Designing with Paper Tirbes

Cristobal Correa, Assoc. Principal, Buro Happold Consulting Engineers, New York, NX USA

Summary
This paper details the author's experiences working with paper as a temporary building material in the work of Japanese architect Shigeru Ban. The paper is present in these projects as a structural element in the form of a paper tube. The mechanical properties of the material are examined and three projects are presented: Two, which have been designed, built, and dismantled and one which is currently being designed for construction in 2005. These projects illustrate the design challenges in using this innovative material.

and Germany. The information shown here is based on the testing done at

Dortmund University in Germany [4].

Some conclusions that can be drawn about the material from the testing are:

- has a stiffness about

wood

1'15 of.

a soft-

Introduction
Paper has emerged as an alternative material for use in temporary structures. Its obvious recyclability and low cost makes it an attractive choice, but its singular nature requires the resolution of numerous design obstacles.

- is sensitive to load duration - is sensitive to variations in moisture content up to about 7"/". After this value, strength reduces about 10% for every 17o increase has a significant rate of creep, with
creep occurring with as little as 10% of the failure load allowable bending stress is generally 50%" greater than allowable compression stresses. Some of the key design values are presented for illustration purposes (Table 1).

Paper is not normally considered

construction material, and there are no existing guidelines for its use as a structural element. In order to design with confidence using this material, it
is necessary, first, to understand its spe-

Fig. 1: Cross section of paper tube used in

the

MoMA arch structure.

Readers should refer to the cited testing data for more precise information on specimen size, testing techniques

cific characteristics. strengths and disadvantages.

structural uses. For this reason, the

projects detailed below were designed using data that was obtained from mechanical testing (Fig.2) of paper tube samples in recognized testing laboratories. These tests allowed for the determination of mechanical properties and the establishment of stress design guidelines for different structural conditions. Tests have been done both

and results. Allowable stresses were

obtained by reducing ultimate load by the appropriate factors. Short term allowable stresses are assumed to be twice the value of long term allowables.

Paper Configuration and Testing

The same way that clay is molded into bricks, the paper used in these projects has been configured into paper tubes for use as a structural material (Fig. 1). Paper tubes have been manufactured for many years for use in the transportation and handling of fabrics. They have also been used as shuttering when casting concrete columns. The fabrication process allows both the diameter and thickness of the tube to be modified to suit the desired application. The tube can also be rolled to an infinite length, the only limitation being the transportation of the finished product.

Parameter

Short Term
10001500 4,4

Long
Term
1000

in

Japan

Young's Modulus

(N/mm') Allowable
Compression Stress

))
aa

(N/mm') Allowable Bending Stress (N/mm')

6,6

Table 1: Paper tube design values

The paper tubes are very sensitive to

The paper in the tubes can be made from fresh or recycled paper pulp that is pressed into sheets, dried and then rolled with an adhesive to form the tubes. Natural moisture in the tubes is about 9% with a density of about 7000 N/m'.
There are no existing specifications for

water infiltration. Waterproof layers

can be rolled into the tubes in or$er to provide protection from water infiltration, but at the tube ends the manufacturing technique leaves paper fibers exposed. These fibers will readily wick up moisture and allow it to enter the

tube
Fig. 2: Testing of paper tubes in Germany

if they are not

treated with

the manufacture of paper tubes for

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sealant. The paper tubes lose strength if they are wet.

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271

12,500
OO-

10 15 20 25 30 36 . 12,500 , 12,500 12,500 . t2,500 12,500 . mmmmmm

r,

Axis of Symmetry of Gridshell

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Mass at

Existing Grade
Level

Compacted

for Load Distribution

Fig. 3: PIan and section view, Japanese Pavilion

Hanover World's Fair

With regard to fire resistance, there is no formal rating for the paper tubes, the behavior is similar to that of heavy timber framing. The paper tubes will burn, but they will not support their own combustion. It is also possible to apply intumescent coatings to the paper tube surface to further increase fire resistance. Generally, for the projects reviewed, there was no significant fire load, so the issue of combustibility was not a controlling point in the design.

