construction and business industrialization in italy in ...131.111.147.69/chs-conf/papers/14....

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Construction and Business Industrialization in Italy in the Second Post-War Period: the FEAL

Stefania Mornati Department of Civil Engineering and Computer Science Engineering, University of Rome Tor Vergata, Italy

Introduction

In Italy of the second post-war period, the theme of construction industrialization of buildings was one of the main objectives to face both the urgency of reconstruction and the urbanization phenomenon that was gradually affecting the big cities. The need to ensure housing for the population that migrated to urban centres clashed with a housing crisis that had manifested itself heavily; overcoming it was recognized as one of the prerequisites for the country's economic and social recovery. The evident inefficiency of the productive factors that governed the building sector, such as "materials, labour and energy", required careful attention in order to ensure housing for a significant number of people. The traditional working procedures, the poor training of the workers (mostly from the agricultural sector) and the ordinary techniques with which Italian building sites managed the construction process proved inadequate to deal rapidly with a national emergency. Moreover, there was a substantial absence of systematic research aimed at optimizing resources and stimulating experimentation projects on materials and building components, on construction techniques, on operating procedures and on financing plans.

The year 1945 marked a starting point for many public and private initiatives aimed at spreading an up-to-date building culture in line with the developments already taking place outside national borders. In December, the first national reconstruction conference was held in Milan. The Conference was dominated by the discussion of prefabrication and dimensional coordination. In the same year, the CNR announced a competition for prefabricated buildings.

In 1946 the Centro Industriale Lombardo di Coordinamento per l’Edilizia, which brought together the major building contractors of Milan, published the first issue of the magazine Informatore Tecnico Cantieri. The magazine addressed unification and mass production. One of the first experiments of the Centro was the construction of four typical dwellings in which different construction systems, including metal formworks for concrete castings, some types of prefabricated slabs, some unified types of windows and sanitary, heating and lighting systems could be tested.

In the spring of 1947, after a seven-year interruption, the Triennale of Milan resumed with its eighth edition. The event was focussed on housing and systems to achieve better quality at lower prices. Among the initiatives promoted by the international exhibition was the construction of the experimental district called QT8, which promoted itself as the only opportunity to test new industrialized construction systems. The program, following the French example of Ilot no. 4 in Orleans, provided for the construction of six multi-storey residential buildings, associated with six different production methods. Construction times were regularly monitored and accompanied


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by rigorous controls relating to assembly methods and other significant construction activity parameters. These themes, however, had already been addressed by designers and companies in the 1930s, but by the early 1950s they were experiencing a marked acceleration, placing themselves among the arguments in support of the demands for renewal in the construction sector, in particular from the economically more prosperous regions of Italy.

The revision of traditional building systems went through the concept of prefabrication which technicians and experts wanted to evolve towards an integrated building industrialization based on the "trinomial: modulation (coordination), unification, mass production and a scientific organization of work essentially by assembly [1]”.

In the face of these initiatives, the daily practice of construction expressed strong contrasts. Ridolfi himself, in the Manuale dell’Architetto published in 1946 by the CNR, had limited prefabrication to doors and windows, while for metal ‘carpentry’, the prefabricated system par excellence, a very small space was reserved: until the second edition of 1953 the Manuale included only an already obsolete iron truss with studded joints, connected to a reinforced concrete spandrel beam on full masonry. Only the subsequent 1962 edition included a larger section dedicated to metal ‘carpentry’ for industrial sheds which also included an 8-storey office building, but with structural spans of less than 4 metres.

Finally, the INA Casa Plan [2], the most important provision of economic and construction policy, enacted in 1949, did not favour the renewal process. The Plan sought to relaunch construction activity, building homes for low-income families and reducing unemployment. The amount of materials required to meet the needs related to the construction of the impressive quantity of housing established by law should have led to a radical change towards industrial construction methods, setting the INA Casa Plan as a real "test bench" for the renewal of Italian construction sites. Expectations were substantially betrayed by facts: the absence of economic investment aimed at developing studies, experiments or proposals resulted, on the technological level, in confining the renewal to the combination of a few construction elements, such as the windows and doors. The legislative project, while sensitive to the pressures from the most advanced sectors of the country, preferred to suggest more usual constructive solutions that were appropriate for the organizational capacity of small Italian companies and the modest ability of the available labour.

