What is the construction process for a membrane structure carport?

The construction process of membrane structure canopies includes the following key steps, ensuring structural safety, functionality, and aesthetic durability:

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### **I. Pre-construction Preparation Phase**

Design Confirmation

Based on site conditions (size, terrain, wind direction, load, etc.), design the form of membrane structures (such as tensioned membranes, skeletal membranes, etc.).

- Determine the film material type (e.g., PVC, PVDF, PTFE, ETFE, etc.), specifying parameters such as light transmission rate, fire rating, and self-cleaning properties.

- Design the drainage slope (usually ≥10%), foundation types (such as concrete foundations or anchor bolts), and ventilation/lighting plans.

2. **Material and Tool Preparation**

- Purchasing film materials, steel frames, connectors, and fasteners, ensuring the film materials are free from defects and the steel frames have passed anti-corrosion treatment.

- Prepare construction tools (such as welding equipment, wrenches, jacks, heat-sealing machines, distance meters, etc.).

3. **On-Site Inspection**

- Inspect the foundation's bearing capacity and surrounding environment (such as the presence of high-rise obstructions or underground pipelines) to ensure construction safety.

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### **II. Basic Construction**

**Basic Positioning**

- Precisely measure the foundation location based on the design drawings, marking the coordinates and elevations of the embedded components.

2. **Foundation Pouring**

- Excavate foundation trenches, pour concrete foundations (such as isolated or strip foundations), and pre-bury steel plates or anchor bolts.

- The base strength must meet the design requirements (e.g., C25 concrete), with a surface flatness tolerance of ≤5mm.

3. Pre-installed Inserts

Pre-bolted steel plates must be welded to the reinforcing steel for secure positioning, ensuring accuracy and providing support for the subsequent installation of the steel frame.

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### **Three: Main Structure Installation**

Steel Frame Assembly

- Pre-fabricate steel frames (such as trusses, columns, beams) in the factory and assemble them on-site.

- Nodes are connected using bolts or welding to ensure structural stability, with verticality error ≤ 2mm and elevation error ≤ 5mm.

2. **Film Cutting and Heat Sealing**

- Cut the film material according to the design shape and size, leaving a heat-seal shrinkage allowance (usually an extra 20-30mm on each side).

- Seam the film materials using a hot air welder, with strict control over temperature, pressure, and time (e.g., the hot air welding temperature for PVC film is approximately 400℃).

3. **Film Material Installation**

- Unroll the membrane material over the steel frame, securing the edges with clamps, pressure plates, or steel cables to maintain a tensioned, wrinkle-free membrane surface.

Tensioned membrane structures require the use of jacks or hydraulic equipment to apply prestress, ensuring the membrane surface is uniformly loaded with deformation not exceeding the design value (such as 1/100 of the span).

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### IV. Detail Handling and Inspection

Waterproofing and Drainage

- Inspect the seal of the membrane joints, ensure the drainage slope meets standards, and set up drainage ditches or overflow openings to prevent water accumulation.

2. **Enhanced Connector Reinforcement**

- Tension bolts and nuts, waterproofing the connection points (e.g., applying sealant), and stainless steel accessories require corrosion protection.

3. **Acceptance Standards**

- **Structural Safety**: Steel frame welds are free of cracks, foundations show no settlement, and the membrane pre-stress meets the design specifications.

- **Functional Testing**: Simulated wind and rain loads (such as 5-level wind) are used to check the membrane stability and ensure proper drainage.

- **Visual Inspection**: The film surface is free of any cracks or color discrepancies; the steel frame paint is even, and the overall lines are smooth.

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### **V. After-Sales Service and Maintenance**

Warranty Period Service

- Offer a 1-3 year warranty on steel frame, a 10-15 year warranty on the film material, and regular inspections (such as every six months) to check for rust and loose issues.

2. **Routine Maintenance**

- Clean the surface with clean water, avoiding high-pressure water hoses or abrasive materials, and promptly remove snow.

- Inspect steel frame connectors, drainage systems; perform local repairs on membrane material damage (heat-sealed patches or replacements).

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### **Key Points to Note**

Safety First: Always wear hard hats and safety belts during construction and use scaffolding for high-altitude work.

- **Environmental Impact**: Avoid construction during rainy, snowy, or windy weather. Hot melting of the film materials must be conducted in a dry environment.

- **Professional Team**: Membrane tensioning and hot-sealing processes require experienced technicians to ensure quality.

By following this process, we ensure the safety, functionality, and aesthetics of the membrane structure carport, thereby extending its lifespan.