USA SHADE’s Design Development Department (DDD) was created to elevate the level of service to our clients by utilizing the most sophisticated 3D/CAD rendering and animation software available. This comprehensive visualization capability enables clients to better understand our company’s proposed solution to their requirements.
DDD complements our progressive approach to innovation and creativity, with a team composed of Industrial Designers and Architects who understand the fundamentals of shape, form, and function. Their creativity and technical abilities enable clients to gain a unique insight into a 3D version of a concept suitable for construction. The animation represented in CAD format typically represents the actual and final product and is the starting point for converting the concept into reality. DDD also plays a significant role in preparing a 3D structural model for engineering analysis. This model enables our Sales Engineering Department to perform preliminary engineering analysis and determine if the structure is stable, whether the membrane is shaped correctly, and if the design is over-stressed or in a position to pond.
Lastly, it provides our Estimating Department with sufficient information on the sizing and weight of the elements, which in turn leads to a cost-effective estimate necessary for our formal proposal. The USA SHADE Design Development Department differentiates us from our competitors by giving our company the edge and our clients the advantage.
USA SHADE’s Project Design & Engineering Department begins by establishing the required centerline geometry of the structure and then modeling it in 3D using highly specialized software to define a final equilibrium shape that meets the requirements of the client. The equilibrium shape is then analyzed under various loading conditions to determine the steel, fabric, cable, and hardware requirements. The results of the computer modeling and analysis are transformed in the graphical design stages of the project into an accurate, extruded 3D model complete with actual steel and cable sizes and connections.
Design drawings are then developed from the 3D model and submitted to the client for review and approval; engineering calculations are also included in the submittal to the client. Upon approval of the design drawings and engineering calculations, the fabric shape is then patterned. Patterning is the art of representing three-dimensional shapes by connecting a series of flat, two-dimensional templates into the fabric assembly. The size and shape of the fabric panels are determined by the Engineer using specialized software and are then provided to our fabrication team for cutting and assembly.
Steel shop drawings are then completed and reviewed by the Project Engineer and Designer prior to commencing with the actual manufacturing of the structural members. Some of our more complex projects require construction engineering and input prior to when the erection process begins and may include things such as specialized hydraulic tensioning components, rigging design, and sequencing plans.
USA SHADE’s Project Management Department was created to handle the ever-increasing scope and value of our many projects. Our Project Managers utilize customized organizational software to ensure all of our projects are completed in the most cost-effective, timely, and efficient manner. We strive to meet or exceed expectations with every client on every project.
Once a project has been sold and handed over to Project Management, a Project Manager then takes control of all aspects of the job. They create schedules, handle submittals and approvals, maintain comprehensive communications logs, and manage costs and logistics, all to ensure successful project completion. By taking ownership of the project, Project Managers are able to guide the job through all critical phases to create an end-product that our clients regard as being the finest available anywhere in the world. As we continue to design and build more imaginative and innovative projects, Project Management will continue to grow and bring great ideas into reality.
At USA SHADE, we recognize that the structural integrity and quality of our products are critical to the long-term success of our business. Our 120,000 square foot fabrication plant in Dallas, TX is certified by the International Accreditation Service (IAS) as meeting or exceeding the highest standards in the steel fabrication industry. The plant has been custom-designed for our unique products and is equipped with state-of-the-art machinery including robotic welding, computerized roll benders, custom swagers, massive abrasive blast and powder coat booths, and industrial baking ovens.
We use specialized tools and equipment to cut raw steel and fabricate all of our plates. Our welders are all American Welding Society (AWC) certified and we employ a full-time Certified Welding Inspector (CWI) to ensure that we always meet our internal and external quality standards. All raw materials are of the highest quality available and we require mill certificates from all of our suppliers. The plant is managed by an experienced team of professionals focused on quality, safety, and delivery. This team is unmatched in our industry and consistently produces structures that exceed our client’s quality and delivery expectations.
At the core of all of our modular and custom structures are the fabrics we utilize to create some of the most architecturally innovative and aesthetically appealing fabric structures in the world. We use the best materials available, including PVC (Vinyl-Coated Polyester) and HDPE, a high-density polyethylene mesh that can block out up to 96% of the sun’s harmful UV rays. Fabrics are selected to meet the specific project requirements as well as our clients’ individual needs and desires. We offer a variety of materials with varying degrees of translucency, light reflectivity, UV and weather protection, and non-combustibility.
Our fabric tops and panels are fabricated utilizing the strongest and most durable seams applicable to the individual fabric which includes heat-sealing, radio frequency (RF) sealing, and sewn seams utilizing GORE® TENARA® PTFE thread. Our fabric patterning, sewing, and cutting teams utilize the most advanced computer-controlled cutting technology available, which provides precision load analysis and tight tolerance.
The modular and custom fabric shade structures we design and build require experts in specialty construction in order to achieve the ultimate results. We offer the most experienced, well-trained, and dedicated construction professionals available in our industry. With construction crews operating from coast to coast, we have built thousands of successful projects, which have resulted in lasting partnerships with our clients.
We have highly-skilled, certified rope access technicians for large-scale projects and we are compliant with the Occupational Safety & Health Administration (OSHA) and U.S. Department of Transportation (DOT) regulations, which attests to our high level of safety and professionalism. Our construction teams have many years of experience in proper foundation and footing construction, steel erection, and fabric installation. USA SHADE provides the ultimate in quality construction with projects built by the best and built to last.