Building materials and industrial criteria

However, some Italian companies were more sensitive to technological renewal in their production methods. They promoted studies of different construction materials, plant systems and building components, not only to improve their performance but also to refine their design. They modified production processes, elaborated innovative proposals, involved engineers, architects and designers for the development of increasingly improved products and aimed at reducing operations on site.

The craft techniques that had governed construction sites for hundreds of years no longer seemed appropriate to satisfy the primary need for houses and the general needs of the building market. All the construction materials were, therefore, involved in this fever of innovation that had affected the country since the 1930s. New ways of using traditional materials were introduced; new mixtures of clays or conglomerates were tried and, thanks to the developments of industrial chemistry, these products offered performances that had previously been unimaginable. The production of various unified components was started for the construction of specific building or structural types or, according to a more open logic, adaptable to different constructive solutions. The panorama of novelties was incredibly vast, witnessed by the growing number of applications for industrial property rights submitted to

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the then Ministero delle Corporazioni to obtain patent protection, and many companies were engaged in this path of modernization of the sector.

The patent archive brings together a complex repertoire of ingenious, and sometimes visionary, proposals developed by Italian or foreign inventors. The most interesting and directly usable ones were brought to the attention of professionals through publication of the list of applications that received a patent each month in specialized magazines. After World War II many of the inventions focused on the topic of prefabrication. The challenge between the different proposals concerned assembly times and, consequently, the quantity of completions, but also executive simplicity and, not least, the architectural expression that could be entrusted to new construction materials, without renouncing the updating of traditional ones.

The evolution of construction equipment, the diffusion of reinforced concrete and, to a lesser extent, that of steel, had in any case largely introduced industrial processing procedures and standard components produced in the workshop to the Italian construction site. The speeding up of the concrete casting phases, the use of recoverable metal formworks, the presence of a prudent but widespread mechanization restored the image of a construction site attentive to technical developments and to the profound transformations that were occurring in the building sector.

The limitation in the use of steel in the autarchic period, which characterizes the fascist economy from 1935 to 1940, had also diverted studies towards metal alloys, timber, floors, walls and, of course, windows. The later sector, already significantly developed from the 1930s onwards, which started on the principles of dimensional standardization, continued to play a leading role in the innovation of building production.

The same steel, after overcoming the constraints imposed by the autarchy and those deriving from the Italian construction tradition, together with aluminium were the object of studies that valued not only the mechanical characteristics of both, but the wide repertoire of production, amplifying the merits related to the precision of the processing in the factory. Vertical and horizontal load-bearing elements in bent sheet metal, self-supporting panels in enamelled sheet metal connected by bolting, aluminum trusses, prefabricated frames ready to be assembled and many other proposals for structural and finishing components demonstrate the attention of the industry towards a prefabricated product that was increasingly qualified and suited to the need to reduce construction times and the consequent economic rationalization. Despite the commitment of some companies and technicians to metallic construction, there were modest applications in Italy when compared – for example - with England, France, and America where at the end of the 1940s significant results were recorded, not only for the level of industrialization achieved, but for the thousands of houses made with metallic materials [3].

The FEAL of Giovanni Varlonga

Among the companies that were committed to promoting the scientific organization of construction, FEAL (Fonderie Elettriche Alluminio e Leghe) certainly stood out and from 1945 - the year of its foundation - it quickly established itself in the sector of prefabricated buildings. The company was founded by Giovanni Varlonga, an engineer who distinguished himself for his propensity for theoretical-experimental research in the field of industrialized building components. He was engaged not only in design and study but also participated in conferences and published articles in specialized magazines.

FEAL was initially born as a study center, to which industrial activity was added in order to create an organizational structure that also had an economic return. Initially, production was oriented towards the fabrication of joints for


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the rapid connection of tubular elements in aluminium or light alloys, intended essentially for the construction of scaffolding and demountable exhibition pavilions.

Simultaneously, Varlonga started the patent activity. The studies and patents of the company soon extended to the design of structures, as can be seen from the request for an industrial patent presented in 1946, which concerned the construction of an arch, of a maximum span of 20 metres, consisting of aluminum profiles, curved and circular sections, assembled by internal connection and fixing pins [4] (Fig.1).

