Folded Shell Structure

This is a study based on the shelter designed by Renzo Piano for a Sulphur Extraction Facility in Italy. The structure is made of repeated triangular FRP shells that are connected along their edges to form a barrel-vault type structure. Folding makes the structure significantly more rigid while keeping the weight of the structure down. Each individual shell is light enough to be carried by a single person, making erection simple and quick without the need for cranes.

An original drawing from RPBW Archives

A fully parametric structure was modeled in Rhino + Grasshopper to allow for quick manipulation of the structure’s geometry for differing sites

The Grasshopper script used to control the structure
The resulting Rhino 3D model

Before doing any work on a computer, it’s always beneficial to understand the real physical structure – get a feel for what you’re working with. As in the above photos, a simple folded model made from paper went a long way in helping figure out how the geometry behaves as a parametric model. Hand sketches and details are the tools used to capture thoughts and assumptions.

The Grasshopper parametric definition was linked with the Salamander plug-in to define the finite element geometry and wind loading on the structure.

Left: Wind loading calculations for a hemispherical shape Right: Detail view on the wind pressure distribution over the barrel structure’s shape

The structure defined as 2D shell elements