Fabric Structures Rev A PDF

021826
Structural Fabric Specification

King Abdullah International Gardens
Stage V Construction Issue Report
Section 13130 April 2009
Revision A
Buro Happold
Revision Description Issued by Date Checked
A Construction Issue LT 24/04/09 JW
021826 King Abdullah International Gardens

Structural Fabric Specification - Section 13130 Report Revision A
Stage V – Construction Documents April 2009
Copyright © Buro Happold Limited Page 1 of 25
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This report has been prepared for the sole benefit, use and information of Riyadh Municipality for the
purposes set out in the report or instructions commissioning it. The liability of Buro Happold Limited in
respect of the information contained in the report will not extend to any third party.
report collation Liam Taylor
signature
date 24/04/09
approval Jeremy Wedge
signature
date 24/04/09

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Contents – 013130 FABRIC STRUCTURES

1. PART 1 – GENERAL........................................................................................................................1
1.1 SECTION INCLUDES..................................................................................................................................1
1.2 RELATED SECTIONS .................................................................................................................................1
1.3 REFERENCES..............................................................................................................................................1
1.4 PRECEDENCE OF DOCUMENTS............................................................................................................2
1.5 DEFINITIONS ...............................................................................................................................................2
1.6 OWNERS APPROVAL ................................................................................................................................3
1.7 DESIGN AND COMPLIANCE WITH SPECIFICATION..........................................................................3
1.8 MATERIALS ..................................................................................................................................................4
1.9 WORKMANSHIP ..........................................................................................................................................4
1.10 DEFECTIVE WORK................................................................................................................................5
1.11 SUBLETTING...........................................................................................................................................5
1.12 STORAGE AND HANDLING .................................................................................................................5
1.13 MARKING .................................................................................................................................................5
1.14 SUBMISSIONS BY THE CONTRACTOR............................................................................................5
1.15 MAINTENANCE AND REPAIR..............................................................................................................6
1.16 LIAISON AND RESPONSIBILITY .........................................................................................................6
1.17 SHOP DRAWINGS .................................................................................................................................6
2. PART 2 - PRODUCTS......................................................................................................................7
2.1 MATERIALS - METALS - SECTIONS, PLATES, BARS.........................................................................7
2.1.1 STEEL GENERALLY ...........................................................................................................................7
2.1.2 STAINLESS STEEL.............................................................................................................................7
2.1.3 CAST STEEL ........................................................................................................................................7
2.1.4 ALUMINIUM EXTRUSIONS PLATE AND SHEET ..........................................................................7
2.1.5 ALUMINIUM FABRIC CLAMPS .........................................................................................................7
2.1.6 ELECTRO-MECHANICAL SEPARATION OF DISSIMILAR METALS.........................................8
2.2 MATERIALS – CABLES AND FITTINGS..................................................................................................8
2.2.1 WIRE ROPE.............................................................................................................................................8
2.2.2 CABLE CLAMPS AND FITTINGS.......................................................................................................10
2.3 MATERIALS - STRUCTURAL FABRICS................................................................................................10
2.3.1 BASE FABRIC AND COATING........................................................................................................10
2.3.2 TEFLON COATED FIBREGLASS ...................................................................................................11
2.3.3 COLOUR AND APPEARANCE........................................................................................................11
2.3.4 MEMBRANE GUARANTEE..............................................................................................................12
2.3.5 TESTING PROCEDURES ................................................................................................................12
2.3.6 FABRIC PROPERTIES .....................................................................................................................12
2.3.7 SUBMITTAL DATA ............................................................................................................................12
2.3.8 PRE-PRODUCTION MATERIAL TESTS .......................................................................................13
2.3.9 PRODUCTION MATERIAL...............................................................................................................13
2.3.10 BIAXIAL STRAIN UNDER PRESTRESS........................................................................................13
2.3.11 WIDE PANEL TEAR TESTS ............................................................................................................14
2.4 MATERIALS – BELTS ...............................................................................................................................14
3. PART 3 - PRODUCTS....................................................................................................................15
3.1 WORKMANSHIP - FABRICATION GENERALLY .................................................................................15
3.1.1 GENERAL ...........................................................................................................................................15
3.1.2 * INFORMATION TO BE SUBMITTED...........................................................................................15
3.1.3 * ERECTION DETAILS......................................................................................................................15
3.1.4 * PROGRAMME .................................................................................................................................16
3.1.5 DESPATCH FROM WORKS............................................................................................................16
3.2 FABRICATION OF STRUCTURAL FABRIC..........................................................................................17
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3.2.1 CUTTING PATTERNS ......................................................................................................................17

3.2.2 SAMPLES............................................................................................................................................17
3.2.3 ERECTION METHOD .......................................................................................................................17
3.2.4 JOINTS NOT SHOWN ON DRAWINGS ........................................................................................17
3.2.5 MARKING OUT ..................................................................................................................................17
3.2.6 CUTTING.............................................................................................................................................17
3.2.7 ACCURACY OF ASSEMBLY ...........................................................................................................17
3.2.8 QUALITY CONTROL OF FABRIC...................................................................................................18
3.2.9 JOINTING............................................................................................................................................18
3.2.10 DETAILS..............................................................................................................................................18
3.2.11 STITCHING OF BELTS.....................................................................................................................19
3.2.12 PROTECTION OF FIBRES ..............................................................................................................19
3.3 WORKMANSHIP - METALWORK AND CABLE WORK......................................................................19
3.3.1 GENERAL ...........................................................................................................................................19
3.3.2 SHOP DRAWINGS ............................................................................................................................19
3.3.3 ALTERNATIVE MATERIALS............................................................................................................19
3.3.4 ACCURACY OF FABRICATION......................................................................................................19
3.3.5 DISTORTION......................................................................................................................................20
3.3.6 PINNED CONNECTIONS .................................................................................................................20
3.3.7 CABLE WORKS .................................................................................................................................20
3.4 PROTECTION OF METALWORK ...........................................................................................................21
3.4.1 CODE OF PRACTICE .......................................................................................................................21
3.4.2 THE COMPOSITION OF THE PROTECTIVE SYSTEM FOR STEELWORK ..........................21
3.4.3 STEEL CABLE....................................................................................................................................21
3.4.4 SURFACE PREPARATION (FITTINGS, CLAMPS, ETC)............................................................21
3.4.5 SURFACE PREPARATION OF ALUMINIUM ................................................................................21
3.5 WORKMANSHIP - ERECTION - METALWORK, CABLE AND FABRIC...........................................22
3.5.1 START OF ERECTION .....................................................................................................................22
3.5.2 SETTING OUT AND TOLERANCES ..............................................................................................22
3.5.3 HANDLING..........................................................................................................................................22
3.5.4 EQUIPMENT.......................................................................................................................................22
3.5.5 SUPERVISION ...................................................................................................................................23
3.5.6 RESTRESSING..................................................................................................................................23
3.6 TESTING .....................................................................................................................................................23
3.6.1 COST ...................................................................................................................................................23
3.6.2 TIME.....................................................................................................................................................23
3.6.3 TESTING AUTHORITY .....................................................................................................................23
3.6.4 CONTRACTOR TO PROVIDE FACILITIES ..................................................................................23
3.6.5 CALIBRATION OF EQUIPMENT.....................................................................................................23
3.6.6 PREPARATION OF TEST PIECES ................................................................................................24
3.6.7 SUBMISSION OF TEST RESULTS ................................................................................................24
3.6.8 * TESTS FOR CABLES AND FITTINGS ........................................................................................24
APPENDICES .............................................................................................................................................25