Fig. 1. G. Varlonga, “Sistema di costruzione di capriate in lega leggera”, patent no.421672, 1946 (courtesy of the ACSR)

While the construction of the exhibition pavilions was also spreading abroad, achieving important feedback, the field of investigation of the company expanded further and was directed towards systems for the construction of prefabricated houses with a metal structure. In 1950 FEAL then began to produce metal elements for structures and anodized light alloy profiles for the construction of all those building components united by the concept of standardization and unification, such as windows, doors, movable walls, curtain walls.

Moreover, the window and door sector was the one that, more than others, had immediately incorporated the concept of mass production for the possibility of introducing many dimensional variations while maintaining the same profile. The companies that had combined the production of doors and windows with constant research were also the first to experiment with curtain wall technology, envisaging the production, supply and assembly of new glazed facades. In those years, these new types of building envelope represented the largest and most immediate manifestation of technological updating to which the large private companies entrusted the "corporate image". Consider, just to name a few, the Curtisa or the Greppi, who signed some of the most famous curtain walls of the Italian architectural panorama: the Pirelli skyscraper (Milan, 1956-61), the Galfa tower (Milan 1956-69), the Eni headquarters (Milan 1955-58 and Rome 1958-60).

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The important technical and formal experiments introduced to the market by these companies soon entered into ordinary practice.

The national level awards achieved by FEAL, verifiable by the number of tasks that the company gradually acquired, stimulated the already systematic study activity with the result of a continuous expansion of the productive framework. At the beginning of the 1950s the company was beginning to deepen its research on modular coordination which, as we have seen, monopolized the debate on the modernization of buildings. The normalization and simplification of the prefabricated construction elements and the improvement of the assembly methods became the main objectives of the Milanese company. In 1960 production was carried out in the two factories in Milan and Pomezia (Rome) where the extrusion, anodizing and painting departments developed the complete production cycle, from the raw material to the semi-finished and finished product (profiles, plates, metal structural work and assembly).

At the same time, the company promoted its construction systems through participation in the most important Milanese trade fairs: the Triennale exhibitions in the editions of 1954 and 1957 and the Milan Fair in 1958.

Fig. 2. G. Varlonga, F. Ratti, “Element of industrialized vertical house”, in Catalog of X Triennale, Milan 1954


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In the X Triennale of 1954, FEAL presented a prototype of an "industrialized vertical house". The project was developed by Varlonga and the engineer F. Fratti, of the FEAL Technical Office, with the collaboration of the architect I. Malaguzzi Valeri. Celebrated as one of the most interesting proposals of the exhibition, due to the absolute independence between the supporting structure and the vertical closures, the sample building applied a system that obtained a patent the following year (patent no. 524970, 1955). The structure consisted of thin Dalmine hot-rolled steel tubes, arranged with distances of 5 and 2 metres, connected with beams produced by Ilva and completed with reinforced slabs cast in situ [5] (Fig.2).

A specially designed and patented joint allowed dry connection between the metallic tubes and the beams. The joint could be produced in series because the external diameter of the supporting structure remained constant and the reduction of the weights on the upper floors was achieved by reducing the thickness of the lamination. Prefabricated external walls and partitions, in aluminum or wood, were placed after the linoleum flooring was installed; the windows were in light alloy with sliding doors. The thermal insulation was entrusted to panels of Eraclit with interposed air cavity, finished outside with sheets of enamelled sheet in light alloy. The main qualities of the system were economy, rapid construction, lightness and use of components already on the market.

In the XI edition of 1957, the new prototype was included in the section "Building Proposals", edited by Gio Ponti. The latter, extolling the versatility of industrialized systems, summarized the essential contents of the exhibition section in the following axioms: “An industrial production leads to the metal structure. A metal structure intended for construction [...] must use elements of normal metallurgical production. A metal structure excludes the «constructive» wall and wants its particular wall [...] with light and insulating elements, it wants light and incorruptible external coverings [6]”.

