Premier Composite domes are high-tech structures made from a sandwich of glass-fibre/epoxy resin composites with a thermoplastic, honeycomb core.
Premier Composite Domes are lightweight yet strong and durable. One composite dome can weigh as little as 85% of the weight of an equivalent concrete dome.
The design and manufacturing process utilizes cutting edge technologies and precision machining to produce millimeter accuracy in tolerances. Whilst the construction and installation system permits significant time and cost savings compared to conventional construction.
The Premier Composite Technologies manufacturing process begins with conceptual designs developed by our team of architects and design engineers. 3-D images are generated with Computer Aided Three-Dimensional Interactive Application (CATIA, DELCAM and Rhino) for detailed design and structural analysis before proceeding to model and mould construction.
The design elements are subdivided into large pre-fabricated panels that are laminated on CNC-milled moulds and oven-cured under vacuum.
Premier’s impressive 5-axis CNC milling machine is used for mould making and complex 3-dimensional forms can be generated with a high degree of precision. This makes it possible to produce surfaces that are curved in two directions, as well as much more complex architectural elements, such as the muqarnas found in traditional Islamic architecture.
The position of all holes for the attachment of fixing details is transferred from the CNC-milled mould to each laminated element. Parts produced in this way not only achieve millimeter accuracy in the tolerances in their overall size, but are guaranteed to fit each other perfectly.
The pre-fabricated panels up to a size of 12 x 2.3 meters are usually employed, the maximum size being determined by transport constraints, although larger dimensions could be achieved.
Edge flanges give them stiffness for a bolted panel-to-panel connection. The system is designed to withstand the most extreme climates. By using high tech materials and techniques our cladding parts and domes are completely waterproofed. Joints are sealed to prevent water penetration. As a secondary back-up system, a drainage channel is moulded into the panel flanges.
In cases where the composite cladding is seen from outside and inside, a double shell construction is used.
With larger domes or roofs, the inner and outer shells are separated from each other by a gap, which permits access for installations, MEP equipment and maintenance.
Some clients prefer the installation of the composite panels on a trussed construction of galvanized steel, anchored to the RC ring beam beneath with base plates, which are either cast in or fixed by chemical anchors. From this structure the inner and outer cladding panels can be suspended; the space between the outer and inner cladding is accessible.
The inner and outer shells can be also structurally self-supporting and require no steel support structure as the materials used can withstand extreme loads. The same materials are used in the aerospace and aircraft industry as well as the automotive industry (F1). Our composite panels are then anchored directly to the RC or steel structure using steel plates fixed to the structural composite panel flanges.
This type of composite construction can have as little as 10 – 15% of the weight of an equivalent roof, cladding or dome built in concrete. This can have major advantages in cases where the bearing capacity of the ground is poor or there is a risk of earthquakes, etc.
It permits significant savings in the concrete ring beam, and the whole superstructure down to the foundations of the building.
The shells of smaller roofs/domes can be pre-assembled in their entirety at ground level and lifted into place in one piece. For larger parts, panels are pre-assembled into larger segments to minimize the work undertaken at heights. This results in time savings and safer working conditions on site.
The PCT system of erection requires no scaffolding for the temporary support of the parts during installation. This applies equally to the self-supporting composite shells and to the trussed steel construction, which can be built up in concentric rings, with temporary support offered by cables.
Since the pre-fabricated parts leave the factory with all decorative finishes already completed, time consuming finishing activities on-site are minimized.
The demand for building composites extends beyond mere advances in technology. The strength and lightweight properties of the construction complements the ease of installation, with a significant amount of pre-assembly.