06_Tensile Canopy Construction

G 10

CONSTRUCTION PROJECT Hargrave Hall / Archway / London

TENSILE CANOPY

Contents.

Page 4 5 6-7 8 9 10-11 12-13 14-15 16-17 18-19 20-21 22 23 24 25 26

Project Brief

Preproduction Phase 24.09.10 25-27.09.10 28.09.10 29.09.10

Fabrication Phase 30.09.10 01-03.10.10 03-06.10.10 07-10.10.10

Construction Phase 11-17.10.10 18-24.10.10 25-31.10.10 01-07.11.10 08-14.11.10 15-21.11.10 Conclusions

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Project : Hargrave Hall, Tensile Fabric Canopy Address: Hargrave Hall, Hargrave Road, London, N19 5SP Client: Carole Montana, Monty’s Montessori Facilitators: Ilona Hay and Mike Whitfield Structural Engineers: Andrea Menardo and Victor Juarez (Buro Happold) Group Members: Ana Abascal Crespo, Eirini Krasaki,

Group 10 Tensile Canopy Project Brief.

Ana Abascal

Silvano Musgrave

Simon Scarlett

Hank Hendriksen

Silvano Musgrave, Simon Scarlett, Hank Hendriksen, Jamie Jiang

Project Description/Brief:

The client is a children’s nursery in Archway for children between the ages of two and six.

In the back they have a garden they use everyday, with a sandbox that is open to the elements and needs covering. The area, to be covered to protct from sun, rain and cats (from digging and using the sand), is 2.2m x 2.3m. All solutions can be integrated within a design or can be addressed as different issues within it. The shelter should have to address forces of rain, wind and gravity.

The client wants the materials to be eco-friendly and sustainable where possible, and is especially keen on natural materials. As a side benefit the shelter could be used to collect rainwater.

The client is keen for the children to observe the building of the project, and thus be involved.

Note there is an additional zone available (circular plan, 5m diameter) that needs a climbing structure. Time, money and effort willing, this could be an additional project related to the first.

Working hours on site will be strict, and are as follows: Mon: 8.45am – 4pm Tues: 8.45am – 6pm Weds: 8.45am – 6pm Thurs: 8.45am – 6pm Fri: 8.45am – 5pm There is no access to site on weekends, However, planning, drawing and fabricating components can be progressed off site when the site is closed.

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Eirini Krasaki

Jamie Jiang

WEEK 01 PREPRODUCTION PHASE 24.09.10

The site, the backyard of the preschool, is an open green space with simple timber shelter that act as classrooms. The sandbox, a key playing feature in the playground was open to the elements and needed to be turned into a sheltered space.

Tasks

1. Head across to Archway to meet with client at 3pm.

• Make initial site analysis.

Procedings

• After introducing ourselves to the client we first discussed our experiences and our specific areas of knowledge in order to best allocate the key roles within the group.

• The initial meeting with the client on site was very useful allowing us to immediately discuss the client’s aspirations for the project and any concerns that would condition our design, like: • Scale of the projest to suit the children • Extra safety precautions as the design was to be used by children.

• We delegated roles that would allow us to comprehensively record the site in detail and undertake an initial site analysis and investigation: • Hank, Ana & Eirini – Record the entire site and locations of any existing structures.

• Simon & Silvano – Record in detail the immediate area around the sand pit.

• Once we had a good understanding of the project we were then able to assign roles within the group:

First Meeting/ Site Visit.

Team Co-ordinator - Ana Abascal Crespo Treasurer/Ordering - Eirini Krasaki Documenter - Silvano Musgrave Risk Assessor - Simon Scarlett Materials Research/Ordering - Hank Hendriksen Materials Research - Jamie Jiang

Progress Update

On the first day we managed to get a head start in understanding the project, the site and the client, and identifying the key issues we had to deal with. The first meeting with the client was informative and productive, and we were quick to identify the most suitable roles for each individual within the group for this project.

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WEEK 01 PREPRODUCTION PHASE 25-27.09.10 Tasks

The first day we all came together with our sketchbooks full of thoughts from the research we had done.

We would usually get together either in University or a small caffee around the corner from the site to discuss the project out of the cold rain.

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1. Research tensile canopies to gain inspiration.

2. Research tensile fabrics to understand design possibilities and limitations for our design.

3. Design and create scale models of initial designs for discussion with structural engineer.

4. Attend meeting with Structural Engineer at offices of Buro Happold.

Procedings

• At this stage the assigned roles did not really come to use as we all focused on brainstorming ideas to bring the project forwards.

