Case Study #6
Parametric Cast-in-Place Concrete Wall
180 Degrees Design + Build pushes the envelope in research and design, developing strategies to take a concept to reality. Seeking a feature statement at the entry to our newly renovated office building, we employed our team to transform an idea into an exceptionally crafted feature wall. Our design team started with a concept design idea and through a digital exploration, generated a design that fit the description. Through a series of mockups, out fabrication team explored fabrication techniques needed to create the best formwork and finish before scaling up to build the final product. Working with formwork engineering teams we developed strategies to accommodate the physical requirements needed during construction while not allowing their presence to impact the aesthetics and design intent inherent in the built form. Our process is built on rigor and patience. We seek restraint while exploring and craftsmanship on the final project.
Design
Concept imagery was digitized and with the aid of 3 dimensional design programs we extrapolate the information needed and manipulate it in a fashion that embodies the original concept while elevating it to a new level. While developing the design, we concurrently are exploring construction methods and identifying construction restraints to develop the best fabrication methods. The depth of the domes was coordinated with the structural engineer to maintain the optimal overall thickness of the wall. The design also incorporated the need to formwork ties, concealing them within the domes so they were not visible and detract from the aesthetics.
Protoyping
Prior to fabricating all components we are huge proponents of full scale mock-ups to verify our shop drawings have no “holes” or “conflicts”. Each component from the aluminum frame, fabric track intersections and fabric wrap and trim is fully mocked up to confirm our expectations are being met.
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Fabrication
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Incorporating the lessons learned in the research and development of the form panels, scaled up to fabricate the full scale formwork panels. Our prototyping process allows us to not only determine the best fabrication techniques but to also accurately establish labor and material needs to construct the form liners.
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Adjusted G-coding was finalized and fabrications of the panels commenced. Materials were ordered and we created the stock in house, laminating them onsite. Having established the balance between CNC cutting speed and labor for final prep, the panels were fabricated and our team finished them by hand to remove the tooling marks.
Construction
Once the panels were back screwed to the form panels, the assemble was picked by a crane and set into place. Digital mapping allowed us to build the entire panelized system horizontally, in lieu of a labor intensive process of building it vertically in place to ensure alignments were met. Working from our in-house fabrication drawings, we were able to keep the budget low and maintain a fast track schedule for completion.
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Construction
The day of the pour, all of our research and development came into play. Our in house concrete team stepped up to the challenge to execute the plan. Expertly placing the concrete and skillfully guiding the vibrator stingers, our team avoided damaging the form liner panels with the domes. Without their skillset, there was a very present danger in deforming or dislodging a dome and not being able to recover it, resulting in a final product that was far from perfect. Instead they performed the task perfectly. As is their mantra – perfect is good enough.
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Final Product
Our research and testing in curing compounds ensured the finish would be exceptional. It is with experience that we learn that the initial unveiling does not hold the final story. Just as during construction we often observe components in a vacuum not understanding their visual presence within a greater context. Time allow materials to cure, age, patina and become observed within a larger whole. Our process allows us to ensure we are able to make the journey while finding the right path to lead to the best results.
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Our firm takes great pride in pushing the envelope with innovative design and fabrication methods. Ultimately, our goal is provide our clients with the best-in-class fabrication practices to deliver superior results when constructing complex design concepts.
