CASE STUDY
CUSTOM CIP PARAMETRIC WALL
Design
Concept imagery was digitized and, using advanced 3D design programs, we extrapolated key information and manipulated it to preserve the essence of the original concept while enhancing it to achieve a more refined and innovative outcome. Throughout the design process, we simultaneously explored construction methods and identified potential constraints, ensuring the most efficient fabrication techniques.
The depth of the domes was carefully coordinated with the structural engineer to maintain the optimal wall thickness. Additionally, formwork ties were cleverly integrated within the domes to remain concealed, ensuring they did not detract from the overall aesthetics.
Prototyping
Early in the process we put our in-house fabrication and equipment in motion to develop prototypes and variations of these for testing. This process allows us to establish the threshold where craftsmanship meets efficiency to allow us to find the optimum time and labor to provide the best craftsmanship without unnecessarily impacting the project budget.
Early testing illustrated hat a built up material stock was the most cost effective material that provided the best results. The tooling and speed of our CNC was examined to find a balance of speed and post fabrication work. We also explored multiple sealers to not only determine their effect on the releasing of the form, but the consistency of the surface of the wall and their impact on the resulting color of the wall as well.
These prototypes are adjusted and modified and tested again to ensure we re reaching the best results. Failure is not feared, instead it is seen as a step forward in finding the best solution.
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Fabrication
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.
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.
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.
After Initial Cure
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.
Final Product
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.
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