• With the data we collected on site, as a group, we built a 1:50 model of the playground to get a better understanding of the existing elementes in the space and of the site itself.

• We felt it would be more beneficial for the initial stage for each member of the group to research tensile canopies individually and then meet in university to discuss possibilities of the design.

• We were able to draw up a design brief that would provide a good ground on which to base our designs.

• Must function year round; • Protects from rain, sun & cats; • Safety is paramount and should be taken into account in all areas of the design from materials used, any moving parts, locking mechanisms...; • Easy to work – open/closing, possible moving parts, time saving, not laborious to use; • Functional in terms of protecting from, and collecting rainwater; • Design must use eco-friendly and sustainable materials where possible.

Procedings (cont.)

• We split up to individually develop quick design proposals. Through sketching and producing models at 1:10 we then presented and discussed as a group each of the ideas brought. This way we were able to hightlight the pros and cons of each possible design and select the three best designs for presenting to the structural engineer. • After the meeting with the engineer and discussing with him our three proposals we revised our designs to make them work better as a tensile structure whilst providing a solution to the brief.

Research/ Design.

The Tent That Stands Over The Sandbox

Progress Update

By this stage we had a good understanding of the types of materials we could use which would help us to advise the client when we presented our ideas. We now had three concept models of possible designs for our tensile canopy that been discussed, revised and corrections had been suggested by the engineer, who highlighted the pros and cons of each design as well as potential problems we might encounter during construction.

This solution proposed for the site uses posts and fabric to create a tent-like structure that covers the sandbox. Both sides of the sandbox are constantly shielded, while the back remains permanently open against the fence to allow for supervision of the children from the courtyard.

From our discussion we developped three designs to show the client, two of which were tent-like tensile canopies that would close up entirely or have an open entrance to the sandpit.

The front of the tent, corresponding with the side of the sandbox facing the play garden, can be opened and kept open while the children play, and closed on rainy days and when the playground is not in use, protecting the sandbox from the weather and animals.

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WEEK 02 PREPRODUCTION PHASE 28.09.10 Tasks

1. Client meeting due to be taken at 10am was cancelled.

2. Continue research into possible materials focusing specifically on tensile canopy material.

Procedings

• Due to the client meeting being cancelled we met in university to work on improving our proposals, discussing which designs were preferred and improving our presentation to the client scheduled for the next day.

• The extra time allowed Hank and JJ to research further on tensile canopy materials and speak to professionals in the field with experience in using these materials. This gave us a better understanding of which materials would be suitable for the tensile canopy, taking into account: • The client’s wish to use eco-friendly and sustainable materials; • Durability and longevity; • Cost; • Aesthetic suitability to existing playground.

• ‘Cat- protection’

Research/ Design.

Progress Update

Due to the client meeting being cancelled we were by this point behind schedule on what already was a very tightly timelined construction project. However, the extra time allowed us to work further on our presentation to the client and gain more understanding of the performance of materials we intended to use.

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We sketched our proposals further, to understand the implications of each design getting ready for the client meeting scheduled for the next day.

WEEK 02 PREPRODUCTION PHASE 29.09.10 Tasks

1. Work out estimated budget per design proposal.

2. Meeting to present our 3 design proposals to the head teacher (client) and the children of the school.

3. Refine chosen design and begin to put together a structural and design package that would allow us to construct the tensile canopy.

4. Carry out detailed risk assessment of site prior to any construction.

Procedings

• During our meeting with the client, where we presented each the three designs, we informed her of the pros and cons of each design. It was at this stage the children got involved as they attended the meeting and were able to choose their favourite design from the presentation.

• We were successful in representing our preferred proposal, as this was the one the client and children were more excited about, which allowed us to positively move forwards in the design.

• The produced sketch drawings of our ideas and details were very beneficial in conveying quickly our ideas to the group; a process that served us very well throughout the entire project.

• After the client meeting the group got together to ultimate the project and work out the final details of the design with the help of one of the project supervisors. At this stage the main components of the design were: • One tensile canopy that would cover the entire sandbox; • Four vertical posts with integrated rail that would allow the up-down movement of the canopy to protect from the sun and rain when raised, and from the cat when lowered; • 8 timber ‘beams’ that brace the structure; • Structural foundations; • A pulley mechanism that would move the canopy.

