Humans are fond of leaving a mark wherever they go. The expeditions, however, have left unwarranted marks on the face of the Earth—through waste and emissions. Diesel fuel pollution in coastal waters is a significant cause of damage to delicate marine ecosystems. The demarcation of protected marine areas around the world which now prohibits the use of diesel engines has been a positive act that underscores the importance of ecologically sustainable developments in the industry. One of the leading green energy sources, hydrogen, is a strong contender to replace diesel, for recreational boating. NatPower group, a UK-based renewable energy company—has invested over €100 million in green hydrogen infrastructure for recreational boating in Italy. Stepping up to this opportunity is British architecture firm Zaha Hadid Architects (ZHA) which has designed hydrogen refuelling stations for NatPower H— part of the NatPower group and stated to be ‘the first global developer of innovative technologies for hydrogen production, storage and refuelling in the pleasure of the boating industry’.

Building on fluid forms synonymous with ZHA’s overarching aesthetic, the station’s design mimics oceanic life forms, emulating a sculptural composition of clam shells which characterises the marine context. The station’s construction will employ the use of 3D robotic material placement to create the segments of each structure and dry-assembled masonry intended to minimise construction waste while also enhancing material efficiencies. Intended to be fully recyclable, it has been stated that the design allows minimisation of waste even after the end of the structure’s life cycle. “The layered composition of 3D-printed blocks echoes the processes evident in nature which create the striated structures and fluid geometries of natural formations within Mediterranean landscapes and marine ecosystems,” states the official press release.

In an attempt to reduce the amount of materials employed in construction without compromising on the structural integrity, the form-finding method for the design process uses the force-density method. This method solves the problem of static equilibrium without requiring material properties, increasing the dependability of the method. The structural form is then divided into components using stereotomy, a process of dividing a form into simpler elements without losing the structural integrity of the framework. This helps in creating ease of construction and assembly rather than printing the structure as a whole. The parts are robotically 3D-printed to achieve material efficiency, and the materiality of the structure transitions from one concrete mix at the bottom to another one at the top depending on structural design requirements.

“Built with low-carbon concrete, the structural strength of ZHA's hydrogen refuelling stations is generated through geometry rather than increased use of materials. Combining the latest innovation in construction techniques with the historic engineering developed throughout the Mediterranean by the Romans more than 2,000 years ago, the stations use advanced circular building technologies, reflecting NatPower H's commitment to an ecologically responsible future,” said Filippo Innocenti, Director at Zaha Hadid Architects. NatPower H’s collaboration with ZHA intends to construct green hydrogen refuelling stations that are ecologically responsible and meet the highest safety standards. The design draws from ZHA’s research into modular systems and is proclaimed to be adaptable to various locations throughout the Mediterranean. It intends to enable customised configuration for each refuelling station based on specific local needs such as overall size, seating, bike charging facilities and pedestrian circulation within each port and marina.

The design has been developed from ZHA’s Computation and Design Research Group’s (ZHA CODE) collaborations with Block Research Group (BRG)—a Swiss computational construction research initiative, and incremental3d—an Austrian 3D concrete printing manufacturers. Together they investigate unreinforced masonry structures, 3D-printed concrete and digital concrete construction. “Evident in the team’s acclaimed Striatus Bridge in Venice and the Pheonix Bridge at the Holcim Innovation Hub in Lyon, circular construction integrating computational design and 3D-printing reduces the structural materials required by up to 50% with no compromise in performance using blocks that can be easily disassembled and recycled,” the design firm suggests on how technological advancements are crucial towards a more sustainable development.

The green hydrogen infrastructure by NatPower H will begin installation in the summer of 2024 and targets the provision of 100 refuelling stations throughout the Mediterranean over the next six years, with further expansion to the world’s most popular regions for recreational boating.