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SECTION 13130
FABRIC STRUCTURES
1. PART 1 – GENERAL
1.1 SECTION INCLUDES
This Specification applies to the fabrication and installation of tensioned fabric structures in PVC
coated Polyester and Teflon coated Glass cloth (PTFE) and the supporting metalwork and cable
work, plates and fittings. It should be read in conjunction with other specifications relating to the
primary structure, and be seen as additional information to that contained within other specifications.
1.2 RELATED SECTIONS
A. 05000 – STRUCTURAL STEEL
1.3 REFERENCES
A. BS EN 12384 Stranded Steel Wire Ropes
B. BS 5950 Structural Use of Steelwork in Building
C. BS EN 10160 Lamination
D. BS EN 10210 Hollow Sections
E. BS 1449 : Pt 1 Cold Formed
F. BS EN 10162 & Addendum 1 BS 1449 Cold Rolled
G. Swedish 055900-1967 Condition of Steel
H. BS EN 10088-1 Stainless Steel
I. BS EN 10292 & BS EN 1011-8 Cast Steel
J. BS EN 485-3 Aluminium Extrusions
K. BS 8118 : Pts 1 & 2 Structural Use of Aluminium
L. BS 4190 Black Bolts
M. BS 3692 Precision Bolts Hexagon Socket Screws

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N. BS EN 20273 Bolt Clearance Holes
O. BS 4933 Countersunk Bolts
P. BS 4320 Washers (Plain & Tapered)
Q. BS 4464 Spring Washers
R. BS EN 14399 HSFG Bolts
S. BS 4439 Threaded Studs
T. BS 1494 : Pt 2 Indented Bolted
U. BS EN ISO 1479 Screws Self Tapping
V. BS 4183 Screws Machine
W. BS EN ISO 1461 Galvanised Bolts
X. BS 970 Stainless Steel Bolts
Y. BS EN 573 Aluminium Bolts etc
Z. BS EN 10264 Wire Rope and Spiral Strand
AA. BS 3424 Fabric Testing
BB. BS 476 : Pts 6 & 7 Glass Based Cloth
CC. BS 3120, BS 3424, BS 5438 Flame Resistance
BS 7157
DD. BS EN 1011, BS EN 12072 Welding of Stainless Steel and Aluminium and
BS 2926
EE. BS EN ISO 12944, EN ISO 14713 Steelwork Protection
FF. BS EN 10264 Steel Cable Wires Galv.
1.4 PRECEDENCE OF DOCUMENTS
A. Instructions on the drawings take precedence over this Specification and both take
precedence over the bill of quantities. In the absence of special instructions on the drawings,
this Specification should be followed.
1.5 DEFINITIONS

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A. "ISO" denotes International Standards Organization.
B. "BS" denotes British Standard.
C. "CP" denotes British Standard Code of Practice.
D. "DIN" denotes German Standard "Deutsches Institut fur Normung”.
E. "ASTM" denotes American Standard Testing Methods.
F. “C.A” denotes Contract Administrator.
G. "Documents" denotes any drawing, schedule, data sheet, instruction or the like issued by the
Owner.
H. "Testing Authority" denotes an independent organization nominated by the Contractor and

approved by the Engineer, fully equipped to carry out all tests and checks required by this
specification.
1.6 OWNERS APPROVAL
A. Any approval given by the Owner in pursuance of this Specification shall not be deemed in
any way to relieve the Contractor of any of his liabilities, obligations or responsibilities under
the Conditions of Contract. Errors and omissions in executed work, Contractor's workshop
drawings or any other part of the Contractor's work shall remain the responsibility of the
Contractor whether approved by the Owner or not
1.7 DESIGN AND COMPLIANCE WITH SPECIFICATION
A. The contractor is to include with his tender the following design responsibilities:
1. Final formfinding and verification analysis of the fabric/cable/primary steel system.

This is to be performed using the final co-coordinated geometry, design loadcases
provided and to meet the general prestress values given.
2. Notify the client if any primary loads exceed those indicated within the tender
package.
3. Complete the design/coordination of the steelwork and concrete interfaces
4. Complete the final design of the steelwork and fabric interfaces utilizing the final 3D
geometry of the cable/fabric analysis.
5. Undertake the detailed fabric design and patterning including all clamp plates, links
and cables.
6. The design is to include all requirements for temporary works, installation and
stressing.
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7. The survey of all primary interface System Points (SP) prior to the final production of
shop drawings. Discrepancies that are outside the specified tolerances of respective
elements, or beyond those which can be absorbed by the steel/fabric design must be
notified to the client.
B. The design of the primary structural steelwork has been carried out in accordance with BS
5950. Any steelwork design carried out by the Contractor shall conform to that British
Standard unless otherwise instructed by the Owner.
C. The design of the any structural aluminium work has been carried out in accordance with BS
8118. Any aluminium design carried out by the Contractor shall conform to that British
Standard unless otherwise instructed by the Owner.
D. The factor of safety defined as the ratio of minimum breaking load/maximum load produced
by the design loads shall be as follows:
1. Cables (wire ropes and strand) 2.5
2. Shackles, Rigging Screws and other fittings. 2.5
3. Polyester Belts 4.0
4. All Fabric 6.0
E. The Contractor is to verify the design and produce cutting patterns for the material which
ensure the final membrane can be pre-stressed with a smooth form, free of wrinkles, which
complies with the required geometry and stresses within the tolerances given in this
specification.
1.8 MATERIALS
B. All materials shall be of first class quality, suitable for the purpose specified, and shall comply
with appropriate National Standards, where such exist, unless otherwise specified.
C. Where the Contractor is required to provide materials to comply with specified performance,
approved samples of the material proposed, together with such technical literature, test
certificates or similar declarations as to prove compliance of the proposed material with all
specified performance data shall be submitted for approval. No such proposed material shall
be used in the permanent work until the approval of the owner is given in writing.
1.9 WORKMANSHIP