Progress Update

Client Meeting.

By this point we had a definite preferred design by the client which allowed us to start carefully laying out the plans of how to go about detailing the design, ordering the materials and begin construction.

When the group got together after the client meeting, with the freedom the client gave us in the meeting to make variations to the design, we were able to ultimate the final components of the project.

Ana made initial contact with Claryl (corset maker in university) to discuss processes for design and fabrication of tensile canopy. At this stage we had little knowledge of pattern cutting techniques and use of materials, although we did have basic fabrication knowledge. This contact within the university was very important to get an understanding of the timing of the fabrication of the canopy.

Simon had also carried out a risk assessment of the site prior to us undertaking any construction on site or fabrication of the designs components in the work shop.

The client meeting was in a very relaxed atmosphere, surrounded bu the children where the client, the kids and the group had a say.

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WEEK 02 FABRICATION PHASE 30.09.10 The proposal that everyone preferred consisted of a frame that supported a tensile fabric that could be lowered and lifted to suit the client’s needs.

Tasks

1. Draw up budget for chosen design proposal.

2. Order all construction materials ready for fabrication of specialist pieces.

3. Finalise construction details and begin fabrication of vertical timber posts.

4. Begin site preparation ready for construction.

The Falling Leaf, The Box, And The Sandpit.

Procedings

The concept is based on the idea of contrast and harmony. The fluid nature of the fabric canopy and the rigid conformity of the box. The canopy is arranged in a spiral formation, it echoes freedom and flight aswell as providing a complete solution

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for covering the sandpit. During use it provides protection from the elements being held up high and at a safe distance from the reach of young children, while at other times it can easily be lowered to stop rain and cats from getting in.

• In order to draw up a budget for our chosen design we had to calculate all the materials we required and then shop around to find the best price for each of the components, which required much coordination and research to allow us to stay within our limit. • When ordering the materials we had to contact the suppliers to get estimate delivery times. Due to the ordering system through the University with the process of submitting material payment request forms and the number of different suppliers we required we were afraid we not going to receive the materials with enough time to allow us to fabricate the components and construct the design. As a last result we purchased the materials from local suppliers from our own pockets which, although ensured we got the materials promptly, also pushed the budget up slightly. At this stage this was not an issue as we were well within our budget, but but if there were to be any problems further into the project we would most definitely go over budget.

Procedings (cont.)

• We were now able to begin fabrication of the vertical timber posts that would house the sliding rail system that allowed the tensile canopy to slide up and down.

To allow the sliding gear to fit into the posts we had to route out grooves in the posts that the sliding gear could then be fixed into. Although this was a long and difficult process taking nearly 2 days to finish all 4 posts, we agreed it was necessary to provide structural integrity for the sliding rail system. • In order to prepare the site for construction and as a matter of safety, we had to move the sand box from its current location to allow us to work in the area with the least obstacles. We were lucky the client offered to have the children remove the sand from the sand box, saving us a great deal of time.

The first thing we did was remove the sand and sandbox to free up the area and allow for space to work after clearly marking the current position of the sandbox.

Soon after we began the fabrication process in the workshop.

Design Development &Manufacture.

Progress Update

We managed to make much progress in the project by ordering and getting a bulk of materials required to start the construction into University, despite the initial difficulty to do so. We were able to begin fabrication of the largest components of the design in the vertical posts/sliding rail system, which was one of the part of the design were most anxious about. There was also some good progress on site once the sand box had been removed from the construction area allowing enough space to continue work on site.

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WEEK 02 FABRICATION PHASE 01-03.10.10 Tasks

1. Finalise foundation details with structural engineer.

2. Finish digging trenches for foundations.

3. Order any materials required for construction of foundations.

4. Continue fabrication of vertical timber posts.

5. Finalise design for tensile canopy.

6. Order any remaining materials required for fabrication and construction.

7. Continue to research and draw up sketch details of specialist construction details. i.e. pulley system, tensile canopy, connection between canopy and sliding rails.

Procedings The foundations had to be dug and work of serveral times following different discussions with the engineers. One of the hardest parts was working with that soil: a mixture of mud, rubble and concrete blocks.

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• The foundations provided a number of problems, modifying the design a number of times.

• One of the options was to use the weight of the sand box to create an anchor for the structure, but after finding out the sand box did not have a bottom and could not act as a weight the design had to change, which required further correspondence with the structural engineer in order to come up with a suitable design, as well as an extra meeting in their offices.

