets loads, caused by bad design or by deemed necessary. Emergency repairs to the stage that the majority of the inappropriate clamping devices. Care to the membrane material shall be particles remain on the surface and must therefore be taken in handling carried out by persons experienced in are easy to perceive then the surface the material at any process stage working with this. One of the great is considered dirty. and while walking on it, to protect advantages of the VALMEX® MEHA- against accidental damage. Inspec- TOP FR materials is that even if PVDF Like any building materials, fabric tors and workmen working on this coated, they are perfectly weldable structures look and in some circum- roof must wear clean, soft, white- without grinding of the surface, even stances perform better when regular- soled shoes. Care must be taken on site, by means of hot-air gun ly cleaned. Following the instruction not to drag any tools or equipment tools. of our maintenance manual will help across the surface which may lead to preserve the aesthetical characteris- premature deterioration of the roof tics of your project. Please refer to material. this additional document for more particular indications. On structures of this type, the mem- brane is a structural part of the roof system, and not just a protective Maintenance and cover. It is mechanically pre-tensioned Cleaning Manual to provide a stable roof system capable of withstanding the design Inspection and conditions of wind, sand, weather Maintenance Manual etc. However, if damaged, redistribu- for Tensile Architecture tion of load can result in a concen- tration of stress that could cause a General instruction propagation of tears. Minor problems for the safe inspection can become major if neglected. In and maintenance order to assure proper service life, it of tensile structures is essential that good operation and maintenance practices are adopted The information issued within this manual is intended to act as a guideline and strictly adhered to. for cleaning and maintenance tasks according to our actual knowledge as per September 2008, and is without legal commitment of any kind
Technical Textiles and is not a substitute for the warranty certificate guidelines.
Mehler Texnologies GmbH Rheinstrasse 11 Edelzeller Strasse 44 D-41836 Hückelhoven D-36043 Fulda Tel. +49 (0) 2433 459 0 Tel. +49 (0) 661 29275 0 Fax +49 (0) 2433 459 151 Fax +49 (0) 661 29275 366 [email protected] · www.mehler-texnologies.com
19 Condensation
In some climatic conditions, internal In case of pneumatical structures (it perature which generate condensa- condensation is likely to occur with is not a matter which material will tion are not exposed to adequate roofs covering a sealed heated space. be used) more control is required and ventilation. Also, is possible that Appropriate design of roof gradients then it is often necessary to incorpo- during installation there may be and edge detailing can minimise any rate a dryer between the air blowing damages to the lacquer (ex. by problems. Ventilation can obviously and the internal skin chambers. sliding the membrane on the floor or reduce the risk but if more control is The dryers prevent the temperature simply carrying the material over a required then it is often necessary to difference (outside/inside) that can cable fitting, etc.) which generates an incorporate a second layer. Controll- generate water condensation in- opening on the coating, exposing the ing the airflow in the air gap bet- between the layers, even if there is material to UV and water penetra- ween two fabric layers is recommen- a permanent air blowing occurring. tion. ded to get the best environmental To reduce the risk of fungal attack, control. A sealed air gap is best in periodical cleaning of the surface by The problem becomes significant on winter for insulation and a good air- use of simply clear water is required. temporary structures, where it is flow in the summer will help cooling. Experienced designer’s use high point necessary to erect and dismantle structures to allow the natural “ne- several times, and in most cases, The design of roofs (particularly gative thermal buoyancy” generated quickly stored for the next event. in conic forms) can make use of a by the roof form to grant permanent There the risk of damage to the “passive stack effect” where natural air flow and at same time excess of lacquers, coupled with humid airflow along the surface of the fabric “vitiated” air evacuation. material, can cause serious problems. is enhanced. This may be artificially Moisture can not only come from reproduced by fans or louvers, to Long exposed surfaces, especially rain, but also from condensation achieve the required performance when not maintained, are more (water forming itself when fabric and to reduce the risk of fungal exposed to fungal accumulation and has been folded and packed, without attack. consequently to aesthetical (and in any protection (as the membrane extreme cases physical) deteriorating folded generates multilayered, almost Therefore, in addition to the inherent of the material properties. “sealed” substrates) and stored in protective additives in the material, sun/shadowing areas or in humid it is of high importance that for the In general the designer takes care of spaces. This is also the problem of design itself, adequate gradients this on permanent structures; there some retractable roofs, in particu- and edge detailing are considered to the problem can appear where venti- lar where dust and water remains optimize the natural ventilation and lation of the inner surface is insuffi- accumulated and where ventilation is minimise any problems. Ventilation, cient or there are “static areas” where insufficient. in natural or artificial way, can ob- differences in outside/inside tem- viously reduce the risk but based on our experience, this is not the only aspect to take in account.
