Sprung pioneers the world's most advanced fabric structures

[Figure 1] While a dozen or more competitors sell fabric buildings in Canada, only one manufacturer has moved far beyond the traditional inventory of industrial storage, shops, and arenas. Just south of Calgary at Aldersyde, Sprung Instant Structures has created a world headquarters with no peer. The 150,000-square-foot complex, erected two years ago, is engineered with an aluminum substructure and architectural membrane. Its facilities include two manufacturing wings, a mezzanine administrative centre, a two-storey glass façade, a full gymnasium in the basement, and more.

Sprung VP Jim Avery says his company has its eye on the resource sector, particularly the oilsands. "These projects, big or small, need shelter for personnel and equipment at an affordable price. At the same time, lifestyle quality has to be high if you want to attract and hold good people," Avery says. "When the energy sector moves back into high gear and Alberta again finds itself facing labour shortages, oilsands operators must minimize the need for skilled construction workers. They also have to move quickly while maintaining construction quality. We've positioned ourselves to meet all of those requirements."

For a Calgary outfit, Sprung's local roots are extraordinarily deep. Started in 1887 by Philip Dorland Sprung, the company manufactured chuckwagon covers, teepees, and other tent-type shelters for settlers and aboriginal bands. Philip Donald Sprung, the current president, is the founder's great-grandson, and several other family members are active managers as well, including Avery's wife.

This pioneering firm has developed what amounts to a new architectural technology that reportedly works well in virtually every environment. Arctic Watch, the world's most northerly lodge, sits less than 130 kilometres from the magnetic North Pole. Another Sprung structure, located in the Aleutian Islands, was engineered to meet sustained wind loads as high as 200 kilometres per hour. Restaurants and mass merchandisers appreciate the hip "wow" factor and large skylights of Sprung structures. The distinctive Sprung building profile not only sheds snow well, but also earns praise from church worship leaders for its acoustic qualities. Casino operators by the dozen have opted for Sprung facilities.

Calgary's Edge School, which serves 300 student-athletes, reportedly saved millions by having Sprung construct its two hockey arenas and gymnasium. The company is also proud of a letter from former U.S. first lady Barbara Bush praising its work in speedily supplying hospitals for charity work in Rwanda. On short notice compared to conventional construction, Sprung can put together a convention centre, restaurant, ski resort, golf club, bush camp, warehouse, mine processing facility, or other low-rise building. An installation crew can progress as quickly as 1,000 square feet per day.

[Figure 2]

Innovation, flexibility, and especially reliability, according to Avery, lie at the heart of Sprung's success. "No one wants their school to blow over," he points out. "And don't kid yourself, it can happen. I've seen two of our buildings standing on either side of a competitor's product that had collapsed during a storm. We've spent a great deal of money designing reliable doors, windows, and other architectural features of many types. But most important of all is our unique integration of architectural membrane, the aluminum substructure, and insulation technology."

Sprung's top-quality fabric consists of five layers, including Dupont Tedlar colour film. The combination resists fire, ultraviolent rays, fungus, solar heat buildup, and other ills. Eight colours are available. The light, bright material provides an excellent backdrop for company logos and other decoration. Where most rivals place their fabrics on top of a steel frame (i.e. no ribs are visible from the exterior), Sprung patented the stressed membrane structure: its membrane panels are placed under high tension within the framework.

Another Sprung hallmark is aluminum, which is more expensive than steel but 66 per cent lighter, highly corrosion-proof, and readily extruded into virtually any shape and size. "Extrusion allows for fitted and bolted connection points rather than welded connections frequently seen on steel," Avery says. "Overall, our technology achieves greater strength and precision. One well-known testing laboratory in the U.K. told us that our structures are the most airtight they've ever tested."

[Figure 3]

The company's aluminum substructure allows precise placement of formaldehyde-free fibreglass blankets. Besides reducing the cost of heating and air conditioning, insulation acts as an effective barrier to vapour and sound. "Our structures carry a higher initial price tag, but the owner can recover that expense over the building's life through lower operating costs," Avery says. "Even for a relatively short-term application, the insulation option usually makes financial sense. The customer that takes proper account of his structure's full life cycle can benefit from superior reliability, comfort, and aesthetics at little or no additional cost."