• As the site had been cleared and we were able to dig the trenches for the foundations, a process that took much longer than expected due to the condition of the ground, which consisted of rubble made up of mud, pebbles, stones, bricks and concrete blocks. This process took a whole day.

To ensure we could shuffle to structure to readjust its position once the poles were in place we decided to cast the posts intro buckets of concrete that could be moved more easily than a block set in the ground.

Procedings (cont.)

• Whilst digging out the foundation we found that the retaining wall to the back of the sand box area protruded further than we expected and so we would not be able to get the foundations to the required depth of 800mm set out by the Structural Engineer.

• This would require us to make alterations to the design in order for it to work: reducing the depth of the foundation to 500mm, and reducing the height of the posts to accommodate the new foundations.

• At this stage we also needed to finalise any remaining unresolved details within the design prior to construction on site, so we broke down the design and allocated the details to be worked out to group members: • Pulley system sourcing – Simon • Tensile canopy manufacturing– Ana & Eirini • Canopy/Rail connections sourcing– Hank • Internal tensile canopy frame making - Silvano

Digging &Detailing.

Progress Update

We finished digging the foundation trenches, but still had not managed to solve the problems with the foundation, which took a another meeting with the enginners to clarify. This was something that needed to be resolved as soon as possible as we would not be able to push the project on site any further as the foundations were to be the first part of construction. Work, however, was mostly made off-site in the university timber and metal workshop. The engineers also suggested different construction processess that modified the order the project was assembled of site which although introduced another variable to the design process allowed us to reconsider our schedule and proved, overall, to be helpful.

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WEEK 03 FABRICATION PHASE 03-06.10.10 Column Detail

Tasks

100mm 100mm

Rail 1735mm

1735mm

1. Finalise specialist construction details. i.e. pulley system, tensile canopy, connection between canopy and sliding rails.

2. Foundation design to be finalised with Structural Engineer.

3. Transfer fabricated pieces and any larger materials from University to site for construction.

4. Meeting with facilitators on site to discuss progress and further developments for the project. (18.30 – 06.10.2010)

Procedings 330mm

• We drew up sketches for the pulley system, tensile canopy and the sliding rail system that would allow us to fabricate the components.

• Through meeting with the Structural Engineer we were able to finalise the design for the foundations and produce some sketch details prior to construction on site.

330mm

100mm

500mm Concrete

Detail: Simpson Strongtie Concealed Beam Hanger (w:40mm)

500mm

100mm 500mm 40mm

101mm 9mm

96mm

After several discussions with the engineers the detailing of the foundations were agreed: where the posts would sit in buckets of concrete within the foundations, protected by plastic bags (as budget insulation) from the moisture of the soil, with a series of nails to anchor the posts to the concrete.

Column 100x100mm

Scale 1:10 in A2

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Procedings (cont.)

• A major problem we faced at this stage was transferrinmg the large materials to site. After looking at the budget and our options we opted for hiring a van; our last resort as we were getting close to out budget limit and we wanted to save as much money as possible as a contingency. • We had a meeting with our facilitators at 18.30 on the 06.10.2009 in order to discuss the progress we had made on the project and draft a programme for completing the project.

Material Transfer.

Progress Update

By this date we had sketch drawings for all of the components of the design, we were moving forward fast with their fabrication, and we had moved the larger components to site However, presure was beginning to affect the group and there were some very heated discussions as to the best way to approach finishing the project. There was still a huge amount of work to be completed and we began to realise that unfortunately we were not going to be able to finish the project on time. The client, due to pressure for the board of directors and parents, as well as a board of trustees (that had the final say), was anxious to have to project completed as soon as possible and was getting anxious, although through correspondence we managed to put her at ease slightly.

The larger elements at this stage: the vertical posts with rails and reinforced beams that had been fabricated off site in the workshop and were ready to be put together were finally on site.

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WEEK 03 FABRICATION PHASE 07-10.10.10 Tasks

1. Discuss with Structural Engineer and finalise the internal structural frame for the tensile canopy.

2. Finish fabrication of the vertical timber posts and form foundations ready for placement on site.

3. Finish fabrication of horizontal cross members ready to connect to vertical timber posts.

4. Fabricate tensile canopy.

5. Prepare for presentation of the project.

Procedings

The design of the internal frame, to support the tensile canopy in tension, was yet to be finalized: we modelled, sketch, and drew up to scale before we started its construction.