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A. All workmanship shall be of the best quality, suitable for the purpose specified and shall
comply with the appropriate National Standards or Codes of Practice, where such exist,
unless otherwise required
1.10 DEFECTIVE WORK
A. Where, in the opinion of the Owner, the materials or workmanship of any part of the finalised
work do not comply with all the relevant requirements of this Specification, that part shall be
classified as defective.
B. All work classed as defective shall be replaced to the approval of the Owner at the expense of
the Contractor.
C. The extent of the work removed and the methods of removal and replacement of this work
shall be in accordance with the Owner's instructions. The Contractor shall pay for any
specialist testing required by the Owner in connection with remedial work.
1.11 SUBLETTING
A. No work shall be sublet without prior written approval of the Owner.
1.12 STORAGE AND HANDLING
A. In order to facilitate inspection at all stages, the work shall always be laid out in separate
holding areas and kept clean. All painted or metal coated work shall be supported clear of the
ground. Individual component marking shall be visible when components are stacked.
B. All bundling, packing, handling, transport and unrolling shall be planned and carried out in a
manner designed to prevent kinks, abrasions, and any damage to the work and any protective
coating.
C. Full allowance should be made for rough handling that can be expected during transport.
1.13 MARKING
A. The Contractor shall mark, document and identify materials so as to ensure that they are
used as specified. His proposals for so doing and his proposed marking system shall be
submitted for approval.
1.14 SUBMISSIONS BY THE CONTRACTOR

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A. * Where an asterisk is shown adjacent to a clause, the Contractor shall submit the
required information with his tender. Otherwise, all submissions shall be made in accordance
with the requirements of this Specification.
1.15 MAINTENANCE AND REPAIR
A. The Contractor shall submit his recommendations on maintenance and repairs of the fabric.
On completion he shall hand over to the owner a repair kit with patches of the original fabric
and instructions.
1.16 LIAISON AND RESPONSIBILITY
A. The Contractor is to liaise with any Sub-Contractors to ensure compatibility where

components relate. The Contractor shall be responsible for ensuring the correct fit of the
fabric structure to adjacent structural elements, provided the setting out of these is shown to
comply with the specification.
1.17 SHOP DRAWINGS
A. The Contractor is required to prepare shop drawings for all components.
B. These drawings shall be submitted to the Architect and Engineer for approval.
C. The Contractor shall allow two weeks for approval and sufficient time to make
amendments.
D. The Contractor shall hand over his proposed schedule of shop drawings and programme
for their completion within two weeks of the start of the contract.
E. Approval of shop drawings will not relieve the Contractor of his responsibility for
dimensional co-ordination.

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2. PART 2 - PRODUCTS
2.1 MATERIALS - METALS - SECTIONS, PLATES, BARS
2.1.1 STEEL GENERALLY
A. Refer to steel specification for all steel requirements. Any further information given in this
specification relating to steelwork is in addition to the requirements of the steel specifications.
2.1.2 STAINLESS STEEL
A. Stainless steel should be austenitic, Grade 316 S16 to BS EN 10088-1 or similar.
2.1.3 CAST STEEL
A. Cast steel shall comply with the requirements of BS EN 10292 & BS EN 1011-8 . The material
shall be Steel A1 unless specified otherwise on the drawings
B. The manganese carbon ratio shall be greater than 3:1 with a maximum carbon equivalent.
C. Welding of castings shall be in accordance with the above documents unless otherwise
specified.
D. Surface finish : the general tolerance on surface dimension is + 1.5mm. The surface
finish on exposed surfaces shall be such that the surface is uniformly smooth after painting
(see also architectural specification).
2.1.4 ALUMINIUM EXTRUSIONS PLATE AND SHEET
A. All aluminium alloys are to comply with the grades specified in BS 8118 & BS EN 485-3
Extrusions are to be Grade 6082 TF unless agreed otherwise.
B. Aluminium alloys are to be selected as suitable for the manufacturing process and conditions
of service, i.e. environmental corrosion.
C. Extruded aluminium is to be free from scratches, burrs and dents.
D. Extrusions longer than 2m will be required to be straightened to tolerances closer than those
specified in the British Standard.
2.1.5 ALUMINIUM FABRIC CLAMPS
A. All corners in contact with the fabric shall have a 6mm radius unless a larger radius is called
for on the approved drawings.
B. Bolts and fittings for aluminium shall comply with BS 8118 with respect to protection of metal
to metal contact surfaces.
C. Site joints to be used only where indicated on contract drawings unless agreed otherwise with
the EMPLOYER Aluminium clamps, where used, should be to grade 6082 TF or similar
approved. The Contractor is to ensure compatibility of all elements of the assembly.