Among the many products presented by the company, “the FEAL industrialized house element”, stood out. It had always been studied by Varlonga and Fratti, with the collaboration of the architect G. Pozzi and the engineer C. Castiglioni. The new project was grafted onto the previous one but introduced the 300 mm module, already adopted internationally, which distinguished all the subsequent productions of the company. The structure, arranged according to standard bays (5.10x1.10x3.30 m), was always made of steel but was stiffened with concrete; it consisted of simple, unified and standard elements such as profiles or hot-rolled tubes; the connection was made with welded steel joints. A further novelty concerned the floors, which also referred to an industrialized procedure: made with a solid slab filled with electro-welded mesh, they were cast into recoverable steel formworks that did not require the presence of temporary supports. As in the previous case, the origin of this system was traceable to an invention that obtained a patent in 1958 (patent no. 582486) (Fig.3).

The complex structural device was formed by tubes, beams and pairs of tie rods. In contrast, for the construction of the floors there were "special metal formworks" consisting of a slab with opposite shaped edges that rested on the lower wing of the beams; a metal mesh was spread over the formworks and the concrete was cast, producing a floor with a load capacity of 700 kg/sqm. The same formworks became the object of further applications for industrial property rights, in which the geometry and dismantling techniques were perfected.

The progressive and constant deepening of the studies, accompanied by numerous patent applications, merged into a definition of the primary characteristics of the VAR M3 construction system, among the first in those years to introduce supporting steel structures, which placed the FEAL in the group of leading companies in the field of light prefabrication. The remarkable success achieved with the projects of the Fair pavilions was consolidated with the export of the new construction system abroad, where in 1960 approximately 30% of production was absorbed. The system was patented in the Soviet Union, the United States, France, Greece, Spain and Portugal.

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Fig. 3. G. Varlonga, “Struttura portante per edifici”, patent n. 582486, 1958 ((courtesy of the ACSR)

In the information brochure FEAL 1960 [7] already completed achievements were listed, starting from 1955 and divided into categories: in addition to the factories in Milan and Pomezia, the repertoire included 35 buildings for exhibitions, of which 22 were abroad, more than 100 buildings for offices and industrial complexes, 40 dwellings, care buildings, cinemas, barracks, hotels, garages and schools. The latter typological segment also became an extensive field of experimentation, so much so that the various school complexes became known as the "Scuole Feal [8]”. The catalogue of industrialized construction elements extended to vertical closures, roofs, false ceilings, internal partitions, and plant blocks, thus completing the system components.

Despite this, the aluminum or steel window and door sector remained prevalent, covering about 50% of the total FEAL production [9]. In 1960, the latching type obtained recognition from the Compasso d'Oro - the oldest and most prestigious award of Italian industrial design, one of which was assigned to the Thermovar radiator, which was part of the building system.


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The VAR M3 system

The VAR M3 name derives from its creator Varlonga and from the 300 mm module assumed as the basis for the dimensional coordination of production. Gradually improved in the 1950s, the "coordinated industrialized building system" was based on the adoption of "a type of standardized structure of steel and concrete with modular components that can be easily handled and quickly assembled [10]”. The VAR M3 system was recognized for its extreme versatility, the possibility of being applied in any building type, single or multi-storey, and the compositional freedom that guaranteed designers maximum freedom of expression, both in the architectural composition and in the choice of finishing materials. (Figs 4-5)

Fig. 4. VAR M3 System: the metal structure

The main objective of the Milanese engineer, pursued over the years, was in fact to obtain a versatile building system, which could be "built with industrial criteria, design free, of high functional level, of high relative cheapness" [11]. The tools to achieve the goal were identified in the rigid dimensional organization, in the total modularity of the construction elements, and in the technological coordination of the construction phases.

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Fig. 5. VAR/M3 system: the recoverable metal frameworks

Later, at the beginning of the 1960s, Varlonga wanted to combine a theoretical-applicative matrix, based on the maximum rationalization of construction procedures, with the competence and critical contribution of a professional profile more akin to the areas of architecture and design. The most distinctly technological aspects of the system, such as the simplification of assembly operations, the rationalization of the construction site, cost reduction or product engineering, no longer seemed sufficient to evidence the effectiveness of the system; these prerogatives had explicitly shown their validity in the construction of the thousands of FEAL schools, where the functionality of the building system prevailed over other aspects of language that, instead, expressed their weight in other building types.

