Design and Fabrication: Kory Bieg (OTA+) and Andre Caradec (S/U/M)

We developed a series of screens to test the limitations and potential of Ductal; an ultra-high performance concrete. The material offers superior strength, durability and the capacity to span large openings with minimal thickness when compared to traditional concrete. In addition, the material is highly moldable and can be poured into small pockets, filling gaps that would otherwise be impossible using standard reinforcing.

Based on our handrail design for a previous client, we generated a pattern that would allow seamless tiling from one panel to the next. The pattern can grow or shrink and be open or closed, depending on the requirements of the client, site and program. The design can be implemented on the exterior of a building as a superficial rain screen, or integrated into a weatherproof exterior facade system. It can also be used on the interior of a building as a visual screen or focal wall.

The panel was fabricated using a CNC mill. The mill allowed us to bypass the time-consuming process of drafting 2d drawings. After finalizing the computer model, we simply uploaded the 3d information directly to the milling machine, which then cut the form from a block of foam. Ductal was then poured into the foam mold. After a few days of drying, the final panel is extracted from the mold and ready to be installed.

---