Example of moulding for wrongly stored temporary structures. It is clearly to see that mould has formed at the internal part of the folded material, probably due to the fact that the Fabric under fungal attack. Micro material was stored wet or organisms have already invaded the that the storage place was coating with possible deteriorating of not adequately dry. the original material characteristics.
20 Frequently Asked Questions
1. Advantages of lightweight, illumination, which allows for natural preserve our environment is beginn- more extensively defined, sus- protection against the elements ing with the strength selection of the tainable architecture. and ventilation, when engineered chemical compounds as per REACH properly. (Registration, Evaluation and Au- Other than the obvious aesthetical Tensile structures perform under thorisation of Chemicals) regulation aspect (most tensile structures tension instead of compression and coming through CO2 emission reduc- acquire landmark status much easier bending as we find evident in most ing investments, recycling process than conventional buildings), there traditional structures. Furthermore, of internal materials rests as well as are numerous arguments supporting tensile structures are flexible when produced fabrics, to packaging and the reasons which have consistently compared to traditional building transportation management tasks. attracted many architects to investi- structures which are generally rigid. One of the most evident advantages gate the field of tensile architecture The aforementioned factors result in of using lightweight structures is and therefore get involved in projects tensile structures to be pre-manu- covering a long span as a suspended that incorporate tensile structure factured and forwarded in smaller roof system capacity, which again has which we have witnessed for more containers to site, rapid execution the benefits of reducing the material than 40 years. with regards to installation, and the mass used, lowering costs, reducing The use of this type of architecture majority of material that was used to delivery time and energy savings. generally assists in the drastic be recycled. This kind of structures can be easily reduction of the transformation of Mehler Texnologies is participating integrated into regular buildings and raw materials and their utilization, actively in Vinyl 2010, the self-com- in many forms of construction, from therefore directly contributing in the mitment EU association coordinating roof to façade and from ceiling to reduction of environmental impact. and financing processes optimization divisors, improving the physical, the Tensile Structures use natural light and recycling activities for the PVC- aesthetics and cost effective proper- thus providing translucency, which Industry sector. Our point of view ties of your project. results in a reduction of artificial regarding active contribution to
2. Interesting, let us talk about forms working as tensile (or tension) structures should start immediately lightweight structures, what is structures that can be mechanical or with the conceptual design carried that? pneumatically supported. out by the design architects under Commonly, these forms of construc- the supervision of membrane specia- Tensile structures are called this tion reject the “angular” idea of lists. Mehler Texnologies high quality because all forces are distributed and enclosed space therefore highlighting PVC-Polyester fabrics have been used they are also commonly lightweight the beautiful, essential and modern by pioneers in this field and due to structures and are characterized by curved design style to a much greater permanent innovation been opti- mass in relation to the forces work- extent. mized for several uses and diverse ing within these structures. The design process is similar to customer requirements. Let’s consider a practical example: conventional buildings which are the weight of 1 square meter of a due to the relatively low level of 7mm float glass for roof construction “know how” to the wide spectrum is approximately 20 kg/m², instead of of a non-specialized designer, it approximately 1 kg/m² for a type III requires follow up measures at the membrane material, and this without very beginning of the whole project taking into account the enormous design stage. It is important to carry sub-structure required involving out for example preliminary analysis traditional construction materials. to define the living loads acting on This type of architecture is catego- the foundations. In other words, this rized by smooth and harmonious means that the design of the tensile
21 Frequently Asked Questions
3. What consideration should A great example of longevity would condition and in particular higher we allow for the membrane be the Grand Stand Open-air Theatre wind and snow loads, is actually one material service life? in Elspe, Germany. Completed in of the most evident examples of pro- 1978, this structure is one of the perties longevity for our materials. Properly designed permanent most advanced and spectacular The material used is a Mehler Texno- construction can yield above 20 year tensile structures to this day, delight- logies Type IV PVC-PES coated fabric. lifespan, which is highly dependant ing visitors with its imposing steel The residual mechanical resistance on the design, the quality of material members sustaining the membrane (tensile strength) when measured used, what the building is used for, roof and suspending it over 2.000m² in year 2007 was 95% of the initial the maintenance grade applied dur- space. The project, designed by the value. This has to be considered an ing the project life and the environ- engineering company Naumann & excellent performance due to several mental conditions of the location of Dollansky, has protected approx. preconditions, good performing engi- the installed project. 4.500 persons daily from possible neering, quality membrane material, Permanent structures will obviously adverse conditions during the daily execution and maintenance tasks). last longer than non-permanent programmed shows since then. The structures and the longevity of non- 25m higher masts are suspending the Up to date, there is no request to permanent structures is predomi- membrane roof so that a 100m area replace the fabric. The membrane nantly dependant on the mainten- could remain free of any obstacle. covering remains a safe and attrac- ance, the utilization intensity, and tive eye-catch structure for all who the erection and dismantling The structure, due to permanent are visiting the park. methods. exposure to typical German climatic Our materials undergo intense internal testing along the complete production process and fulfil most of the commonly used quality test methods.
