What Are Fabric Structures?

A solid, long-lasting fabric structure is an enormous investment for any operation. Most buildings are required to stand up to a lot, from extreme weather to corrosive materials to regular use by occupants or livestock. While traditional buildings made from wood, steel, or concrete are usually what people think of, there’s another option — fabric buildings.

Opting for a fabric structure building can be optimal for many businesses. These durable, easy-to-install structures are useful for temporary or permanent applications across a broad range of industries. Although fabric structure design has roots in ancient societies, modern fabric building architecture is innovative and contemporary in both appearance and function.

Continue reading to learn more about the definition of fabric structures and typical applications, the top benefits of installing a fabric structure and important design considerations.

What Is a Fabric Structure?

Fabric structures are structures that consist of a fabric membrane stretched across a structural framework. This framework is typically made of steel or another highly durable metal. The fabric membrane can be made from a variety of different materials, including engineered high-density polyethylene (HDPE), which provides increased protection against wear due to its high strength-to-density ratio.

There are two main types of fabric structures:

• Tensile structures: Tensile fabric buildings are thin-shell structures that rely on double curvature to provide high degrees of stiffness. While these structures are incredibly lightweight, they can handle heavy loads and severe weather due to the substantial tension within the fabric. Usually, tensile structures are used for temporary buildings, atrium roofing and architectural showpieces because of their striking appearance.
• Tension structures: Tension fabric buildings are made with steel frames and industrial-strength fabric membranes. Unlike tensile structures, tension buildings rely on their framework to provide structural support. These are stronger and more durable than tensile structures, making them ideal for more permanent uses like storage facilities and indoor recreation centers.

Unlike traditional buildings, fabric structures can cover large areas without support beams, which maximizes the clear span, or the floor space between two supports. As a result, fabric structures are highly suitable for functions that require lots of open space, like sports facilities or fertilizer production plants.

5 Benefits of Fabric Structures

Fabric structures are affordable, durable alternatives to traditional buildings. Their high return on investment (ROI) makes them attractive choices for companies, but these buildings offer more benefits than just monetary gain.

The top five advantages of fabric structures include:

1. Energy Efficiency

Because fabric structures are typically between 16% to 19% translucent, natural light can easily pass through the membrane, providing suitable illumination for your space. As a result, you only need minimal electrical lighting inside your structure.

Similarly, fabric structures are non-conductive, which means they’re less able to absorb heat. Compared to conductive materials like metal, fabric structures are much cooler in the summer and warmer in the winter, meaning you can save on heating and cooling costs.

2. Sustainability

In addition to their incredible energy efficiency, fabric structures are often reusable or recyclable at the end of their usable lifespan.

Creating a fabric building requires far less energy consumption and raw materials than other, more conventional structures — such as those made of wood or steel — which means they’re less environmentally harmful to produce.

3. Flexibility

It’s far easier to add to a fabric structure than to expand a traditional one. That’s part of what makes these buildings so convenient — you can make alterations to your structure any time your operation’s needs change.

Fabric structures are also easily customizable. You can create unique, high-profile designs by changing the fabric color, structure shape, end wall and mount style. Their flexibility also means they can be permanent, temporary or even portable. They’re easy to erect and can be mounted to multiple different foundation types, making them excellent options for seasonal uses, or for businesses that rent their property.

4. Lower Maintenance

Fabric structures require much less maintenance than their traditional steel and wood counterparts. For example, fabric coverings can go without regular cleaning. On the other hand, most steel buildings require annual washing and painting to keep them looking clean and fresh.

Fabric covers will typically last anywhere from 20-25 years before needing minor repairs. Using high-quality materials like high-density polyethylene fabric or PVC can increase your structure’s ability to withstand damage from severe weather and heavy use.

Additionally, reinforcing materials like hot-dip galvanized (HDG) steel can boost the framework’s ability to weather corrosion and rust. In most cases, internal steel frameworks can last for generations — all you’d need to repair or replace is the fabric cover.

5. Cost-Effectiveness

Purchasing and installing a fabric structure costs far less than buying a permanent one. This cost difference is a result of the following factors:

• Fabric structures use lighter materials than other buildings.
• Fabric buildings are easier to build, so they require less labor.
• You’ll save more on temperature control and lighting with a fabric building.
• Durable fabric structures require fewer repairs than permanent buildings.

Industries and Applications

These benefits make fabric structures useful to various industries, from public works to sports to agriculture. Here are some typical uses for fabric structures:

Agriculture

Fabric structures can help optimize your agricultural operations. For one thing, fabric storage facilities are more airtight than conventional structures, allowing for greater protection against moisture and heat loss.

Clearspan hoop barns shield livestock from harsh weather conditions and dangerous predators while still letting in high degrees of natural light, which can boost your operation’s productivity. For example, studies have shown that increased exposure to light can increase a cow’s milk production by 8% to 10%.

Other agricultural uses for fabric structures include:

• Greenhouses
• Agricultural storage
• Fertilizer storage
• Aquaculture fish farms

Mining, Oil and Gas

Building requirements for the mining, oil and gas industry are incredibly rigorous because they need to keep employees and nearby citizens safe. Fabric structures can easily meet these requirements due to the hot-dipped galvanized steel frames and optional fire-retardant fabric.

Other applications within this industry include:

• Equipment storage
• Packaging facilities
• Bulk product storage
• Mess halls
• Excavation shelters
• Forestry and logging operations
• Decontamination buildings

Sports and Recreation

Sports facilities need to be strong and durable to provide athletes and families with necessary safety features due to its high-occupancy use. Calhoun’s open web truss frames easily allow additional lighting, fire prevention systems, and security to be installed without interference. The clear span interior allows athletes to perform without running into support beams or other obstacles.

