How to build the Perfect Shade Structure every time! Step 3

Step 3: Sail Manufacture & Installation

After going to all the effort  to get the first stages completed to perfection, now let’s look at a few crucial points to ensure that the same standard is maintained in this final stage.

1. Point to point measurements
   Are laser measurers and levelling technology used once the shade poles have been installed to get accurate measurements for manufacturing the sail?
2. Cutting the shade fabric for the sails
   How is the shadecloth measured and cut? 
   
   Automated Cutting Machines
   These world-leading fabric cutting machines facilitate Shadespan’s meticulously accurate fabrication methodology. The data is loaded to the in-built CAD system which re-creates a 3-D model of the structure, then automatically patterns the sail, and sends the data to the cutting machine. This performs a continuous cut to ensure 100% accuracy of the sail to the minutest detail to ensure perfectly fitting sails – every time!
   
   An additional feature is the ability of the CNC Cutting Machine to cut any shape or pattern in the fabric which can be used either to create a difference or to repair damaged sails. Hey! Now’s your opportunity to really make a statement!
3. Manufacturing the shade sail
    
   Is a quality shade-cloth being used? Shade-cloth such as Commercial 95 or Monotec 370 offer uncompromising quality along with a good supplier support network. These shade-cloths are selected because of their proven track record in Australia. 
    
   What thread is being used? Cheap threads can affect the life-span of your shade sail – if the thread wears out, the sail comes apart. Specify a ‘Tenara / PTFE Thread – this thread has a lifetime warranty which means no restitching will be required which can be a costly exercise on poor quality systems in the future. (Remember the saying “Quality is free. It’s what’s ‘unquality’ that costs money!”)
    

   Is wire rope being used on the sail? By inserting wire rope into the hem of the sail, this acts as a double tension system. This is regarded in the tension membrane industry as “Best Practice”. For your interest Shadespan does not use webbing in the hems on the sail as this method doesn’t maintain the tension in the sail as effectively as the wire rope system.
    

   Shadespan wire rope superior tensioning system

   Webbing edge system – inferior tensioning ability

    

4. Installing the Shade Sail

   The shade sail should be installed using chain winches or a similar tensioning system. A short length of chain should be included in the corner to allow further tensioning later in the life of the sail if required. A Shadespan sail is “pre-tensioned”, which means the wire rope length is set and clamped off prior to the sail being installed. A unique sacrificial corner tie is installed which indicates when the wire rope has been tensioned sufficiently. This is very important as the sail needs to be tensioned sufficiently to prevent the sail being affected by the wind, but also prevents over-tensioning which can damage the sail. Much like tuning a guitar- its got to be correct otherwise it just won’t sound right!