It was a deep-seated and widespread belief that the inclusion of industrial products in architecture must inevitably pass through the collaboration of the designers and, consequently, be additional to their more traditional role. Architects were called, therefore, to expand their range of action, to arrive at a full understanding and interpretation of the industrial component in order to adapt it to the specific needs of the architecture. This new dimension led the designer to collaborate with the company to perfect the finished product and make it compatible with the needs of a modern architectural language. The study of construction details to improve joints and connections between building components, a field in which the architect could make a valid contribution, was added to the constructive and technological analyses conducted by the companies most open to experimentation.

The occasion for FEAL to compare the technological contents of its products with more general architectural requirements presented itself when the company planned to build a residential complex in Milan, in Laveno street (1961-63). The project was entrusted to the Milanese architect and designer Marco Zanuso (1916-2001), who had distinguished himself since the 1940s, due to his propensity to investigate the aesthetic potential of mass production.


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The role of the architect in the face of the inevitable push towards the modernization of building processes was, for Zanuso, that of bringing together the legitimate aspirations of the designer with the new production strategies that saw modular coordination as one of the most effective tools for the integration of building components and, therefore, to optimize the productivity of the sector. He was strongly convinced that modularity, internal to the concept of dimensional coordination, did not necessarily lead to slavish repetition but to place the design action in the difficult field of determining the "degree of variety" of the product, above and below which the compositional possibilities had not yet been carefully investigated. Countering the risk of leveling architectural language - the probable outcome of a superficial approach to standardized production - was one of the main objectives of the Milanese architect.

But operating within the constraints imposed by the size and assembly methods of the factory product was only possible if the designer became "guarantor of a whole series of skills both on a production and a specialized plan [12]”.

Useful elements for understanding the design of Laveno street can be found in an undated and unsigned typewritten report, preserved in the architect's archive and attributed to him; it underlined the attempt to "respond to the demand for architecture, for a richer and more complex plastic structure, with the use of different materials, with the possibility of coexistence with other construction systems of completion [13]”.

Zanuso designed two identical buildings, rotated by 90°. Based on a rigorously modular matrix, they have a very articulated layout, developed on three staggered levels. The whole project was based on the adoption of the integral VAR M3 construction system which involved extending the industrialized methods to the organization of the working phases and to the casting procedures (Fig.6).

Fig. 6. M. Zanuso, Housing in Laveno street

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The system used steel columns with dry-connected main and secondary beams. Using procedures already adopted abroad but which were absolutely pioneering in Italy, the technology involved placing the metal structures of the floors, stacking them on the ground, and inserting the recoverable metal formworks. With the aid of jacks, the floors were then raised to different heights, using the pillars as sliding guides. Subsequently, the reinforcement was arranged, and the concrete cast was performed. The structural stiffening was entrusted to the concrete cores of stairs and elevators. The internal partitions consisted of 6 cm thick fitted walls, made of metal, plaster or wood, which were dry mounted (Figs 7-8).

Figs 7-8. VAR M3 system: scheme of overlapping floors (left); the structure under construction (wright), (Mendrisio, Archive of the Modern, Marco Zanuso Fund)

Of particular interest, on the technical-architectural level, was the solution adopted for the envelope, which happily combined technological updating and construction tradition. The wall consisted of the FEAL panel, already tested on many other occasions, consisting of a double metal plate (steel inside and aluminum outside) with an interposed insulating layer of expanded polystyrene, for a total thickness of 6 cm. The panel was connected to a series of secondary aluminum posts anchored to the floors. An 8 cm cavity separated the panel from the external finish, made with unified slabs of antiqued gray Piperino trachyte stone, 3 cm thick. The slabs were inserted dry into natural anodized light alloy profiles, fixed to the rear structure (Fig.9).


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Fig. 9. Detail of the façade (from G. Patané, “Maisons d’habitation à la périphérie de Milan”, Journal de la Construction de la Suisse romande. n. 15, 1966)

The use of thin slabs of stone for the complete covering of the buildings had been adopted since the 1930s, when the slabs, generally 2 cm thick, were anchored with mortar and clamps to the wall behind, as a combination of reinforced concrete and masonry. The traditional technique associated with the thinness of the slabs turned out to be the cause of dangerous problems, due to frequent stone detachments. The introduction of prefabrication in the decades following the post-war period involved the bonding of even thinner slabs to a prefabricated panel anchored to an underlying frame. This system, even if it drastically reduced the construction time, again presented problems related to the stability of the slabs due to their detachment from the support itself or their deterioration due to the humidity present in the binder during maturation. The solution conceived by Varlonga proposed, instead, the total independence of the slab, which was not too thin, from the continuous support behind and represented a significant evolution of the construction technique, overcoming those problems that other technologies did not face.