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• We were in the process of designing the structure for an internal structural frame for the tensile canopy.

The engineers stressed this element was crucial in order to create the best tensile structure, as the rail system itself would not be enough to create the tension needed. This element provided a number of issues as we did not want the structure to be so visually strong so as to reduce the visual strength of the tensile, but it had to be strong enough for it not too collapse under the tension created by the canopy. • We made sketch designs and began to assemble two possible designs that we felt we could use.

Through testing the designs we eliminated one of the designs and focused on the proposal we felt would perform the best. • Due to the shape of the frame we would not be able to fully close the sand box to prevent cats from entering at night. The the best way to solve this problem would be to build up the sand box itself to fit the shape of the frame , thus allowing the structure to be sealed when not in use.

Procedings (cont.)

1500

• In the meantime, a part of the group began to fabricate the tensile canopy.

After a meeting with Claryl (corset maker and Fashion tutor in University) we created a canopy template scale 1:1out of paper that we could use to check we had the correct measurements for the final canopy and we maximized the use of the material we had purchsed.

We cut the paper exactly as we would the fabric and pinned the pieced so we had an exact paper copy of what we were to have in fabric. We then did the same with the fabric we had ordered. • Although we would not have the project completed by deadline we put together a presentation of our project up to date to present to students and tutors. To keep the project moving Hank and Simon were assigned the task of compiling and presenting the project while Ana, Eirini and Silvano continued to work on the tensile canopy and the frame for the tensile canopy.

1231

1825

Presentation Day. Work Continues...

Progress Update

We were now very close to having all of the off-site fabricating completed on the project but there were a few problems with the structural integrity of the tensile canopy frame that would need to be addressed before we could fix it to the sliding rail system. Ana and Eirini had made very good progress with the tensile canopy leaving just the sewing of the hem to do, around the edge, to form a channel for the wire reinforcement that would later connect the canopy to the frame.

To maximize the fabric and avoid mistakes we began the fabrication of the fabric by drawing up the pieces to scale showing how to cut them and sew them. Then we did a 1:1 model out of pape and only then did we begin to work on the actual fabric.

6000

90

200

1825

919

15

30

100

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WEEK 04 CONSTRUCTION PHASE 11-17.10.10 Tasks We did a recap of out work so for the AVA presentation: We had the posts ready, measured up and the foundations were cast, the fabric was being fabricated and the rail detailing was done. In the meantime the work continued.

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1. Finish fabricating the tensile canopy.

2. Finish internal structural frame for tensile canopy.

3. Finalise the design for the winch/pulley system.

4. Research and order the connections between the tensile canopy and internal structural frame.

5. Prepare 3 photographs for exhibition.

6. Construct main structural frame on site (position vertical timber posts and fix horizontal cross members in place).

7. Re-position sand box once structural frame is in position.

Procedings

• Ana and Eirini worked on the fabrication of the tensile canopy.

• Following the meeting with Caryl and after cutting the 1:1 paper pattern we concluded the fabric had to be cut along its bias (so that the warp and weft, the way the fabric has been woven, is at 45°) to give the fabric enough elasticity.

• The paper pattern, and the fabric, was divided into three parts: a central one and two corners, to fit the fabric piece we had. How these pieces were connected was very important stage of the fabrication process as it needed to be strong enough to anticipate the forces that will appear on the canopy. Following the advices of Caryl Court, the patterns were stitched together. The fabric was finished, the hem was sewn, and the cable was passed through the hem to complete the fabric.

• In the meantime Hank and Silvano worked on the internal frame of the structure after deciding on the design and working on finishing it. The intention was to finish the internal frame, attach and tense the fabric on it, and test this part of the construction off site, in university, before taking it to site.

Procedings (cont.)

• Simon worked designing and sourcing the winch and pulley system.

• He worked out the position of the pulleys on the frame and the route that the rope to move the system will follow. At the same time he researched suppliers that could ensure delivery on time and within the budget. The intention was to design a system that would match the aesthetics of the construction and would create a safe space for the children to use.

• Hank later researched types of connections that would suit the type of thread we were using to attach the tensile canopy and the internal structural frame.

• At the same time a part of the group got together a presentation and three photographs for an exhibition in the AVA; three photos that would explain the project.

• Ana, Simon and Eirini visited the site on Thursday afternoon to put the vertical posts of the extrernal frame in place.