Detailing of the structure involved the resolution of some key connections. These are the cross points between two tubes, the connection of the tubes to the ground plane and the connection of the tubes to the cladding as well as to the wood ladders. Example detail construction for paper tubes will be reviewed in the next project. The completed structure is shown tn Fig.6.
Fig. 4: Physical model of Japanese Pavilion

Projects
Japanese Pavilion, Germany The Japanese Pavilion was built for the F{anover World's Fair in 2000 and remained in place for seven months. The building covers approximately 2500 m'

(Fig.3).

It was conceived as a flexible grid shell structure that would be assembled and laid flat on the ground, and then lifted and formed into place by a protruding scaffolding system that would give it a final geometry which would be fixated by a stiff border element at its perimeter edge. The material for the grid shell is 120 mm diameter,22 mm thick paper tubes that are lashed together where they cross by plastic straps. The overall dimension of the hall is 15 m by 35 m with a rise of up to 15,5 m.
The design and modeling of this structure was part of an intense design effort which included a form-finding exercise and the construction of physical models (Fig. q in order to determine the project geometry as well as the possible buckling failure modes. Rigidity is aided by wood arches at regular intervals. Steel strut at the ends were incor-

Fig. 5: Japanese Pavilion under construction

porated into the grid at the insistence of the German checking authorities although analysis indicated that these were not needed (fig. 5).

MoMA Arch, USA This temporary structure was erected as part of a retrospective of art and architecture of the 20th Century at the Museum of Modern Art in New York City. It is made up of 200 mm diameter, 25 mm wall thickness, tube sections that define the top and bottom chord of 600 mm deep paper tube arches.
Fig. 6: Japanese Pavilion completed

These arches span approximately 24 m and are linked transversally by a paper

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278

Temporary Structures

Spl ice line"

c, Tiuss' Grid tube.lo-w--. Grid tube high.

,;'.."..
N?'...

'7

t\A

r ' Grid tube infill area

Construction unit
2 trusses
,-,-,---,- ------ -\-^-*

Fig. 7: Plan and elevation of paper tube arch at MoMA

tube grid-shell of 150 mm diameter tubes

Facade line

with a 25 mm wall thickness (Flg. 7). Cable stiffening ties are also located under the arch and attached to the bottom chord. The overall size of the structure is approximately 24 mby 24 m. It was installed over the summer season for a period of 90 days.

above Ol2mm

BA

lomm
Steel pla

0onst

Structural analysis of this structure was more straightforward than in Hanover. Grid shell behavior was conservatively ignored in the arch span direction with the grid shell contribution reduced to providing lateral support for the spanning arches.

Fig, B: Connection detail at base

A19mm

Detailing of this structure was complex because of the mixture of material that created different connection conditions. The top and bottom chords of
the trusses are paper tubes but the vertical and diagonal elements are steel rods and cables. The attachment of the trusses to the building and base are by means of the steel connection plates.

Because

of the method of

construc6 mm

tion, element splices were also necessary for this project. These details are
shown in Flgs. 8,9 and 10.

thick

Fig. 9: Typical arch construction detail

Initial construction took place offsite

where the roof was laid over a series of scaffolding elements much the way a ship's hull is built in a shape-forming cradle. The grid shell paper tubes were modeled three-dimensionally in order to determine the precise location and

,Pl-a-stic

straps

2100 mm

angles of the pre-drilled holes for the connections which would follow the project geometry. After the tubes arrived on site, holes were drilled into them, then the bottom chord was laid down on the scaffolding, the vertical
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6lli-'cj

Fig. 10: Grid shell connection detail

Temporarr Structures

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,?3
l

--*
..-.....

5,Q

f ,Q

-2,3

ql

a ''J
)

Top of triangle

c\l r);

Top of columns'
F

v)
X

Fig. 11: Structure complete on scaffold ready to be cut for shipping

Fig. l5: Nomadic exhibition

general configuration elevation

Fig. 12: Cut structure on flatbed trucks

elements were inserted, and the grid shell elements were added. The diagonal truss cables were inserted into the truss and then the top chord was attached (Fig. 11) in order to complete the truss. Once assembled and painted with a waterproof coating, the struc-

Adjacent to the museum site the pieces were partially connected together, lifted into place and then attached to the receiving support points (Fig. 13). The completed project is
shown in Fig. 14.

ture was cut into eight half-arch slices in order to be able to transport it on flatbed trucks to the museum (Fig. 12).

