The Story of a Truss Arch Building Part 3- Manufacturing and Production

Truss Arch WeldingWe’ve reached the midpoint to the story of a Truss Arch Building. Previously we’ve discussed our sales and financing process and last week you learned about our engineering and design teams. Well, hold on to your safety glasses and weld shields because today we’re going to discuss the birth of a Truss Arch Building; that’s right – manufacturing and production!

Bending round steel tubeOur manufacturing team is responsible for turning your Hercules Truss Arch Building from a drawing to a reality. They ensure that all structures meet the highest level of quality, following the engineers’ calculations and design specifications. In addition to skilled labor, the excellence of the products we use to construct our Hercules Truss Arch Buildings is unmatched. We purchase only premier USA-made, triple-galvanized structural steel tubing for our building frames. We like to use round tubing which we find is far superior to square tubing. Round tubing is not only proven stronger than square tubing, but more flexible at weld points, especially in high wind and snow-load areas.

Cutting steel tubeThe trusses (steel frame) of our buildings are not mass produced. Because each building is unique in its own design our steel workers must individually construct each truss in accordance with the design specifications. Our steel team uses a Computer Numerical Control (CNC) machine to cut the steel tubing to the correct size. From there they will also bend the tubing to the proper angle.

Robotic welderOnce the tubing is properly angled, cut and bent, our welders take over. The welders join the steel tubes together creating the webbed effect and strength for which our trusses are known. Some truss components, such as anchors, require extreme precision when being welded. This is when we rely on the help of our computer-operated welding machine. Our entire welding department is housed in our 160’W x 320’L Hercules Truss Arch Building.

Rip-stop scrim weaveAs much as we like to brag about our trusses, another element exists that contributes to the durability of our structures— our fabric covers. Made from either 12.5 oz. polyethylene or 22 oz. vinyl, all our fabric can be recycled and is fabricated with UV inhibitors and a rip-stop scrim weave. Rip-stop means that if the fabric were to tear or be punctured the incision would not continue to tear and become bigger over time.

Heat sealingThe size and customizations of your structure determine the fabrication process. Most buildings less than 100′ wide have a one-piece cover for their frame. This ensures a secure, leak-free fabric cover. First, members of our cover department cut the fabric into smaller sections ensuring the cover will meet the structure’s design specification. Next, each section is lined up, angled properly and heat sealed into one whole piece. Typically, if a structure is over 100′ wide or has some intense customizations, we use individual fabric panels for each section of truss. This is beneficial because less weight and pressure reduces the stress on the structure, and fastening the fabric to individual trusses can be done more securely on larger buildings with this method.

ProductionOnce the fabric cover is complete, it is paired with the correct steel trusses and readied for shipping. Get ready for next week when we discuss the final stage in the Story of a Truss Arch Building—shipping and installation.

We’ve talked about some really important jobs pertaining to our Truss Buildings. If you worked for ClearSpan which job would you enjoy the most?

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