Case Study
Windsor Realty
Tensile Roof Structure for Cafeteria
Tensile Flanges
Tubular ERW Pipes
Project Engineer Aakruti Tenso structures & Façade Pvt. Ltd.
Client Windsor realty
Architects M/s. Talati & Panthaki & Associates ( Mr. Cherag Bardoliwala)
Requirement Open Air cafetoria for all seasons
Size 300 sq. ft. plan area
Span Max span of 65 feet or 20 meters X 15 meters across
Design Aakruti Tenso structures & Façade Pvt. Ltd.
Fabrication By our team of enginners & craftmen
Installation Inhouse team from Aakruti Tenso structures
Date/month of installation Jun-12

Existing 2 level cafetoria -club house-Gym having open terrace type structure on level 2 , used for open air seat out. The requirement is to cover the open air seat-out with a fabric to protect against excessive sun & Rains. Also to arrest water leaks to the levels below. ( presently a lot of leakages are observed which were literally unplugable).


The challenge was to transfer all the loads to existing columns - Beams without disturbing existing interiors- exteriors. The client did not have structural drawings of the existing structure showing column beam positions. Most of the wall/ flooring was cladded with stone, wood, fibreglass,glass etc. At places the gap between the civil structure & wall was more then 750mm. Only way one can find out internal structure was to physically examine false cieling or drilling few holes at place to judge internal details. All the time Restaurant has to be functional with easy movment of people and materials.


The total plan area of the terrace is 300 sq. mt or 3000 sq. ft.


From Legal point of view Fabric - Tensile membrane structure was the only option feasible. Due to limitations in data available for the existing architectural structure size & location, naturally initial presentations were made with considerable steel members supporting the multi-point Hypers. The roof form was accepted however in the middle of the project the architectural roofing was decided to be extended further then outer perifery of the Terrace by atleast a meter, complicating the structural issue further.

After considerable thought, we decided to have a structural design form free of any bending moments, where in we would be transfering all the reaction forces directly to the major columns we located from the levels below. We followed members directly mounted on columns through pin joints. We used fairly long members to ensure the coverage as desired.

At locations where the columns were not in the vicinity, we creatively took supports from 2 adjcent beams with slanted members meeting at the desired anchor points again having Pin joints in the base.

This eliminated on site work time to just a week , where all the members were now fabricated to final form in our Factory. Only he base plates with flanges for pin joints were insertde at the column positions & recladed again. The normal functioning of the Cafetoria continued right untill the fabric was installed.

Design /Analysis

Detailled Analysis of the structure was carried out with FORTEN3000. FEM - Membrane analysis software. In absence of Local codes for Governing construction of PTFE Tensile membrane structures, British standards were followed to generate wind loads depending on geometry, height of structure, height from sea level, distance from sea, surface roughness, tropology, etc .

Once structure was analysed, the dimensional detailling of each individual structural members were carried out after STAAD analysis depending on the max. load generated in load combinations. Auto cadd 2011 was used for drafting purposes.

Primary Structure

Almost all the members were fabricated form Hollow round tubular ERW pipes of Diameter, 138mm X 6 mm. The base plates of 25 mm. thickness with 20-25 mm. flanges for pin joints were machined - fabricated.

12 mm galvanisded wire strands were used to reinforce fabric, as well as to support struts in angular positions.

Fabric details

The Fabric used was Type 2 Ferrari 902 S . The weld joint of 38 mm Lap was used.

The single piece fabric was lifted to the upper level. The fabric was fixed in aluminium kedar profile which inturn were clamped on the steel structure through self threading screws.


The rest of the fabric was anchored through assembly of SS316 end plates, turn buckles, M20 Studs, Ball washers, Nuts etc. The whole installation was complete in 3 Days .

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