Hybrid structural system: PVC‐PES membrane & prestressed concrete

Abstract

Numerous client requests for aircraft hangars within 60‐day timeframe, it became necessary to develop a new design methodology. The use of primary structural elements of GLT or steel, combined with architectural membranes, imposes certain limitations. Moreover, these solutions can be costly, with steel structures in particular requiring extended production times. To meet the market demands for longspan halls (20 to 50 meters), high load capacity, fast production and installation, and cost‐efficiency – innovative technical solutions had to be considered.

A new request has been received from a company specialized in copper mining to design an industrial hall for rail vehicles and the storage of mining deposits. Serbia a trapezoidal base of 3000m ² had to be covered. The deadline for project design, production and installation was 70 days.

The structure had to be 62,00 meters long and accommodate a span ranging from 42,50 to 52,00 meters. Also, to meet the space requirements for rail vehicles and machinery, the minimum internal height had to be no less than 10,00 meters. Additional supports were only allowed at the midpoint of the span. Hall was to be situated at an elevation of 374 meters above sea level. Additionally, due to the presence nearby industrial operations, the structure was required to be both chemically and fire‐resistant.

As a result, a new design of a hybrid structural system was proposed. The structural design consists of “auto‐stabile”, pre‐stressed concrete, double span frames and a double curved PVC‐PES membrane. This novel approach integrated two familiar materials in a completely innovative manner. The concept established a link between heavy and lightweight, as well as rigid and flexible structural components.

Major challenges included heavy snow loads, geometric constraints of the precast concrete components, membrane connections, transport and logistical issues. Additional potential risks arose due to the harsh environment, as well as challenging assembly conditions, such as working at height and significant exposure to heavy mine dust.

In just 30 days, the precast concrete and secondary steel elements were installed, also was membrane in additional 20 days. The project was completed within the required timeframe, and the final structure proved to be both functional and aesthetically pleasing. Through this project, the concept of this innovative idea was validated. Numerous advantages, along with significant potential for future development were recognized.