8-Step Sequence
Engineered for Fast, Bolt-Together On-Site Assembly
No on-site welding required. Every chord, strut, purlin, and baseplate is CNC pre-punched for rapid mechanical assembly.
01
Site Grading & Foundation Baseplate Anchoring
Leveling of ground and placement of foundation systems. Depending on site soil geotechnical data, Champion structures utilize cast-in-place concrete piers with chemical anchor bolts, steel screw piles, earth anchors, or ISO container twist-locks.
02
Ground-Level Truss Chord & Web Assembly
Curved and pitched arch segments are laid flat on the prepared ground pad. High-strength Grade 8.8 / 10.9 hot-dip galvanized bolts and torque washers connect chord joints together according to marked shop drawings.
03
Crane Hoisting & Baseplate Pin Connection
Mobile cranes or telehandlers hoist assembled truss frames into vertical alignment. The base hinges are pinned to the anchored foundation plates with high-shear carbon steel pins.
04
Horizontal Purlins, Diagonal Cable Bracing & Truss Interlock
Structural purlins and cross-cable tension rods are installed between adjacent bays, locking the structure into a rigid three-dimensional space frame capable of withstanding construction-phase wind gusts.
05
Gable End Wall Framework & Door Posts
Vertical endwall columns, header beams, personnel door jambs, and aircraft Megadoor framing tracks are secured to the gable arches.
06
Continuous Winch Pulling of Architectural Membrane
Heavy PVC/PVDF fabric covers are unfurled alongside the building. Heavy-duty pulling winches gently pull the membrane over the arches through specialized aluminum Keder tracks or friction-free web guides.
07
Biaxial Ratchet & Pipe Tensioning
Internal tensioning pipes and calibrated mechanical ratchets pull the fabric taut across all directions (3.5–5.0 kN/m pretension). Drum-tight membrane tensioning prevents wind flutter and ensures zero water ponding.
08
Door Installation, Perimeter Sealing & Final Inspection
Hangar megadoors, ventilation louvers, and perimeter ground skirts are sealed against dust, rain, and vermin. A full bolt-torque and membrane pretension inspection report is signed off.