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2.1.6 ELECTRO-MECHANICAL SEPARATION OF DISSIMILAR METALS
A. When proposed, the Tender is to demonstrate how it is proposed to provide electro-

mechanical separation between dissimilar metals (e.g. stainless steel/normal steel,
aluminium/normal steel) as indicated in outline in the tender drawings by the use of polyamide
(Nylon) bushes, P.T.F.E. foils and tapes.
2.2 MATERIALS – CABLES AND FITTINGS
2.2.1 WIRE ROPE
A. Wire rope and spiral strand shall be manufactured from galvanised wire (Class A) complying
with the requirements of BS EN 10264
B. Unless noted otherwise on the drawings the wire rope construction shall be 6x19 Right hand
ordinary lay with wire rope core, complying with the requirements of BS 12384.
C. The cable construction shall provide the MBL shown on the drawings. The cable sizes shown
on the drawings are based on the table 4.1 below. If the MBL is not shown on the drawings
an equivalent MBL for the stated cable size shall be provided.
Table 1 -6x19 (9/9/1)IWRC 180 Grade tensile, Galvanised, Right Hand Ordinary Lay
SIZE (mm) MBL (kgf) STEEL AREA (mm2)
8 4110 29.0
9 5220 37.3
10 6440 46.0
11 7790 55.7
12 9270 66.1
13 10900 77.2
14 12600 90.4
16 16400 117
18 20800 152
19 23200 167
20 25700 185
22 31100 226

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24 37000 266
26 43500 311
28 50400 361
32 65900 473
35 78800 566
36 83400 603
38 92900 669
2
Table 1 note: An apparent modulus of elasticity of 110KN/mm based on steel area has been
assumed in the calculations and the cable construction shall provide an equivalent EA.
Table 2 - Spiral Strand Stainless Steel cables (based on Pfeifer PE cable properties)
SIZE (mm) MBL (kgf) STEEL AREA (mm2)
6.1 2650 22
8.1 4791 38
10.1 7441 60
11.9 10296 83
14.1 14373 117
16.6 19878 161
20.5 30377 246
24.1 41692 338
28.6 58919 477
32.1 74414 602
36.6 96330 780
Table 2 note: An apparent modulus of elasticity of 130KN/mm2 based on steel area has been
assumed in the calculations and the cable construction shall provide an equivalent EA.

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D. * The Contractor shall determine the construction stretch of the cables by load cycling
from 10% to 45% of the MBL until no inelastic stretch is noted. The construction stretch is
measured at 15% MBL. Test results shall be sent to the Engineer for approval.
E. The design of fittings assumes that the cable strength is reduced by not more than 10% at
bends of internal radius of 4 x cable diameter. Any variation of the cable construction to
achieve this flexibility shall be at the Contractors expense.
2.2.2 CABLE CLAMPS AND FITTINGS
A. All steel clamps fittings and fabricated guides etc. are to be detailed and constructed
such that there is neither kinking nor abrasion of the cables due to movement deflection
or other cause during handling and erection. Where a cable enters a rigid fitting such as
a mast head guide the exit radius of the guide shall be 5 x the diameter of the cable.
B. End terminations including swaged talurit eyes, swaged terminal fittings and hot poured zinc
fittings are to be fitted in an approved rope working shop in accordance with the
manufacturers instructions. Under load testing the rope should fail away from the fitting.
C. All Tenderers shall include with their Tender documents a complete specification of the rope
they propose to use. This should include size and diameter of wires, the thickness of the
protective coating, and the corrosion inhabitants used to fill the cables.
D. All Tenderers shall include with their Tender documents details of the proposed end fittings
and the Sub Contractor they intend to use for the rope work with information on the failing
load and method of ensuring that the protective treatment at the junction of cable and fittings
is satisfactory.
2.3 MATERIALS - STRUCTURAL FABRICS
2.3.1 BASE FABRIC AND COATING
A. PVC COATED POLYESTER FABRIC
1. Yarn - The yarn used in the base fabric shall be high tenacity polyfibre of the highest
commercial quality and shall be free of broken fibres after the weaving process
2. Weave. The weave shall be plain weave, panama weave or Malimou weave. The
weave shall be uniform, with the warp and fill at right angles to each other with a
tolerance of 5 degrees. The bow in the fill direction shall not exceed 30mm or 1 in 30
offset to width over any length.

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B. PVC PASTE
1. The PVC paste shall consist of new PVC resin, plasticisers, UV inhibitors mould
inhibitors, flame profing agents and extenders. The formulation shall be
demonstrated to have given satisfactory performance in the past with regard to
flexibility in handling, adhesion and durability in use.
C. SURFACE COATING
1. The PVC shall be coated on both surfaces with acrylic or fluoropolymer lacquer as
noted in the detailed specification Clause 5.4.
2.3.2 TEFLON COATED FIBREGLASS
A. COMPONENT MATERIALS
1. The coated fabric shall be manufactured from a base fabric of glass fibre cloth coated
with PTFE Homopolymer Copolymer thermoplastic resin.
B. BASE FABRIC
1. The yarn shall be of the highest commercial quality with sufficient flexibility to be free
of broken fibres after the weaving and coating process. Beta glass yarn as
manufactured by Owens-Corning Fibreglass Corp is considered suitable. Other yarns
shall be proven by tests on the finished product. The weave shall be plain weave.
The warp and fill shall be straight and uniform and at right angles to each other with a
tolerance of 2.5 degrees. The bow in the fill direction shall not exceed 1.5 in 100
offset to width ratio.
C. COATING RESINS
1. The base coating shall be pure PTFE Homopolymer applied in dispersion and
sintered to the base cloth. Mineral additives which improve coating flexibility and
abrasion resistance may be acceptable. Resin additives to improve adhesion and
flexibility of the base cloth must be demonstrated not to have harmful effects on the
long term performance of the product.
D. The outer layer shall be FEP Copolymer as manufactured by EI.Dupont Co or similar equal
and approved.
E. The coating should completely isolate the fabric from exposure to moisture, air and sunlight.
2.3.3 COLOUR AND APPEARANCE
A. The colour and translucency of the coated fabric shall be as specified and consistent
throughout the structure. The coating shall have been applied so as to achieve a surface with
no discontinuities, discolorations, spots or lumps which would be objectionable in appearance
to the unaided eye from a distance of 3m, held 1m away from a white wall in daylight. This
includes any tears or patches to repair tears whether carried out in the works or on site. The
coating shall not discolour because of UV degradation, plasticiser migration, mould growth or
other internal changes within the guarantee period.