Firstly we ensured the bottom of the foundation holes were levelled to assure the posts would be the same height. Once they were in place we tested their accuracy using a spirit level, and then covered the holes in order to anchor the structure. The part of the timber frame that was to touch the ground was covered in plastic bags to ensure the lifespan of the material and keep it from rotting in contact with the ground. A safety fence was place around the space to ensure the area would be safe the next morning and keep children from approaching it.

• Hank, Silvano and Eirini delivered the remaining parts to site, including the internal frame for the canvas, and they assembled it on site.

• This weekend was one of the few we had access to the site, which we used to solve any issues with the frame and the canopy. Because of issues with the weight of the internal, moving frame, and the possible danger of having children around and under such a structure we decided to abandon the use of the internal frame and attach the tensile canopy directly to the structure.

The fabric was cut and sewn following the paper papern, and the cable that would allow it to be tensed was passed through the hem.

At the same time on site the external structure was starting to take shape.

Progress Update

4 Posts 1 Canvas.

By the end of this week we have the vertical posts in place, tensile canopy fabricated and delivered on site and the design of the winch has been progressing. The alterations on the internal frame took longer than we had expected but we believed it ended up being a safer design solution.

Making these alternations on the design meant we needed to re-research the type of connections between the fabric and the rails, and re-check the winch system to fit a lighter structure.

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WEEK 05 CONSTRUCTION PHASE 18-24.10.10 Tasks

1. Finalise the design for the winch/ pulley system.

2. Research and order the connections between the tensile canopy and internal structural frame.

3. Fix horizontal cross members in place.

4. Re-position sand box

Procedings

With the vertical posts in place we proceeded to add the beams that would brace the structure together. It was at this stage that the project bagan to take shape within the site.

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• After getting rid of the internal frame structure we needed to make slight alterations to both the design of the pulley system and the connections between the tensile canopy and the rails. As the structure was much lighter we concluded we would not need a winch to move the canopy up and down, and a system of pulleys would suffice. We sourced the pulleys and sketched the idea in order to decide which was the best mechanism to keep the rope fixed securely in place when the canopy was raised. • The connectors between the canopy and the rails still had to be sourced, and they were firstly sketched to get an understanding of the function they needed to do. We got in touch with different suppliers to get quotes but in the end we decided to manufacture these connectors ourselves as this was the only way to ensure they would work like they were required and still save some money

from the budget.

Procedings (cont.)

• On Friday 21.10.2010 we worked on site fixing the beams to the external structure and placing the wedges that brace the structure in place.

• At this stage we realized we would need to raise the sandpit 150mm to allow the canopy when lowered to fully enclosed up the sandpit. We levelled the soil beneath the sandpit, using bricks and the rubble we had previously dug out. As they new height made the sandpit inaccessible to small children we built up a gentle slope with a 10% inclination that would lead the children from the entrance of the garden to the sandpit. We piled soil around the sandpit to make the ground soft, and added woodchip the client owned to homogenize it with the rest of the site.

Frame fixing.

Once the frame was in place the sandbox was returned to it’s original position and final adjustments like adding the corner edges for bracing were added to complete the work on the structural part of the project.

Progress Update

The structural frame was finished in place, and the mood of everyone in the group, so tense until this point, was uplifted. We were all happy with they new simplified scheme as we realized it would make the canopy easier and safer to use as well as allowing us to work faster to complete the design 21

WEEK 06 CONSTRUCTION PHASE 25-31.10.10 Tasks

1. Order and attach the connections between the tensile canopy and sliding rail system.

2. Order materials and setup pulley system.

3. Replace sand in sand box.

4. Have the structure checked by the engineers 5. Connect the tensile canopy to the frame

Procedings

• We began construction of the connectors that would attach the tensile canopy to the sliding rail system out of timber and threaded hooks we connected the cable to.

• In order to set up the pulley system we bought two double pulleys and rope that run from the fixings in the rails on two opposite points of the canopy through the pulley. We set it up and tested it.

• During the construction period, we had temporarily stored the sand in plastic boxes found on site, well protected from rain. When the sandpit was in place and in the right position we put the sand back into the sandbox.

• On Thursday 29.10.2010 Ana met with Victor Juarez, one of the engineers from Buro Happold, on site so he could inspect the structure and ensure it was safe to use. He gave his approval and briefly spoke to the client giving him his opinion and reassuring the client Carole the external structure was sturdy and safe.

• The canopy and moving mechanism was connected on Sunday 31.10.2010, although the pulley system was not fixed in place at this point yet.