The elevations of the Milanese buildings took place according to the ordered modular sequence of the stone slabs arranged with the horizontal joints staggered and underlined by the visible metal profiles. The crenellated outline of the crowning line, one of the few decorative accents, bravely referred to the motifs typical of the historic Milanese building; the choice to use visible natural stone, finally, with standardized dimensions, summarized the combination of the techno-industrial culture, with the design and the local architectural tradition.

Conclusions

FEAL also continued its research in the direction of perfecting the technique of assembling stone slabs, improving the behavior of the panels and facilitating possible replacement interventions, studies of which some patents remain as evidence (patent n. 725960, 1965). Zanuso, in the aforementioned report, highlighted the experimental nature of the technology adopted, which - he claimed - would have deserved further development precisely in order to

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investigate the potential of combining modular experience in dry assembly techniques with the use of natural materials.

A further opportunity to use the integral system VAR M3 was granted to Zanuso in 1970 with the project of another residential complex, always commissioned by the company. Like the previous one, it consisted of two identical buildings of five floors plus an attic, located in Solaroli street (today Coari street), in Milan (Fig.10).

Fig. 10. M. Zanuso, Housing in Solaroli street (Mendrisio, Archive of the Modern, Marco Zanuso Fund)

The volumetric, distributive and architectural layout was simplified in favour of the maximum exploitation of the opportunities offered by the construction system conceived by Varlonga. Zanuso, therefore, renounced the staggering of the floors and the original profiling of the stone slabs of Laveno street to bring the project back into the lines of a more replicable series production. In 1971 the project obtained the silver plaque for "industrialized building works" because it constituted an exemplary attempt at transferring residential construction processes that, until then, had been limited to hospital, school and industrial sectors; a feature that is already fully underlined with the buildings in Laveno street.

The executive procedure of the VAR M3 system, which included the raising of the frame of the floors to the different heights testified the high degree of industrialization achieved in the Italian sites; the technical-constructive innovation offered itself to the attention of the companies to rationalize the executive process whilst offering the designers an opportunity for qualified architectural experiments.


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References [1] G. Ciribini, “Attività di sperimentazione edilizia in Italia”, Informatore tecnico internazionale Cantieri, n. 12,

1948, pp. 7-12. [2] Law n. 43, 28 february 1949 "Provvedimenti per incrementare l'occupazione operaia, agevolando la

costruzione di case per lavoratori". [3] G. Minoletti, “Case in grande serie. Invito alle industrie”, Informatore tecnico internazionale Cantieri, n. 17,

1949, pp. 3-4. [4] G. Varlonga, “Sistema di costruzione di capriate in lega leggera”, patent no. 421672, 1946 (Central State

Archives of Rome, ACSR). [5] ‘Elemento di casa verticale industrializzata’, in Decima Triennale di Milano: esposizione internazionale delle

arti decorative e industriali moderne e dell'architettura moderna, 28 agosto-15 novembre 1954. Milan: Crespi, 1954, pp. 416-418.

[6] A. Pica (Ed.), Undicesima Triennale. Milano 1957, Milan: Crespi, 1957, pp. 269-271. [7] Fonderie Elettriche Alluminio Leghe, FEAL 1960, presentation of G. Varlonga, Milan: Crespi, 1960, p. 3. [8] I. Giannetti, “Costruire la Scuola. Progetto e produzione in Italia dal dopoguerra agli anni ’80” (Ph.D. thesis,

University of Rome Tor Vergata), 2012. [9] C. Corsini, G. Wiskemann (Eds.), “Per una edilizia industrializzata”, Stile Industria, n. 28, 1960, pp. 28-35 [10] Fonderie Elettriche Alluminio Leghe, (Note 7), p. 2. [11] FEAL, VAR M3: sistema coordinato di edilizia industrializzata. Company catalog, Milan: 1975, pp. 2-3. [12] Corsini and Wiskemann G, (Note 9). [13] M. Zanuso, Project report, p. 1, (Mendrisio, Archive of the Modern, Marco Zanuso Fund).

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