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2.3.4 MEMBRANE GUARANTEE
A. The Contractor shall provide a guarantee under which he shall replace the membrane in
whole or in part free of charge for a five year period from contractual completion of erection, if
there is any failure of the membrane structure due to a failure of the material to comply with
this specification or due to faulty workmanship.
2.3.5 TESTING PROCEDURES
A. The testing procedures for coated fabrics shall be in accordance with BS 3424 or to those
other national standards specified.
B. * All fabrics shall be required to meet the flame resistance requirements of BS 3120.
Three samples of the actual fabric delivered to the Contractor shall be tested for spread of
flame in accordance with BS 3424, BS 5438 and BS 7157 by an independent testing authority
and certificates sent to the Engineers.
C. Where requested glass base cloth fabrics shall be tested to BS 476.
D. PVC coated polyester fabric shall also comply with DIN 4102 B1 in respect of Flame Spread
Resistance. Certificates of compliance to BS 3120 and DIN 4102 B1 and to be returned with
tender.
2.3.6 FABRIC PROPERTIES
A. See appendix table for drawing series and details relating to the fabric of the relevant
structure.
2.3.7 SUBMITTAL DATA
A. * For each material to be used in the works the Tenderer shall submit one square
metre of fabric and the following information at the time of tender:
1. Name of fabric manufacturer and technical literature.
2. Type of yarn and weave
3. Coated weight g/ms
4. Grey cloth weight
5. Thickness mm
6. Thickness of top coat and chemical composition
7. Roll width
8. Original dry, folded and wet tensile strengths N/cm
9. Fire resistance Test Certificates to BS 476 and 3120 and DIN 4102 B1, reports to BS
7157 and BS 5438

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B. The Contractor shall also submit details of the material manufacturer’s quality control
procedures in respect of base cloth and coating to meet the requirements of this specification.
2.3.8 PRE-PRODUCTION MATERIAL TESTS
A. The Contractor shall submit results of the following tests prior to commencement of
production of the structure. These tests should be carried out on actual production material,
or on a representative sample of the same standard and formulation from the membrane
manufacturer:
1. Strip Tensile (warp and fill).
2. Trapezoidal Tear (warp and fill).
3. Wide Panel Tear Test (Clause 5.8)
4. Seam Strength Test (Clause 8.9).
2.3.9 PRODUCTION MATERIAL
A. The membrane manufacturer shall provide certificates with each roll giving details of cloth
batch, coating batch, coated weight etc.
2.3.10 BIAXIAL STRAIN UNDER PRESTRESS
A. The Contractor shall carry out Biaxial load extension tests on the actual production material to
establish the appropriate stretch correction factors:
B. PVC COATED POLYESTER FABRIC
1. The tests shall be carried out on an approximately 1.3m square sample to give a 1m
gauge length. When the fabric is taken off the roll a 1m square shall be marked on
the cloth. The panel shall be loaded with springs to give a uniform distribution of
tension. It shall be loaded to a stress of 1.5 times the prestress level and heated to a
temperature of 40_C and held at that condition for approximately 16 hours but no less
than 12 hours. The load will then be reduced to the prestress level and
measurements taken. Note that this method of testing should not be used for fabric
which has a base cloth which has been prestressed in both warp and weft directions
prior to coating (e.g. Ferrari Precontraint).
2. Alternatively, either procedure C below may be used, or other testing procedures to

establish the appropriate stretch correction factors must be agreed with the Engineer.
C. PTFE COATED GLASS FIBRE
1. The Contractor shall carry out Biaxial load extension tests to establish:
• the stretch compensation, and
• the biaxial stiffness properties

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2. All measurements shall be taken from the slack condition. The fabric shall initially be
loaded to the specified prestress level in small steps fluctuating about the prestress
load ratio. The warp/weft stress ratios shall then be cycled in the working range of the
fabric with stress ratios 5-1 and 1-5. After cycling to the point that the extensions are
repeatable, the extensions shall be recorded at prestress level and within the cycled
range.
3. A minimum of three tests shall be carried out on each batch of material from the
coating process. Full records of the local roll width shall be kept for all samples used.
2.3.11 WIDE PANEL TEAR TESTS
A. The 40mm crack propagation stress shall be determined by the Contractor on 800mm x
400mm samples of coated fabric. A 40mm long cut shall be made at the centre of the fabric
and the fabric tested with uniform uniaxial load to failure to determine the crack propagation
stress (CPS). Tests shall be carried out on five samples in the warp direction and five
samples in the weft direction and related to strip tensile tests on adjacent materials. The
crack propagation stress shall be defined as the minimum percentage of the strip tensile
strength found from these tests. If the tests show an unacceptably wide scatter a further
series of tests shall be carried out.
2.4 MATERIALS – BELTS
A. Belts shall be woven from the stiffest available high shrinkage polyester fibre. The extension
at break should not exceed 12%.
B. The weave shall be such that initial extension from 0 to 1kN load on a 90mm wide belt shall
be less than 2%. This extension shall be measured over a 2m length with the belt loaded with
weights.
C. The Tenderer shall submit the name of the belt supplier and a 2m sample of the belts he
proposes to use, with load extension diagrams of a test to break and a test of 0-1kN as
described above

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3. PART 3 - EXECUTION
3.1 WORKMANSHIP - FABRICATION GENERALLY
3.1.1 GENERAL
A. The Contractor shall obtain authorisation to start the fabrication. Such authorisation will not
formally be given before all shop drawings have been reviewed and approved or before the
fabric and belt stretch correction factors have been evaluated and incorporated into the
cutting patterns. Any tests on seam strength required by this specification shall also have
been carried out and results approved
B. The contractor must provide the following information at least six weeks before the start of
fabrication to the Employer.
1. All Reactions (KN) at interfaces for verification.
2. Fabric samples and properties
3. Erection proposals including position and details of site joints
4. Fabrication GA drawings and details of all connections
5. Results of Material tests
6. A mathematical model of the canopy that demonstrates the equilibrium of the

structural frame and fabric. The model must also demonstrate that the form of the
fabric is in compliance with the engineers scheme design.
7. Clarification that the structural frame is set out correctly and co-ordinates with the
existing structures in terms of the connection details.
C. The Contractor shall be responsible for preparing shop drawings and samples of details, for
measuring and evaluating the Biaxial stretch correction factors and for ensuring compatibility
of fabric to steelwork connections and the fitting together of shackles, pins, bolts and other
components.
3.1.2 * INFORMATION TO BE SUBMITTED
A. Tenderers shall submit with their Tender documents the name of the supervisor who will be
responsible for preparing the shop drawings, co-ordinating the work of the metalwork
fabrication and ensuring the compatibility of fittings.
3.1.3 * ERECTION DETAILS
A. The Contractor shall state with his tender his proposed method of erection.
B. The Contractor shall prepare and submit details for approval of the following in accordance
with the approved programme of drawing submittals. Before starting to erect the cable or
membrane structures the shop drawings for the fittings and details must take into account the
methods of erection.

