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To achieve that taut tensile fabric look, you need to start out with a sail that is properly made and installed correctly. Don't be fooled by catalogue sails that hang limp. The Shade Sails we make are manufactured to hold the tension. Our new sails now use a higher rated UV blocking fabric, stronger corner rings, and a double row of locking stitch, using PTFE thread which has a warranty of 10 years.
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Custom Shade Sails
Shade Sails are made of high density polyethylene shade cloth that is especially manufactured with tensioned fabric structures in mind. The knit is made using monofilament and tape filler. The fabric is treated with a UV stabilizer to give it long live in direct sunlight. Depending on color, the average shade rating is 90% and the UVR  block is approximately 95%
Custom and commercial sails are manufactured with a stainless steel cable (wire rope) double locked stitched into its perimeter. This cable terminates at a stainless steel ring located at each corner. These rings are used to fasten the sail by a shackle, turnbuckle or wire rope pendant to a hard point either on a post or existing structure. Each corner is further reinforced with extra layers of cloth and strapping to distribute forces. All stitching is performed using a locking stitch, outdoor "PTFE" thread is used throughout. The size of stainless cable and rings, as well as attachment hardware are engineered to be the appropriate size for each sail and application.
The perimeter of each sail has a catenary curve designed into it that controls the fabric tension in the center of the sail. Therefore, when tension is placed on the perimeter cable, the fabric will have uniform tension. They do not sag or flap in the wind.
Attachment hardware is all marine grade stainless steel and has locking mechanisms to assure that sails do not detach or come loose accidently. Generally one or two turnbuckle is used per sail, and the remaining corners are attached using "D" or "Twist" shackles of the appropriate size for the expected corner loading.
Sails can be attached to excisting structures with a variety of custom made brackets and hardware. They can also be supported by there own columns made of steel pipe. We prefer to use schedule 40 galvanized steel pipe embedded in concrete reinforced footings. The dimensions of the pipe and the footings are engineered for each sail and its application depends on the size of the sail and the expected wind loading. the columns can be painted to help protect them and provide the desired color.
Depending on local building codes and engineer's requirements we add either threaded rod or rebar to the footing or posts to tie the concrete and post together. In general, there is very little gravitational load, but uplift is the concern, and footings can be quite deep.
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