Project details

Fabric name: PS Cover
Fabric producer: Naizil Coated Fabrics Inc.
Fabric supplier: Naizil Coated Fabrics Inc.
Engineer: Peter Sullivan, Peter Sullivan & Assoc.
Design: Craig Flanagan, Shade To Order Pty Ltd
Architect: Shade To Order Pty Ltd
Fabrication: Jason Barnes, McKanna Fabrications
Project manager: Craig Flanagan, Shade To Order Pty Ltd
Installation: Craig Flanagan, Shade To Order Pty Ltd
Location: Cnr King & Crowne St Newcastle NSW AUSTRALIA
Photos: Ashlie & Scott Bruce, Bruce Photography

Please describe the project specifications.
The Hotel is located on a corner that has two street entrances. The owners require a 133 square metre “L” shape awning to curve along two sides adjacent of the streets. The awning runs for 30 metres along Hunter Street then another 25 metres along Crown Street. The fabric is high frequency welded and is in one continuous piece. The traditional frames were manufactured from 75 mm x 75 mm x 3mm square hollow section alloy to reduce weight on the fixing points.

What was the purpose of this project? What did the client request?
The purpose of the awning was to provide shelter for patrons entering the Hotel from two street entrances. The client requested a traditional looking awning for a traditional style well-known hotel. The original awning, built in the 1900’s, was made of cast iron steel with intricate rail patterns that cantilevered towards the street where is was supported by timber columns that were bolted into the sandstone guttering. The owner wanted to continue this theme but without the use of columns supporting the structure.

What is unique or complex about the project?
Due to an earthquake in 1989 the Hotel was extensively damaged. The internal structural steel ring-frame that holds the walls in place was repaired rather than replaced. This resulted in a poor quality render to the outside walls. The Hunter Street repair was so hastily done that the wall was up to 300mm out of line. This required careful and accurate measuring. Allowances had to be made to every frame on the Hunter St side to keep the outside rail straight, likewise with the fabric. It was a one-piece fabric with different widths running in parallel with the frame. The frames needed to attach to the structural steel inside the hotel. This presented many engineering challenges. Given the Hotel’s age, poor quality bricks and Earthquake damage, it made it impossible to attach the frames to these walls. The inside wall needed magnetic drilling through the structural steel frame using special cantilever supports to carry fasteners to the outside brickwork. The concrete filled outer wall was core drilled to allow studs to be chemically anchored to the concrete behind the iron beam on the inside wall. The concrete was 800mm from the outside wall and there was a 200mm void in between. Attaching the frame to the outside walls was extremely difficult due to these challenges.

What were the results of the project?
The results of the project were many. Adhering to the brief of one awning, in a traditional style and colour and built in the required time frame. While having many engineering challenges, we delivered on time and on budget a complete “L” shaped awning running along the entire outside of the hotel, with a traditional awning complimenting the theme of the Hotel to give patrons a waterproof covered area to enjoy. All manufactured from modern day materials.

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