Chemical Research Centre in Venafro

General information

• Location address

  Venafro

• Location country

  Italy

• Year of construction

  1990

• Short description of the replacement or dismantling

  The M&G Ricerche chemical industry research centre in Venafro was designed by Philippe SAMYN and PARTNERS, architects & engineers, and completed in 1991. It is part of an industrial area located in a valley surrounded by hills near Venafro. In the early 1990s, this was one of the first designs in which a membrane structure effectively served as a building with a controlled indoor climate. This meant that it became more than just a sculptural canopy.
  The membrane was recently renewed. The renovation was carried out by the original contractor, Canobbio Textile Engineering. After 35 years, this building still has a unique appearance and architectural qualities.
  The research laboratory for the chemical industry was housed under one large tent-shaped roof. The programme of requirements included laboratories for heavy experiments as well as for delicate research, supplemented by function-supporting spaces. The plan allowed for the possibility of adjustments to the programme. An optimal shape for the hall led to an elliptical design. The building was also designed with a focus on optimal climate control. Temperatures outside can reach 40°C in summer, while snowstorms can occur in winter. In the original building, the 'cracking' unit generated heat that was beneficial in winter. The oval reflective pool on which the building stands has high thermal regulation properties. In summer, it cools the building by drawing air in from underneath the pool.
  The oval floor plan (85m by 32m) is spanned by six truss arches with a maximum height of 15m. The optimal span for the roof membrane is between 12m and 15m, which determined the number of arches. The triangular cross-section varies along the length of the arch, with maximum dimensions at the top, and taps towards the arch support. The arches are connected to each other by pre-stressed cables. These stabilising cables are connected to the arches via pyramid-shaped supports. Daylight is allowed into the spaces below by a PVC-coated polyester membrane stretched between the arches.
  New owner, new function
  The tensile structure and the entire surrounding area were acquired several years ago by RES – Recupero Etico Sostenibile, a company operating in the waste recovery sector. Under the existing membrane structure, RES installed a series of laboratories dedicated to material recovery testing and experimentation. Prior to our intervention, the client had already carried out a thorough cleaning and redevelopment of the site, restoring order and operational functionality to the area.
  Renovation project
  The first phase of the work of Canobbio Textile Engineering involved the replacement of the skylights. The existing membrane was already aged and had undergone modifications over time; therefore, the new skylights had to be designed with an adapted solution compared to the original project. A valance system with an internal tensioned cable was introduced, installed over the existing membrane, as any attempt to weld onto the aged fabric would have been ineffective and technically unreliable. Before installing the new skylights, the steel structure was also repainted and restored, improving both protection and durability.
  The following year, after an exceptionally severe storm, the membrane panels - which had already reached the end of their service life - suffered extensive tearing. At that point, a complete replacement of all roof panels became unavoidable. The first step was to return to our historical archives to retrieve the original documentation, construction details, and fixing systems used at the time of the initial installation, including all modifications and improvements introduced over the years.
  During the negotiation phase, we emphasized a key differentiating factor: our direct and in-depth knowledge of the original project. It is essential to understand the special fixing details, critical areas and modifications carried out in a structure of this complexity. Entrusting such an intervention to companies that have never operated on the structure represents a tangible technical risk. This awareness, combined with our specific expertise, ultimately led the client to appoint us for the refurbishment.
  Once the project was launched, formTL was engaged to design the new roof membrane system (approximately 3.150m²), including arch closure flaps, special lower closure flaps, membrane cable systems, and secondary steelwork. Serge Ferrari 1202 S2 membrane (2,65m roll width) was selected, consistent with the performance and characteristics of the original material. formTL reconstructed the cutting patterns based on the recovered historical data, accurately integrating flap geometries into the cutting models and producing complete workshop drawings, including structural steel details and cable layouts. Throughout this delicate phase, we actively supported and assisted the design process to ensure full coherence with the structural realities of the existing framework.
  The execution phase represented the most challenging part of the project. Unlike the original installation in the 1990s - when the space beneath the structure was completely empty - the refurbishment had to be carried out above fully operational laboratories and technical systems. This required extremely careful planning of dismantling and installation operations.
  The works were executed by our specialized rope-access team, highly experienced in tensile structures and accustomed to operating at height under complex logistical constraints. A network of webbing straps was installed between arches to allow controlled handling and deployment of the membrane panels. The crane initially planned for installation proved too heavy following ground load verification, requiring a complete reorganization of logistics. A lighter truck-mounted crane and a forklift were used instead, operating simultaneously. Adverse weather conditions further increased the complexity of the installation, yet thanks to the team’s experience and coordination, all panels were successfully installed and tensioned in accordance with the design specifications.
  Another delicate aspect concerned the terminal portions of the panels. In the original structure, these elements had been custom-made on site with hinge systems and elastic absorption mechanisms. Replicating the same functional behaviour required testing and on-site adjustments. Furthermore, while the original project had used Crystal material for these terminal parts, the refurbishment opted to use the same membrane as the roof panels, ensuring homogeneous aging performance and improved long-term durability.
  Once installation and tensioning were completed, the structure was handed over ready for reopening.
  This intervention highlights three key strengths: the ability of Canobbio Textile Engineering to interpret and manage a technically layered and historically complex structure; the rigorous engineering contribution of formTL in reconstructing and optimizing the membrane system; and the high operational competence of the specialized rope-access team, capable of handling a constrained and logistically demanding site without compromising safety or quality.
  Marcello Canobbio
  marcello.canobbio@canobbiotextile.com
  Canobbio Textile Engineering Srl
  www.canobbiotextile.com
  
  Name of the project: New membrane for the former Research Laboratory M&G Ricerche, Venafro
  Location address: Venafro, Italy
  Client (original): M & G Ricerche
  Client (of the renovated structure): RES – Recupero Etico Sostenibile
  Function of building: Laboratories and research centrum
  Year of construction: 1990
  Year of renovation: 2024
  Architects: Philippe SAMYN and PARTNERS, architects & engineers
  Structural engineers: formTL
  Contractor for the membrane (Tensile membrane contractor): Canobbio Textile Engineering
  Manufacture and installation: Canobbio Textile Engineering
  Material: Serge Ferrari 1202 S2 membrane
  Covered surface (roofed area): 2700m2
  

• Name of the client/building owner

  Guido Ghisolfi, Sinco Engineering S.P.A., Tartona

• Function of building

  Laboratories & research centres

• Degree of enclosure

  Fully enclosed structure

• Climatic zone

  Temperate - cold winters and mild summers

• Number of layers

  mono-layer

• Primary function of the tensile structure
  • Rain protection
  • Space defining elements