Living example of longevity: The grand stand of the open-air theatre in Elspe (D), realized in 1978 with Type IV PVC-coated membrane by Mehler Texnologies.
4. Amazing, but… how can you The UV stabilization substances out. The special surface lacquering ensure that your materials are absorb the UV rays and protect the system “MEHATOP F” provides addi- resistant to external agents? colour pigments against bleaching. tional protection against infestation It is true that after a period of time, by fungus and micro organisms. Our Mehler Texnologies materials for depending on the UV intensity grade, architecture materials are generally architecture are designed to resist the plasticizer components start to guaranteed for 10 years from pro- environmental factors and general migrate, which results in the PVC duction date which is dependant on external agent influences. Projects coating becoming stiffer. This results the project characteristics, the end located in areas which have extreme- in change of colour intensity under use design, the material type and the ly high UV exposure require materials certain circumstances and this helps guarantee is extendable to longer with high UV stabilization sub- us to recognize projects whereby period of time which is dependant on stances. regular maintenance was not carried other circumstances of the project.
22 Frequently Asked Questions
5. Are our materials available in production of colour pigment addi- post production. We currently have different colours? tives and cleaning of machinery is many standard colours in production a process that requires a substantial with some in a metallic finish. Parti- Technical textiles are available in a amount of time with the involve- cular requests are carefully analyzed wide range of colours upon request. ment of a multitude of resources; we so that we can adequately advise the Tensile roofs are realized in white therefore provide support to our client of any added costs and delivery most commonly so to increase the customers by making hand samples time. maximum grade of natural light available of the coated fabric pro It is important to note that our transmission. duced in our laboratory. We will pro- products are highly UV stable. If we Theoretically, all colours can be duce the requested colour additives use a scale of 7, our product line generated taking into consideration and be ready for the coating proce- VALMEX® will achieve a grading of 6. that an entire batch has to run dure only after the client has pro- This explicitly means that the colour through a coating machine. It is vided us with approval of the hand fastness of our products is to be con- easily understandable that the samples so to ensure superior results sidered very good to excellent.
6. How much natural light tone. The covering looked very good to note that our material translu- transmission is necessary and due to the aesthetical appearance cency is standard measured at 550 how much are our products but this led to the tennis player nanometers of light spectrum inten- allowing? becoming disturbed with the green sity (daylight intensity, that is very shadowing on the tennis court. close to the frequency to which the Using natural resources in buildings In reality, anyone can feel uncomfor- human eye is most sensitive). This is for purposes of functionality are table underneath a highly trans- the range where we detect light in- considered “intelligent architecture” parent covering when the sun is tensity changes; some other material items. The reason for this is to fully shining. The quantity of natural light producers use higher light intensity understand the needs in energy, and and the high UV transmission causes references to increase their values. therefore environment, saving. For this space to become very warm and For particular uses (for example, a normal use, a space with a general, consequently may disrupt common circus tent) completely block-out diffuse light transmission of 5% is tasks that may have to be carried out material may be most suitable, which appropriate to carry out living and by people while in the confines of are practically not permeable to the working tasks (e.g. reading a news- this construction. external light and can be produced paper). Our products allow for different in combined and different (exter- Lower transmission grade fabrics may grades of transmission from 2% to nal/ internal) colours. Please consult require to be artificially illuminated 15% (HFT pigmented), also depen- http://www.mehler-texnologies.com or in comparison, spaces with too ding on the strength of the material, or contact us for a more detailed much light (UV) transmission can be the thickness of the coating and the indication of the properties with found to be unpleasant by the public. colour of the coating. It is important regards to our material. The grade of natural transmission has to be carefully analyzed “case Average daylight during summer in Middle Europe by case” as this can have dramatic consequences to the final results and Sunlight 100,000 LUX depends very much on the intended application of such a building. Membrane with For example, a sport complex com- light transmittance of 5% =~ 5,000 LUX pany was planning to install tennis court coverings a few years ago. The architects preferred to integrate arch Reading a paper supported tensile coverings into the requires 300 LUX surrounding area with a light green only
23 Frequently Asked Questions
7. How does the material mance standards worldwide whereby low danger of falling sub-structure perform in case of fire? our materials are also compliant; components when compared to individual country valid certification traditional construction methods VALMEX® material range has been is available upon request. Our mate- should we take practical examples approved by the German Institute for rial has a very low mass ratio due to into consideration. Construction and the normative for it being only a few millimeters thick Furthermore, the material surface material classes DIN 4102 as B1 and in comparison to other construction will melt open natural smoke vents is therefore graded as flame retar- materials. An additional advantage of which help ventilate the construction dant and self extinguished classifi- using our materials for tensile with regards to smoke generated by cation. There are several fire perfor- architecture is that there is a very burning material below.