Additionally, indoor athletic spaces require less maintenance than their outdoor counterparts. For example, both grass and turf fields experience constant wear from exposure to the elements in addition to the usual foot traffic from athletes. By providing a durable cover for your fields, you can reduce the impact of the elements and provide a safe space for sporting fun.

Other uses for fabric structures in sports include:

• Soccer fields
• Tennis courts
• Indoor mini-golf courses
• Dog training room
• Basketball courts
• Ice skating rinks
• Indoor gymnasiums

Storage

Fabric structures are an excellent choice for storage applications because they allow for higher clearances and larger widths for less money than more traditional structures. Additionally, because fabric structures rely on fabric tension for support instead of beams and pillars, they allow for more clear span floor space, which means you can store more supplies.

Some common commercial fabric storage structures include:

• Cold storage
• Warehousing and distribution
• Industrial storage
• Manufacturing facilities
• Bulk storage
• Equipment storage

Events

Event companies can benefit from the flexibility of a fabric structure, as they can quickly erect a temporary tension fabric structure before an event and take it down or relocate it when the space is no longer being used. Additionally, companies can easily customize their venues to create a striking look that pulls the whole setting together.

Here are some examples of event venues using fabric structures:

• Wedding venues
• Concert halls
• Conference centers
• Multipurpose rooms
• Gaming centers
• Trade show venues

Public Works

Waste and recycling facilities require excellent ventilation to keep operations running smoothly. Fabric structures are uniquely suited to this application due to the breathable nature of the material and the ease of installing ventilation systems.

Similarly, sand and salt storage buildings require extra-strong frameworks due to the caustic nature of their contents. By using HDG steel, engineers can craft a building that is highly resistant to rust and corrosion — this process can significantly increase the longevity of your building and reduce maintenance costs.

Other public works applications include:

• Transfer stations
• Offloading and unloading enclosures
• Maintenance garages
• Compost facilities

Fabric Structure Customization

Customization is a key aspect of the design of fabric structures, and it’s one of the biggest advantages of these buildings. From the buildings’ components to their fabric covering, you can tailor virtually every aspect of your building to suit your operation’s needs.

Standard customization options include:

• Colors: It’s easy to match your brand or nearby architecture with fabric structures because they come in many colors. Because the color is part of the fabric, you won’t need to touch up the paint like with other types of structures.
• Fabric: Fabric can come in many different types with many protection options. For example, some industries might require their building cover to be fire retardant, which means it can extinguish itself. Other industries might require PVC coating, which is chemically stable and flame resistant.
• Foundation: Depending on your site and your application for the structure, one type of material might make a better foundation than others. For example, many equestrian facilities use engineered wood posts because they’re semi-permanent and supportive for buildings up to 62 feet. Similarly, many fertilizer plants will choose helical anchors because they transfer loads from the shafts to the soil.
• End and side walls: Your walls are critical to both your building’s longevity and appearance. You can go with no walls, or you can fully enclose your building depending on your specs.
• Insulation and liners: If your area is subject to severe weather conditions, or if you deal with caustic materials like salt, it can help to insulate your building. Different types of insulation for fabric structures are available to meet your requirements.
• Doors and windows: Accessibility is one of the most important aspects of any building. The type of access you choose will depend on your application, your individual needs and any local building codes that apply.

Choosing a Fabric Structure Company

While many fabric structure companies exist, only a handful will be able to provide the kind of service you need for your operation. Keep the following factors in mind when you’re evaluating which company to go with:

• Solid reputation: Like with any major purchase, you want to find a company that you can trust. Read through case studies and testimonials on both the company site and local review sites. Ask about structures the company has built near your area and, if possible, go check the site out yourself.
• Site evaluation: It is crucial to choose a company that offers this service — the site evaluation provides designers and engineers with valuable insight into your site’s unique characteristics, like surrounding vegetation, wind speed, typical snow load and seismic conditions. Without this data, it’s difficult to create a high-quality structure that will meet your specifications.
• Customization options: Some companies will have more options for customization than others. Ask your sales representative about the customization process before you make your final decision to ensure you can meet your needs.
• Material quality practices: Check to make sure your building company uses open web trusses that have been hot-dip galvanized in their buildings. This configuration allows for higher clearances than bent web trusses. Additionally, open web trusses make installing electrical systems, like HVAC and lighting, a simple process.
• Long history: How long has this company been operating? When it comes to complex projects like buildings, experience is everything. The longer a company has been in business, the more likely they are to provide excellent products and services.
• Typical cost: Find out how much the company charges per square foot. Additionally, some companies offer financing plans that allow you to pay for your structure in regular installments instead of one large upfront sum. This information should be readily available on the company’s website, but you should feel free to reach out if you’re having trouble finding it.
• Long-term options: With proper care, your fabric structure should last for years. Any good company will offer long-term support and post-service options to ensure you get the most out of your purchase. Ask your sales representative for information about repairs and warranty options.

Trust Calhoun for the Best in Custom Fabric Structures

At Calhoun, we’re committed to delivering the highest in structural performance and customer satisfaction. From our first consultation to the final installation and beyond, we strive to create the best structure for your needs — that’s why businesses, public works professionals and retailers across North America trust us to build their structures.

We’re dedicated to getting things right the first time. Many fabric structure manufacturers use standardized computations to guide their design process, but we understand that each site requires a different approach. Our 3D Non-Linear Finite Element Analysis (FEA) software allows us to account for site-specific variables in our designs so we can create a structure that meets your unique size and configuration requirements.

Click here to browse our fabric structures, or contact us today to request a free quote.