Draped Stone

TYPE Material Research & Pavilion

DATE 2018

LOCATION Madison, WI.

COLLABORATOR Quarra Stone Company

DESIGN LEAD
David Costanza

Draped Stone uses stone in tension through fiber reinforcement, producing a hanging marble canopy. The form of the canopy is derived from a hanging mesh simulation that produces a catenary draped surface. Rather than a traditional tensile structure, where the surface is stretched between two boundary conditions,  resulting in an anticlastic surface, the hanging canopy utilizes the weight of the stone to put the fiber reinforcement into tension, allowing for a synclastic tensile structure. 

        Each of the units is conceived of as a sandwich panel. The fiberglass reinforcement is located in the middle of two doubly curved, machined, marble blanks. Because the marble was reinforced, the canopy was constructed entirely from scrap marble. Many marble blocks which otherwise could not be used because of fracture lines and other natural deficiencies, could now be reinforced with fiberglass and used in a structural capacity. The reinforced hanging canopy, which reads as precise, delicate, and thin, made from white marble and digitally produced, is held up by a dark grey granite wall, which is massive and rough, exposing the texture derived from the quarrying process.


Final Street Elevation Revealing The Quarried Textures And Color Variations From The Repurposed Blocks


Granite Wall With Unfolded Elevations
Granite Wall Elevations With Part To Whole Surface Discretization Using Found Sizes Of Existing Blocks


As Built 3D Scanned and 3D Printed Model of Wall A
As Built 3D Scanned and 3D Printed Model of Wall B
As Built 3D Scanned and 3D Printed Model of Wall C

Marble Canopy With Unfolded Elevations. To Manufacture The Canopy, The Simulated Mesh Was Discretized Into 3 Closed Bands, 
Resulting In 36 Discrete Units
Sections
Marble Tensile Canopy Construction Process





An As-Built 3d Scan Model Of The Granite Wall Was Built Before The Canopy Was Constructed To Compensate For The Construction Tolerances. The Model Was Embedded With The Material Qualities And Textures


The Concrete Foundation Was Hydro Vacuum Excavated

Wall A And Wall B Which Define The 90 Degree Corner Were Installed First Leaving The Oblique Wall C As The Last Wall To Close Of The Space

Granite Wall Sequenced Construction

The Construction Order Of The Blocks Were Sequenced To Allow Courses Above To Counter The Center Of Mass Of Courses Below Stabilizing The Overhanging Oblique Cuts




01 — 
Marble Blank on 5 axis CNC
02 — 
Blade Machine Inside Face A
03 — 
Blade Machine Inside Face A
04 — 
Blade Cut Part A & B
05 — 
Laminate Part A & B with Fiberglass
06 — 
Building Nylon Vacuum Bag
07 — 
Vacuum Bag Compression
08 — 
Adhere Part B to Part A to Produce Sandwich Panel
09 — 
Sandwich Panel on 5 axis CNC
10 — 
Blade Machine Backside of Part B
11 — 
Blade Cut Sandwich Panel
12 — 
Finished Sandwich Panel