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1. Method and sequence of erection
2. Type of cranage
3. Temporary stay cables
4. Lifting points
5. Jacking and stressing systems
6. Transportation proposals
7. Scaffolding and access equipment
8. Name of erection supervisor and numbers of operatives.
3.1.4 * PROGRAMME
A. Each Tenderer shall submit with his Tender documents his intended programme for the
fabrication and installation of the structure, the programme shall include all intended shop
drawings, samples, tests and other information required by this Contract.
3.1.5 DESPATCH FROM WORKS
A. The Contractor shall advise the Client of intended dates of dispatch to site of cablework,
membranes, metalwork, and accessories in such a way that inspection can take place prior to
dispatch.
B. The Contractor shall satisfy himself that, within tolerance and allowance for stretch
compensation, the overall geometry of all made-up components of the structure are
compatible with each other and with the defined geometry of the structure Confirmation that
this check has been carried out will be sought before approval to commence erection is given.

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3.2 FABRICATION OF STRUCTURAL FABRIC
3.2.1 CUTTING PATTERNS
A. The Contractor is responsible for producing full cutting patterns and calculating all relevant
geometry for the project.
B. The Contractor shall be required to prepare and submit complete shop details and information
as follows:
1. Drawings showing detailed arrangement of all joints and boundary details.
2. Full size drawings of corner details.
3.2.2 SAMPLES
A. The Contractor shall prepare samples of joints and boundary details
3.2.3 ERECTION METHOD
A. The membrane details shall take into account the proposed method of erection.
3.2.4 JOINTS NOT SHOWN ON DRAWINGS
A. No fabric joints other than those shown on the shop drawings shall be placed without
approval.
3.2.5 MARKING OUT
A. Fabric panels shall be marked out along and at right angles to the centre line of the roll to an
accuracy of 1mm. If the panel is laid out on the floor prior to marking there shall be no
diagonal distortion of the weave.
3.2.6 CUTTING
A. The fabric shall be cut along the marked line to an accuracy of + 1mm.
3.2.7 ACCURACY OF ASSEMBLY
A. Fabric panels shall be assembled before welding of the joints so that the tolerance between
the marked system lines is + 1mm. If necessary additional lines shall be marked on the fabric
to check the accuracy of assembly.
B. Fields bounded by ridge site and boundary cable lines shall be checked after all the cloths are
welded together. The overall tolerance in the weft direction shall not exceed + 15mm.
C. After assembly of the field edge details the tolerance in position of cable and belt lines shall
not exceed + 5mm. D ring terminations shall have a tolerance of +0 -10 mm relative to the
cloth system point or system line, ie the belt should be slightly short.

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3.2.8 QUALITY CONTROL OF FABRIC
A. All fabric shall be visually inspected for coating flaws, bow or angular distortion of the warp or
weft yarns before marking out proceeds.
B. One strip tensile test in the warp and weft directions shall be carried out on every 100 sq m of
fabric. The strength shall be above the minimum tensile strengths quoted.
C. One trapezoidal tear test shall be carried out in the warp and weft directions and shall be
carried out on every 200 m of fabric. The strength shall be above the minimum value quoted.
D. If results of B and C above indicate possible non-compliance with the specification, the
Engineer shall be informed immediately. At his discretion further testing, including biaxial
stiffness and wide panel tests, may be required before work may proceed.
3.2.9 JOINTING
A.
1. PVC coated polyester fabric shall be joined by heat sealing with RF heating
equipment.
2. PVDF coatings shall be removed at joints by buffing. Such buffing shall leave the
yarn undamaged and covered by PVC.
3. Teflon coated fibreglass shall be joined by heat sealing with an interlayer of FEP foil.
B. All seam welds in the fabric shall be tested to give 100% fabric strength at 20oC. Seam welds
shall also be tested for long term loading to give:
o
1. 80% Fabric strength at 40 C
o
o
C. In the jointing process, the integrity of the coating shall be maintained so as to exclude water
and air from the fibres.
D. * Before any structural jointing is carried out, the Contractor shall submit details of his
jointing procedure and of samples of joints for testing as B above. He shall also submit
details of the quality control procedure used to ensure consistently satisfactory joints, and of
test procedure and results according to B above.
3.2.10 DETAILS
A. Cable cuffs will be bias cut strips of fabric with the yarns at 45 degrees.
B. Cable cuffs will be pre-fabricated with reinforcing belts where required, made up to the
correct length with D ring terminations if necessary and stitched to the cuff. Stitching is
to be covered with 600 gm PVC cloth.

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C. Cable cuffs, tablings, and reinforcement patches may be cut from fabric not meeting the
Specification requirements for bow and angle of weave.
D. Details will be joined to the fabric using the same jointing procedure as structural seams.
Roped edges will be formed using 8mm hard polypropylene or polyester rope.
3.2.11 STITCHING OF BELTS
A. At D ring terminations, the belt shall be turned back a minimum of 30cm, or the length shown
on the drawings, and box stitched in such a way that in a load test the belt fails away from the
stitching (10 rows of stitching 30cm long over a 50mm width).
B. A sample belt termination shall be tested to demonstrate the adequacy of the stitching
arrangement. With long turn backs the 30cm at the end of the turnback shall be stitched in
the same way as the sample. With 50% of that amount of stitching/cm between that part and
the D-ring.
C. The ridge belts shall be stitched to the lower cloth with three rows of double stitching.
D. Belts shall be stitched with polyester thread having a MBL of 30kg.
3.2.12 PROTECTION OF FIBRES
A. All polyester fibres in the belts shall be protected from direct sunshine. Where the belts pass
over D-rings or similar, they shall be protected by a strip of lightweight PVC coated fabric or
by PVC Paste.
B. No stitching threads shall be exposed to direct sunlight.
3.3 WORKMANSHIP - METALWORK AND CABLE WORK
3.3.1 GENERAL
A. Unless noted otherwise, fabrication of steelwork shall comply with BS 5950 Part 2. Fabrication
of Aluminium shall comply with BS 8118 : Part 2.
3.3.2 SHOP DRAWINGS
A. The Contractor will receive from the Employer design intent metalwork drawings showing
principal dimensions, sizes and thickness of material. The fabricator shall prepare full size
shop drawings showing cutting dimension, weld sizes and sequence, etc.
3.3.3 ALTERNATIVE MATERIALS
A. The Contractor shall notify the Employer where he intends to use alternative materials to
those specified on the drawings.
3.3.4 ACCURACY OF FABRICATION
A. Metal components shall be fabricated to the following tolerances.