Some readjustments had to be made to the height of the sandbox and slight landscaping had to be made to make the sandbox suitable for children using the rubble we had dug out. This ensured the fabric touched the sandbox when lowered.

When we were sure the things were in place the sand was put back in the sandbox.

The Sandbox.

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Progress Update

The reassurance from the engineers that the work we had done was good enough and safe to use helped the group spirits and reinforced our desire to finish the project. Also finally seeing the canopy tensed in place, although lowered because the pulley system was not set up yet made us realise how close we were to completion.

WEEK 07 CONSTRUCTION PHASE 01-07.11.10 Tasks

The sandbox in place, the tensile canopy attached, what we had to do was work out the positioning of the pulley system that would help with the pulling up and lowering the canopy’s mechanism.

1. Set up the pulley system.

2. Alter tensile canopy to allow it to be fixed to the sand box when it is the lowered position.

3. Construct the ‘window sill’ profile to add up to the sandbox.

Procedings

• Having the tensile canopy already connected to the rail we connected the rope to the system, up along the posts, through the pulley, across the structure, and down the outside of the posts again to a point where a single person could pull the whole canopy up and down.

• We also needed to find a mechanism to connect the canopy to the sandbox once it was lowered- a series of clips that would allow the canopy to be fixed down during the nighttime.

• As an extra precaution to keep rain from falling into the sand we decided to add a ‘window sill’ wedge to the top of the sandbox, sloping down and outward from the sandbox so the water would slide outside, and not into, the sand.

This ‘window sill’ profile would allow us to waterproof the sandbox, but it was to be the last thing to be done to allow it to fit perfectly to the tensile canopy.

Pulleys &Tensions.

Progress Update

This week turned out to be very progressive in terms of problem solving our design, but fairly slow in terms of visible progress on site. This caused a number of problems mainly with the client wanting the project finished as she was not aware, despite our emails and conversations with her, of how far the project had evolved and how close it was to completion. The fact that by this stage we were heavily into the course and other modules of the course did not allow us to dedicate as much time as we wanted to this project, despite the constant meetings and continued work. We were all very eager to finish the project as we felt we are a few hours’ work away from completing the whole project, although it did seem that throughout this project, for every piece of fabrication or construction solution a new problem would arise.

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WEEK 08 CONSTRUCTION PHASE 08-14.11.10 Tasks

1. Order and attach the connections between the tensile canopy and sliding rail system.

2. Order and fix in place a cleat to provide fixing for rope when the canopy is in the raised position.

3. Alter tensile canopy to allow it to be fixed to the sand box when it is the lowered position.

Procedings

• This week we mostly concerned ourselves with trying to solve the problem of getting the fixings we had made to connect the tensile canopy and sliding rail system to work. We tried a number of ways of connecting the two together but as soon as the tensile canopy was raised and put under a small amount of tension the connection piece would fail.

• To ensure the durability of the materials and the connectors we ended up substituting these crafted connectors for galvanized metal cable tensioners as are used in wire balustrade systems that made a sturdy connection and allowed us to tense the fabric as much as we needed once in place.

• The final thing to be done to the pulley mechanism was attach a cleat to the side of the post that would allow the client to tie down the rope that moved the canopy once tensile fabric was in place, which still had to be sourced.

• We continued trying to source the mechanism that would connect the fabric to the sandbox. We decided the best way to connect them would be through clip-on buttons from boat covers that could be fixed to the sand box frame and the tensile canopy. This would create a safe and efficient way in which to fix the canopy at night. We still had to find a supplier that would allow us to buy these connectors within our budget and as soon as possible.

Final Stretch.

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Progress Update

We replaced the fixings that connected the fabric to the rail several times as the tension of moving it up and down continued to snap them.

When we did find a suitable replacement all that was left to do was connect the pulley system.

This week was again another week without much visible progress on site, as we tried to push the project through to completion. We knew now that once we had the specialized connection pieces we could be able to make the final adjustments to the project and complete it. That would allow us to hand the final hand-over to the client.

WEEK 09 CONSTRUCTION PHASE 15-21.11.10 Tasks

1. Order materials from week before and attach: • Connectors between the tensile canopy and sliding rail system.

• Cleat to provide fixing for rope when the canopy is in the raised position.