8. Material maintenance and sharp objects which can be repaired PON®, a solvent free and non alkaline cleaning, is this an argument? on site eventually and can be execut- detergent produced by the company ed usually when normal cleaning Max Bail which is located in Germany. Due to low adhesion of dirt on the occurs. The cleaning intervals may The surface must be rinsed off by material surface which is increased vary from the type of material and tempered and clear water; the deter- even further with fluorpolymer top the project location. The mainten- gent can be sprayed or applied by coated product line, the pollution ance program should be evaluated clean cloths and then simply wash that may occur will predominantly be at the very beginning of design as away by water after a few minutes. removed by rain. Depending on the this may require additional safety Please follow cleaning instructions as design in comparison to conventional equipment. specified by the detergent company covering materials, the maintenance No aggressive or polluting detergents regarding dilution and environment required by membrane is considered must be used when the material protection. very low. Regular inspections would surface is cleaned. We recommend initially locate damages caused by specialized products such as UNGA-
9. What kind of guarantee We warrant that the material is in includes approved information in does Mehler Texnologies offer? accordance with the released data general on the project scope and use, sheet, that the tensile strength of the on the design, on the statistical ana- In standard form, we provide 10 year product will not reduce more than lysis, the engineering details, and the warranty time on our products 3% per year on an average base and manufacture and installation process (MEHATOP F, PVDF lacquered). that the material will remain water- and not at least on the mainten- This warranty covers any abnormal proof (if not damaged) and flame ance program. The aforementioned deterioration which causes the fabric retardant. information is then evaluated by our to become unsuitable for weather The project warranty certificate will technicians and if all information protection, including abnormal be issued on the basis of the infor- provided is satisfactory, this can lead deterioration in tensile strength, mation provided by the customer at to a longer guarantee being issued. fire retardancy and waterproofness. the time of the order process. This
24 Frequently Asked Questions
10. Fine, all above is clear, but… This evaluation at the beginning of A PVC-PVDF membrane covering how much does it cost? the project where the majority of the price can range as purely demons- information has only been analyzed trative value between Euro 100/m² The costs of the membrane material superficially is the very challenge for to Euro 300/m² and as seen this vary vary due to the several types, reliable cost estimation, due to its according to design, type of fabric, strength, coating and finishing pro- customised nature adding to the type and range of structural support, perties. difficulty of estimation. This is an- project location and difficulty grade However, compared to other tensile other example whereby tensile during the installation task, without building materials, PVC-PES mem- structures differ from standard to consider wastage factors, trans- brane is effectively the most approp- constructions when compared. Each portation duties and taxes. riate choice under the performance/ realized project is a unique ad-hoc Material wastage and labour costs costs optic. design solution; each detail can vary on conic forms as example are much Furthermore, due to the easy and from manufacturer to manufacturer, higher than on other typical designs. widely used high frequency (HF) statistical and quality requests are In comparison and even considering welding technique, the high grade different between various countries this as indicative, a PTFE-coated of flexibility and the extremely rapid and finally the experience in this membrane covering of same kind production time, PVC-PES material field of all partners involved during could arises the whole costs of 30% makes the project increase cost execution can play a crucial role to 50%, not only due to the consi- effectiveness. regarding the costs evaluation and derable price difference between the the actual project costs. materials but much more because of Mehler Texnologies materials has the complication during manufactu- been tried and tested within the Therefore, once all of the aforemen- ring and the quietly difficult installa- most reliable and specialized mem- tioned is established, it is obvious tion methods. brane manufacturing industries that the estimation of tensile Air supported structures (pneumati- for many decades, optimizing the structure should be undertaken by cally supported) require continuous material performances during the professionals which must be carefully air support even if only to replace projects manufacture process. Reliable taken into account at the beginning the eventual leakage, and as a result properties like easy handling, easy of the design stage. have higher operating energy costs welding and easy installation due to than tensile structures. the variable stretch ratio assists our The costs of the membrane material, clients in reducing unnecessary costs in the case of PVC-PVDF fabric, arise These values are to be understood and execution time. between 5% and 15% of the total as purely demonstrative and do not The cost of installing customised project amount, depending from exclude deeper investigation of tensile structures depends greatly material type. As consequence, costs generation on the project you not from the difference between the should be not there where cost needs are planning to realise. The examp- PVC-PES material choices, but much to be saved on material quality les of cost above are related to a more by other kinds of material charge. 4000m² large single layer high point choices. shaped tensile structure, realized in Other factors playing a crucial rule Europe during mild weather condi- in defining the project costs are: tions, without foundation and any the project size, the design form other civil construction. and its complexity, the statistical requirements, the structural support types, cables, quality of fittings with regards to the accessories materials and connections, the manufacturing and installation method required and finally the local soil and weather conditions.