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1. Lengths greater than 2m + 4mm
2. Lengths less than 2m + 2mm
3. Angles + 1 degree
B. All components which join together shall be checked for fit up and marked if necessary before
leaving the workshop.
3.3.5 DISTORTION
A. Welding procedures shall be such that distortion is reduced to a minimum and local distortion
rendered negligible in the final structure. Corrections, if necessary, shall be undertaken by an
approved method.
3.3.6 PINNED CONNECTIONS
A. Pins in solid clevis type connections shall have a retaining system capable of resisting 10% of
the shear load on the pin.
B. Pins in link plate type connections shall be long enough to allow some transverse movement
of the plates, ie the extra clearance should be 25% of the pin diameter. The pin retaining
system should be capable of taking 15% of the load on the pin.
3.3.7 CABLE WORKS
A. The Contractor shall prestretch the cables by cycling to 45% of MBL (see 4.1 D). The cables
should then be marked at the defined tensions. Alternatively, the procedure below must be
adopted.
B. The Contractor will determine the construction stretch at the design load from the cable
manufacturer and compensate the cable lengths accordingly. If this information is not
available tests will be required.
C. Cables will be terminated to a tolerance of + 4mm over the cable length.
D. An additional tolerance in construction stretch of + .05% is acceptable.
E. Cables shall only be cut using carborundum disc cutters or other approved mechanical
devices. Under no circumstances will thermal cutting be approved.
F. End fittings for all cables shall be supplied and attached so as to develop 100% of the
minimum breaking load of the cable, unless otherwise approved. Under no circumstances will
splicing of cables between the end fittings be allowed.
G. The Contractor shall proof load all terminated cables and connection fittings to 1.25 times the
design loads.
H. Swaged end fittings shall be galvanised or zinc plated before swaging. Immediately after
swaging the swaged portion shall be treated with an organic zinc-rich paint system to BS4652.
The whole fitting shall be repainted after installation.

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3.4 PROTECTION OF METALWORK
3.4.1 CODE OF PRACTICE
A. All stages of preparation and protection at the works shall be carried out in workshops with
suitable facilities including lighting, heating, and ventilation.
3.4.2 THE COMPOSITION OF THE PROTECTIVE SYSTEM FOR STEELWORK
A. The materials to be used shall be those listed in the summary of protection systems.
B. Before work begins, the Contractor may submit alternative proprietary materials or protection
systems which may be approved, subject to the proposal being supported by evidence to
show that they are at least equivalent to those specified.
3.4.3 STEEL CABLE
A. All wires from which steel cable is made shall be galvanized
B. Cables, end fittings and rigging screws to be galvanized, cleaned of all grease and over
painted on site with etch primer and zinc rich epoxy to achieve a finish to the approval of the
EMPLOYER Threads to rigging screws, where freedom will be required for re-tensioning, to
be fully cleaned and re-greased internally immediately after erection.
3.4.4 SURFACE PREPARATION (FITTINGS, CLAMPS, ETC)
A. Either before or after fabrication, as appropriate, and prior to galvanizing, all the millscale rust
and grease shall be removed by grit blasting. Light steelwork or steel forging may be cleaned
by total immersion in hydrochloric or sulphuric acid.
3.4.5 SURFACE PREPARATION OF ALUMINIUM
A. All aluminium surfaces shall be free from scratches, burs, dents or sharp projections.
B. Surfaces which are to be painted shall be prepared as follows:
1. The surface shall be cleaned, dried and thoroughly degreased by an appropriate

organic solvent. Flame cleaning will not be permitted.
2. The cleaned and degreased surface shall be treated to ensure paint adhesion. This
may be carried out by mechanical roughening with abrasive paper or abrasive-
impregnated nylon pads or by abrasive blasting, providing that in each case, the
abrasive is either alumina or other non-metallic and copper-free grit. Mechanical
roughening may also be done with corrosion-resisting steel wire brushes. Copper-
plated steel wool or wire brushes shall not be used. Alternatively paint adhesion may
be obtained by the use of a chromate conversion coating or an etch-primer or wash
primer, provided that the metal surface is clean and free from thick or irregular oxide
coatings.

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3. Before overcoating surfaces shall be thoroughly dry, and coatings applied when the
o
ambient temperature is about 4 C unless otherwise agreed.
3.5 WORKMANSHIP - ERECTION - METALWORK, CABLE AND FABRIC
3.5.1 START OF ERECTION
A. The Contractor shall obtain authorization to start erection. Such authorization will not
normally be given before the information required under this Specification has been
submitted, reviewed and approved.
3.5.2 SETTING OUT AND TOLERANCES
A. * The Contractor must satisfy himself at least ten days before erecting any metalwork,
fabric or cables, that the foundations and anchorage points to tie down positions or support
points for masts and cable work or its temporary works has been correctly placed within
tolerance . He shall notify the Engineer in writing that he has done so.
B. The Contractor shall achieve the geometry, mast loads and rope tensions calculated by the
Engineer, allowing for the effects of temperature and any construction weights and within the
following tolerances:
1. Perimeter system points:
Plan ± 15mm
Elevation ±10mm
2. Mast Top system points:
Plan ± 15mm
Elevation ±10mm
3.5.3 HANDLING
A. During transportation and unloading, care shall be taken not to damage, crush, or kink any
wire rope cables. Care shall also be taken with folding and packing of the fabric, to ensure
that there are no residual crease marks, abrasions or other damage to the cloth.
B. During unfolding of the fabric on site, the area on which the fabric is placed shall be covered
with clean 300 gauge polyethylene sheeting.
C. Personnel shall only walk on the fabric under direction of the erection supervisor, and then
they shall wear clean rubber soled tennis shoes, canvas over boots or stockinged feet.
3.5.4 EQUIPMENT
A. The Contractor is responsible for ensuring that he has all necessary equipment available on
site at the start of erection.
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B. If the Contractor makes an arrangement to hire or take on loan any equipment, labour or
other assistance from any other party, this arrangement shall be confirmed in writing to the
Engineer by both parties.
C. The Contractor shall include in his erection costs the hire or purchase of all necessary
equipment.
3.5.5 SUPERVISION
A. The Contractor is responsible for the safety of the structure and personnel during installation.
No advice, guidance, or instructions given by the Engineer shall relieve him from this
responsibility.
B. The installation shall be directed and supervised by the Contractor's representative named in
the tender documents. All instructions shall be given by him.
3.5.6 RESTRESSING
A. The Contractor is responsible for inspecting and prestressing the structure two weeks after
installation and again six months after installation at the end of the maintenance period. PVC
structures may require further prestressing after one or two years, but this shall be the Client's
responsibility.
3.6 TESTING
3.6.1 COST
A. The Contractor shall include in his price for the cost of tests procedural trials, supplying test
pieces and providing facilities (attendance, tools, etc) for the inspection and testing.
3.6.2 TIME
A. The Contractor shall allow in his programme for the necessary time for all tests, procedural
trials and trial assemblies.
3.6.3 TESTING AUTHORITY
A. * All tests shall be carried out by an approved testing authority. For the galvanizing,
welding, membranes, cables, clamps, and end fittings names and details of the testing
authority shall be submitted to the Engineer for approval.
3.6.4 CONTRACTOR TO PROVIDE FACILITIES
A. The Contractor shall provide all necessary facilities for inspection and tests in fabrication shop
and on site.
3.6.5 CALIBRATION OF EQUIPMENT
A. Load measuring equipment shall be calibrated at regular intervals to the satisfaction of the
Engineer.
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3.6.6 PREPARATION OF TEST PIECES
A. When required, the Contractor shall prepare test pieces to suit the appropriate testing
method.
3.6.7 SUBMISSION OF TEST RESULTS
A. Test and inspection results shall be submitted to the Owner immediately they are available.
3.6.8 * TESTS FOR CABLES AND FITTINGS
A. The Contractor shall proof load all terminated cables, rigging screws and other fittings to 1.25
times the design load shown on the drawings.
B. The Contractor shall submit test certificates relating to the cables and end fittings used in the
work. The tests shall be those described in the appropriate National Standards.

