Have you ever found yourself asking the question, “How do they do that?” No matter how many times we explain the process of designing, engineering and manufacturing a ClearSpan fabric structure, we know that often times seeing is believing. That’s why this week, we are giving a behind the scenes look at our centrally located Dyersville, Iowa manufacturing building to show how we produce each of our 100 percent America-made fabric structures in a ClearSpan Hercules Truss Arch Building of our own.
Naturally, the first step in creating these structures is design. Our team of engineers take these buildings from concept to creation using computer programs to ensure every detail is accounted for and that the building is constructed to meet all necessary building codes.
You may not have guessed it, but the first step in our manufacturing process is creating the rip-stop polyethylene fabric cover. Many may assume that we produce this section last, however, what is a ClearSpan fabric structure without the fabric? We first measure, cut and stitch the fabric as needed before we begin on the triple-galvanized steel frame structure.
Numerous sections of US-made, triple-galvanized structural steel tubing are kept on hand within our manufacturing facility. Once the buildings are past the design stage and ready for manufacturing, the proper piping is selected by gauge, length and shape.
With the proper sections of steel selected, the piping is then designed and engineered to order. To create our classic arched-frame, members of our manufacturing team place the necessary sections of steel into patented, heavy-duty steel bending machines. The engineered steel adds a great deal of strength to the structures, giving them long-lasting durability with a 50-year warranty.
Once all the required pipe is cut and bent, the sections are moved along to our robotic welder. This welder ensures extreme precision in our buildings’ frames. It is during this time that the supports are added to the two sections of bent steel, creating our classic truss arch frame.
After the robotic welder, each truss arch section is sent for quality checks and final touches. During this time, a team of welders inspect each weld made by the robotic welder and clean up or repair any welds that may need it.
For pony-wall buildings, we also use a robotic welder to manufacture steel base plates, which are used to safely and securely connect the truss arch frame to the foundation.
With the frame and fabric complete, the building is ready for shipment. Smaller pieces, such as base plates, keder rails and hardware, are boxed and sent to the loading area until they can be picked up for shipment.
Since the trusses are so large, they must be loaded directly onto a flatbed truck for shipment. Related boxes and trusses are loaded onto flatbed trucks, reducing the risk of shipping errors and increasing the speed in which customers receive all necessary pieces.
The next time you come across an American-made ClearSpan fabric structure, take a moment to admire the hard work and great amounts of effort it took to produce that beautiful piece of American engineering. We strive to produce the best buildings we can, and no matter what the job may be, we can design a one-of-a kind structure to meet your needs.