25 Frequently Asked Questions
11. OK. Last but not at least: • For over 60 years, Mehler has • Our weldable PVDF top coated ma- when PVC-PES membrane − continually developed innovative terial (MEHATOP F line) has more why Mehler Texnologies? quality products making us a refer- than 14 years proven in the market. ence for the whole industry • We deliver in attractive widths of We offer our clients all our know- • Our organisation pro-actively up to 5 metres (standard 2.5m). ledge and experience in this field. preserves our environment. Our • To reduce CO2 emission we operate Mehler is a well-accepted pioneering products strictly follow the Euro- warehouses around the Globe, to Company in production of Polyester- pean rules and can be recycled into deliver promptly throughout the PVC coated fabrics and holds long different products. year. term experience and good relation- • We offer our high quality materials • We produce 50 million square ships with most accredited pro- in various grades and finishes. meters/year of high-quality fabric fessionals all around the world. products at our 3 facilities in EU.
12. Any other questions?
Then please, do not hesitate in contact our specialists at [email protected]
Note: This information has been provided with the intent to help understand the applications of our material and cannot be considered binding for any personal evaluation or reference. Mehler Texnologies GmbH retains the right to change, replace or modify this information at any time without prior notice.
26 Copyright note Texnologies GmbH is the originator has to be printed into or next to the of or contributor to the publication described material. A corresponding The brochure and the entire content unconditionally requires the written proof has to be furnished within 8 is protected by copyright. Mehler permission from Mehler Texnologies days after publication / use in form Texnologies GmbH is the exclusive GmbH. of a specimen copy. The same rule holder of the copyright of this applies in context with written infor- material. When using pictorial material under mation or excerpts from texts issued the express permission of Mehler by Mehler Texnologies GmbH. Any use of the material, text des- Texnologies GmbH, the copyright cription, pictures, or also excerpts remark: Digressions of any kind on the above of them as well as the Mehler logo, (Material description) note shall be persecuted by law as or other graphic components which © Mehler Texnologies GmbH, per German rule. allow the conclusion that Mehler [email protected]
The Autor well-known tensile manufacturing Thanks specialists, with worldwide compa- Mr. Paolo Giugliano joined Mehler nies, covering several positions from Special thanks to Prof. Dr.-Ing. Bernd Texnologies GmbH in early June manufacture through to installation, Baier for his support. 2008, responsible for the tensile and then sales/project manager. Thanks to Maffeis Engineering for products segment. Mr. Giugliano the renderings. knows this specialised construction In addition to extensive and practical industry acquiring practical expe- know-how of textiles architectu- Thanks also to riences over 15 years. During his re, Mr. Giugliano has expertise in Prof. Dr. Robert Off, Institute director, career he was employed, until his determining the cost evaluation and and the staff of the IMS Institute for move to Mehler Texnologies, at project planning/control. Membrane and Shell Technologies for the attentive supervision.
Mehler Texnologies – Technical Textiles Worldwide Europe• Mehler Texnologies has sales com- USA• • panies and sales offices all over the China• Emirates• • • world. India If you are interested in contacting us, you can reach us at Brazil [email protected] • Australia • • South Africa • Additional information on New Zealand www.mehler-texnologies.com
Disclaimer: The details and information given correspond to the current state without any legal validity and are subject to alterations without notice. This infor- mation indicates the general performance of the materials only. Specific details must be confirmed for each project and where necessary from the producer directly. (02/2009)
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E002/GB/12/2010