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APPENDICES
A1.
List of packages with Fabric

elements
Drawing
Series Name Description of fabric element Type of fabric
200 Physics Garden Steel frame with fabric cladding panels PTFE mesh B18909
0000 Ticketing Facility Steel umbrella frame supporting and
Building arrangement of scallop cables and fabric PTFE
panel
3000 Site Towers Steel frame with fabric cladding panels PTFE
5200 Nursery A regular grid of cantilever posts 50% solar
supporting low prestress cables and transmission
shade fabric Proprietary Shade
fabric to be approved
6600 Central Canopies An arrangement of steel trusses
supporting fabric panels, linked with
PTFE
scallop cables and a flying steel ring and
post
6700 Front Canopies An arrangement consisting of ridge,
valley and scallop cables supporting
PTFE
fabric panels and a number of inclined
posts stayed to ground.
6800 North Watch Tower Steel frame with fabric cladding panels PTFE
6900 South Watch Tower Steel frame with fabric cladding panels PTFE
9000 Aviary Steel frame with fabric cladding panels PTFE
Further information on the details of each fabric element should be found on the relevant drawings.
END OF SECTION 13130 – FABRIC STRUCTURES


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021826

Structural Fabric Specification

Revision Description Issued by Date Checked

A Construction Issue LT 24/04/09 JW

021826 King Abdullah International Gardens

report collation Liam Taylor

approval Jeremy Wedge

021826 King Abdullah International Gardens

Contents – 013130 FABRIC STRUCTURES

3.2.1 CUTTING PATTERNS ......................................................................................................................17

021826 King Abdullah International Gardens

1.1 SECTION INCLUDES

1.2 RELATED SECTIONS

A. 05000 – STRUCTURAL STEEL

A. BS EN 12384 Stranded Steel Wire Ropes

B. BS 5950 Structural Use of Steelwork in Building

D. BS EN 10210 Hollow Sections

E. BS 1449 : Pt 1 Cold Formed

F. BS EN 10162 & Addendum 1 BS 1449 Cold Rolled

G. Swedish 055900-1967 Condition of Steel

H. BS EN 10088-1 Stainless Steel

I. BS EN 10292 & BS EN 1011-8 Cast Steel

J. BS EN 485-3 Aluminium Extrusions

K. BS 8118 : Pts 1 & 2 Structural Use of Aluminium

L. BS 4190 Black Bolts

M. BS 3692 Precision Bolts Hexagon Socket Screws

N. BS EN 20273 Bolt Clearance Holes

O. BS 4933 Countersunk Bolts

P. BS 4320 Washers (Plain & Tapered)

Q. BS 4464 Spring Washers

R. BS EN 14399 HSFG Bolts

S. BS 4439 Threaded Studs

T. BS 1494 : Pt 2 Indented Bolted

U. BS EN ISO 1479 Screws Self Tapping

V. BS 4183 Screws Machine

W. BS EN ISO 1461 Galvanised Bolts

X. BS 970 Stainless Steel Bolts

Y. BS EN 573 Aluminium Bolts etc

Z. BS EN 10264 Wire Rope and Spiral Strand

AA. BS 3424 Fabric Testing

BB. BS 476 : Pts 6 & 7 Glass Based Cloth

CC. BS 3120, BS 3424, BS 5438 Flame Resistance

DD. BS EN 1011, BS EN 12072 Welding of Stainless Steel and Aluminium and

EE. BS EN ISO 12944, EN ISO 14713 Steelwork Protection

FF. BS EN 10264 Steel Cable Wires Galv.

1.4 PRECEDENCE OF DOCUMENTS

021826 King Abdullah International Gardens

A. "ISO" denotes International Standards Organization.

B. "BS" denotes British Standard.

C. "CP" denotes British Standard Code of Practice.

D. "DIN" denotes German Standard "Deutsches Institut fur Normung”.

E. "ASTM" denotes American Standard Testing Methods.

F. “C.A” denotes Contract Administrator.

H. "Testing Authority" denotes an independent organization nominated by the Contractor and

1.6 OWNERS APPROVAL

1.7 DESIGN AND COMPLIANCE WITH SPECIFICATION

1. Final formfinding and verification analysis of the fabric/cable/primary steel system.

3. Complete the design/coordination of the steelwork and concrete interfaces

1. Cables (wire ropes and strand) 2.5

2. Shackles, Rigging Screws and other fittings. 2.5

3. Polyester Belts 4.0

4. All Fabric 6.0

021826 King Abdullah International Gardens