210 mm Cable

COL. see elev.

12x75mm
50 mm vertical

ltromudic Exhibition, (JSA

Fig. 13: Hoisting into museum garden

m2 temporary exhibition hall is intended for a traveling venue that will highlight the work of a contemporary artist. The hall is approximately 20 m wide by 200 m long. It is constructed of materials typical used in temporary structures including fabric, scaffolding, cribbing and even the containers used to ship them. It has a central roof support that is made up of two large diameter paper tubes surmounted by a paper tube triangle that connects to the roof ridge (Figs 15 and

This 4000

Fig. 16: Paper tube connection details to metal plates

added condition that all pieces must be able to fit within a standard 6,1, m container. For this reason, the paper tube

16).

detailing has been designed in such a way as to minimrze the wear and tear on the paper tubes. This has been accomplished by permanently affixing steel plates and elements to the paper tubes. In this way the connection points can be restricted to more durable connections which are steel on steel.
The project is currently being designed

The structural loads on the paper tubes

can be determined from a straightforward analysis. The difference from the previous projects is that in this case although the structure is temporary it is meant to be assembled and disassembled a multitude of times. with the
Fig. 14: Complete installation

and built and should be installed in NewYork City in March of 2005.It will then be disassembled and shipped in its own containers to Los Angeles,
Tokyo and points beyond.

280

Temporary Structures

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Conclusion
Paper has been used successfully in a number of temporary structures. Although there are specific design constraints to using this material, with careful detailing and calculations backed-up by testing results, it is possible to design structures that serve their purpose
and are both beautiful and elegant.

[3] CORREA, CRISTOBAL. Nomadic Exhibition - Fire Study Strategy and Literature Review Internal Buro Happold document October 2003. [4] BLOCK, KLAUS. Report Nr 99.03.01-1 The Structural Behavior of the Load Carrying Paper

SEI Data Block

Japanese Pavilion, Germany

Owner:

Made

2000, Institut

for

the Japanese Pavilion at the EXPO fiir Bauforschung, Universitiit

JETRO - Japan External Tiade

Organtzation, Japan Structural Design: Buro Happold, New York, USA Contractors: Takenaka Europe GmbH, GermanY May 2000 Construction Date:

Dortmund. November 1999.

[5] CRIPPS, ANDREW. Cardboard as a Construction Material: a case study - Building Research and Information (May-Ju ne 2004), 32(3), pp. 207 219. www.tandf.co.uk/journals. K.; ROGERS, P. AND WESBURY P. The Japan Pavilion for the Hanover Expo 2000, paper presented at the IASS-2001 Conference: Theory, Design and Realization of shell and Spatial Structures, 9-13 October 2001, Nagoya, Japan.

Most importantly, this work shows that as engineers we should enthusiastically accept challenges to use materials and technologies in new and interesting ways. We should not underestimate our strengths as professionals, as many problems can be successfully solved using first principles, a testing regime and our own natural inventiveness as
designers.

[6] DICKSON, M.; HARDIE, G.; LEIBLE,IN

MoMA Arch, USA

Owner: Museum of Modern Art. New York,

USA
Structural Design: Buro Happold, New York/Takenaka Corporation, USA Contractors:

Atlantic Heydt Corporation, USA

Construction

Date:

APril2000

References
[1]MCQUAID, MATILDA, Shigeru
Phaidon Press,2003. [2] CRIPPS, ANDREW. Constructing
Ban,

Nomadic Exhibition, USA

Owner: Bianimale Foundation, USA

Structural Design:

Card-

Buro Happold, New York, USA

Co

board Building-Design Guide - Internal Buro Happold document unpublished September 2001
available at www.cardboardschool.co.uk

ntr acto

r s.' B

ovis, USA

Construction

Date:

FebruarY 2005

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