• Clips to fix the tensile canopy to the sandbox when lowered 2. Do the client hand-over

Rail Cross-section 28x29mm

Frame for tensile structure (see detail)

Sanbox 2200x2200mm width of board 50mm

Procedings

• The group was slow in progressing with the sourcing of the remaining materials, but we never got the chance to proceed further than that.

• Once the whole thing was to be completed we were to have a meeting with the client and one of the team supervisors, possibly Ilona Hay, to do the final handing over of the project, which also never happened.

Beam 50x100x2270mm Structure bracing Steel pole

Bracing (see detail)

Columns 100x100mm

The construction of the design was complete, the canopy was position and the pulling up and down mechanism was working; all that was left to do were the final adjustments...

Pulley mechanism

The End...

Bracing

Frame for tensile structure (see detail)

Simpson Strongtie Concealed Beam Hanger w:40mm (see detail)

Beams 100x50x2270mm

Progress Update

Rail depth 25mm width 28mm height 1310mm

One day this week Alan Chandler met with and Ana, as team coordinator, to inform her and the rest of the group of recent news regarding the client and the project. As Alan explained the client had gotten in touch with the University program coordinators directly claiming she had no way of contacting any of the group members or supervisors, and wanted the project taken down because she felt the structure was not safe. This came as a surprise considering the previous correspondence kept between the Carole Sandbox 2200x2200 Lowest 330mm Highest 790mm

Columns 100x100x3000mm

Plastic waterproofing (bag)

Concrete Foundation 300x300x500(800)mm

100mm nails with waterproo fing

Montana, the client, Ilona Hay, the supervisor, and Ana Abascal, as well as the number of phone calls throughout the length of the project.

Alan informed the team he and another member of staff were to visit the site during that week to personally speak to the client and inspect the situation of the site and project. From the information recollected the client had hired a personal team to remove the structure and restore the site to its original state, and dealt only with the university, no longer with us, the

Scale 1:20 in A2

group that had been working on the project. Considering the amount of work and effort we put into this project the whole team felt it was a shame it concluded as it did. We can understand from the client’s point of view the unrest the constant delay to complete the project and the whole situation could have created, although we would have appreciated to have heard these concerns from the client as they arose and to have been told to terminate the project by the client directly instead of through the university tutors.

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As a whole our project cannot be considered a successful construction project as we were unable to fully build and deliver the tensile canopy to the client, although what we learned from the whole project was more than we would have anticipated. Perhaps it was the high aspirations of the group to design a complex mechanism that would perform as a cover and as an aesthetic focal point for the garden that would surpass the client’s expectations what doomed the project from the beginning: we immediately created a demanding design on a tight budget and even tighter time schedule.

Although essentially the design of the structure was relatively simple the complication lied in the moving mechanism, in the sliding rail system. This proved an elegant solution designwise that allowed for one single mechanism to fulfil the two separate opposing functions of allowing access to the sandbox while protecting from the sun and completely closing it up.

However, this solution also increased material costs, fabrication time and created a series of technical problems that in hindsight were not suitable for our budget or schedule. Many things could have been done differently throughout the project, especially in

the design stage, but thanks to those mistakes we feel we have managed to challenge ourselves more than if we had worked on a very simple structure. From this experience we have learnt the importance of designing according to the realities and limitations presented by the project’s budget, timeline, and the constructor/designer experience.

a working structure that would have served the school had it not been taken down. As a group we were able to adapt as the project progressed and changed and we collaborated with each other beyond our designated roles within the group when needed in order to help with certain tasks as an urge to move the project forward.

Conclusions.

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The hardest thing within our group was getting the whole team to work together and take the project in the same direction. Different opinions on how the project should be approached and delivered lead to very long and heated discussions within the group that at times disrupted the progress of the project. However, in the long run the group remained tightly knit most of the time and worked together despite occasional disparities in opinion.

Despite the failures of the project many positive things came out of this construction project. The amount of time and effort we put into this project, working hard over a number of weeks well past the deadline, showed the extent of commitment of the group and allowed us to provide the client with

Things would definitely be done differently if we were given a fresh start: we would first assess the possibilities of the budget, time constraint and our current knowledge before designing a structure and pitching our idea to the client. We have learnt how to work within an intense group environment whilst being involved in a live project, how to work together and effectively, and how to tackle our projects understanding both the process of design and construction. Through trial and error, from the group and as a group, we have been able to learn how to avoid making mistakes and correct those we have made and understand the process of design from beginning as an idea till completion and the final product, taking us forwards into our careers.