The word “building” brings to mind concrete, rebar, brick, steel, lengthy construction times and high costs. Fabric structures defy these expectations, engineered for quick construction, durability and reduced expenses.
Agriland FS, Inc. provides agricultural products directly to farmers and so are under tight deadlines for product delivery. Requiring a permanent fertilizer storage building at their Woodbine, Iowa, location, the company needed to act fast.
“We were working on a very aggressive timeline,” said Curtis Hoakison, procurement manager at Agriland FS. “We bought the land in February, and we needed to be operational early in the fall.”
After several consultations, Agriland FS partnered with Legacy Building Solutions to construct a three-tiered building design for bulk fertilizer storage. Design of the building needed to emphasize effective use of interior space and structural resistance to corrosion due to the presence of fertilizer.
A design-build construction process ensured the facility was operational in time.
With design-build, Agriland FS contracted Legacy to do the both the building design and final construction. Time is saved avoiding solicitation of bids based on the final design, and component manufacturing took take place during the design process.
Engineering Customization of Fabric Structures for Reduced Cost
The customization capabilities of Legacy’s fabric buildings allowed Agriland FS to eliminate excess square footage, increase efficiency and get a faster ROI, while housing all their needs in a single complex.
“We needed a building we could adapt,” said Hoakison. “Having everything contained in one facility was easier than trying to add another part to an existing building.”
The final building design affords Agriland FS over 19,000 square feet of clear span space for storage, mixing and loading fertilizer. All steel framing members were hot dip galvanized for protection.
Pre-cast concrete panels were used to construct the fertilizer bins, and a trough in the center of the building contains hoppers and loading equipment. One area of the building is outfitted with overhead doors to allow entry for trucks. A transloading conveyor was suspended from the frame to load the storage bays.
Legacy uses computer design and engineering software to include features like lean-tos, offset peaks, overhangs and varying column heights to their designs, with 3D renderings and blueprints available to assist in the permit process.
A Legacy engineer reviews all building plans, factors that influence building soundness and proves that the correct loading for the tension fabric building location and purpose were used to calculate the base plate reaction at the foundation.
A time-lapse video of a Legacy fabric building being constructed is available to watch here.
Rigid frame engineering is used to support cranes, conveyors, HVAC, lighting and sprinkler systems; the frames can be widened or spaced as necessary for structural integrity.
Customizable overhangs can protect the area next to the building from ice and snow, and divert moisture. Offset peaks can be included in the design to accommodate conveyors or catwalks and support lean-tos and other building loads.
A lean-to is a rigid-steel frame extension of the building on one side that provides additional space without adding excess square footage. An enclosed lean-to could be used as storage, a heated work area or even office space. Open lean-tos protect vehicles, equipment, bulk materials and more from rain and moisture.
Higher Tensile Strength and Structure Durability for Various Applications
Fabric buildings are not only ideal to store farming equipment and products but can even be used for additional space for manufacturing facilities. Climate control options can protect equipment and products from weather, both mild and extreme.
The fabric itself is non-conductive, allowing for a cooler interior in the summer and warmer conditions in the winter. Legacy’s fabric buildings can be insulated to meet local energy codes, which along with HVAC and ventilation systems, can be added to the building frame.
The Agriland FS building is covered by white ExxoTec Elite PVC fabric, which won’t corrode from the fertilizer while allowing natural light into the facility.
“The ability to use natural light is great,” said Hoakison. “We do have lighting installed in the building, but we don’t need it during the daytime.”
Legacy uses its own ExxoTec fabric instead of the more common polyethylene fabric.
“ExxoTec is up to twice as strong as the other fabrics commonly used on fabric buildings,” said Paul Smith, Sales and Project Design Representative. “The biaxial tension stops the fabric from moving and rubbing along the frames, which extends the life of the fabric. Individual panels are also easier and cheaper to repair and replace than the monocovers which are typically used.”
ExxoTec Elite has tensile strength of 745lbs, and is treated with UV stabilizers to help protect against UV damage. ExxoTec fabric is permanently attached to the frame with biaxial tension for greater durability and a wrinkle-free finish.
Legacy buildings are designed as permanent structures, although they can be relocated according to business needs. The architectural fabric cladding can also be recycled in most cases.
The frames are engineered to support load requirements, with existing buildings designed for up to 200 mph windspeeds, 220lbs snow loads and seismic requirements like ASCE 7.
Fabric structures can range in size and design complexity, so it’s important to understand the design factors that will determine the structure’s longevity and lifecycle cost. For more information on fabric building design, from issues including fabric choice, frame type, attachment and fabric pressure, download Legacy Building Solutions’ “Getting Technical with Fabric Structures” whitepaper.
For more information, visit the Legacy Building Solutions website, here.
Legacy Building Solutions has sponsored this post. All opinions are mine. --Kagan Pittman