More Practical Than Plaster and Cement: This Material Is on Our Reno Radar

Matter at Hand, a material research studio co-founded by Assemble's Lewis Jones, has developed a novel clay-based construction technique called Poured Earth. This method aims to simplify and increase the accessibility of building with earthen materials, drawing inspiration from concrete casting. Traditional earthen construction methods, such as rammed earth and cob, are highly sustainable but often demand significant labor. Poured Earth seeks to address this by leveraging a process similar to concrete casting, enabling scalability and the reuse of existing equipment. The development of Poured Earth was part of Matter at Hand's residency in the Art in Manufacturing programme at the National Festival of Making. Jones highlights the utility of flowable, castable solid materials, as demonstrated by concrete, while acknowledging concrete's substantial carbon footprint. Poured Earth offers a practical alternative, allowing for similar ease of use with earthen materials, thereby promoting a more sustainable approach to construction. The method also introduces new design possibilities and surface finishes not typically associated with earth construction. Poured Earth samples are created by combining clay with varying amounts of sand, aggregate, and natural fibers. Crucially, these mixtures do not require binders like cement or gypsum, making them easily reformable or returnable to the earth at the end of their lifecycle. The process involves mixing these materials in a cement mixer, pouring them into formwork, and then vibrating the mixture to eliminate trapped air before demolding. Matter at Hand collaborated with ceramic manufacturer Darwen Terracotta, integrating slip-casting techniques used for architectural ceramics into the Poured Earth development. A key innovation distinguishing Poured Earth from other earthen construction methods is the incorporation of deflocculants, chemical agents commonly used in ceramic slip-casting. Deflocculants such as sodium silicate, soda ash, or bark tannins enhance the flowability of the clay mix without requiring additional water. This results in a denser material with minimal shrinkage, unlike traditional methods where adding more water to achieve fluidity can reduce strength and increase drying time. Jones notes that while deflocculants are foundational to ceramic slip casting, their application in earth construction is a relatively new and promising area. Poured Earth samples were showcased at the National Festival of Making in Blackburn Cathedral. The exhibition featured structural Poured Earth walls made from clay, crushed ceramics, and recycled construction aggregates, designed for both in-situ construction and precast panels. Also presented was a lightweight insulative panel, framed in timber, composed of clay, wood chip, hemp shiv, and foamed recycled glass. Prototypes of hollow clay cast blocks filled with loose, natural insulation were also displayed. A composite wall, drawing from the CobBauge system, demonstrated a dual-layer structure with an internal load-bearing layer and an insulative layer. Matter at Hand intends to scale the Poured Earth prototype into a full-scale building, aiming to demonstrate its viability as a mainstream, contemporary building method. Jones emphasizes the need to re-establish unfired clays as mainstream construction materials in the face of the climate emergency, advocating for both design innovation and practical advancements to facilitate their broader adoption. #PouredEarth #SustainableConstruction #EarthenMaterials #MaterialInnovation #ClayConstruction #ConcreteAlternative #Deflocculants #GreenBuilding #ConstructionTechnology

Rieder Smart Elements GmbH & Co KG presents their 'concrete skin' facade panels, manufactured from fibreC glass fiber reinforced concrete. This material aligns with contemporary preferences for natural, eco-friendly, and sustainable building components, offering a modern and aesthetically pleasing finish. The panels are notably thin, measuring just 13 mm, and are available in a diverse range of colors, surface finishes, and textures, providing extensive design versatility for custom building facades. The 'concrete skin' facade panels are characterized by their non-combustible properties, excellent weather resistance, and long-term durability. They can be produced in custom sizes, extending up to 5 meters in length, which allows for expansive and creative architectural designs. These panels are designed as rain screen facades, essentially forming a protective 'skin' of extruded concrete over buildings. This functionality opens up new possibilities for modern ventilated wall systems that offer enhanced longevity. A distinctive feature of these panels is the 'Twine' texture. This design incorporates irregular lines that traverse the slabs, creating a visual effect reminiscent of interwoven ribbons. The interplay of straight and angled lines, some of which partially overlap and vary in size, produces an engaging and dynamic visual on the facade. The fluid arrangement of these lines is intended to integrate harmoniously with the overall architectural aesthetic. All 'concrete skin' facade panels are uniformly colored throughout using natural color pigments. They are offered in a selection of 23 different colors and three distinct surface finishes, providing a wide array of creative choices in terms of color, texture, and form. Additionally, special colors can be requested to meet specific design requirements. The 'twine' texture, in particular, is highlighted for its ability to create an interesting visual effect on facades, enhanced by the interplay of light and shadow across its surface. The panels are suitable for various applications, including facades, ventilated walls, roofs, and interior spaces. Their use extends to educational, residential, hotel, cultural, and corporate buildings. Key characteristics include their composition of fibreC, glass-fiber reinforced concrete, and their 100% non-combustible nature. Installation methods can involve either visible or concealed fastening onto a metal substructure. They are dyed throughout with natural color pigments and are available in panels with maximum dimensions of 1510 mm in width and 5000 mm in length. The surfaces come in ferro soft, ferro light, and ferro finishes. The product holds ISO 9001 and ISO 14001 certifications, and is classified as A1 “non-combustible” under DIN 4102. #FacadePanels #ConcreteSkin #FibreCConcrete #ArchitecturalMaterials #SustainableDesign #ExteriorCladding #BuildingMaterials #RiederSmartElements

Ryno, a manufacturer of construction systems, has introduced a new line of pavers crafted from porcelain, aiming to blend the aesthetic appeal of natural materials with the enhanced performance characteristics of ceramics. This paving range is composed of a mixture of clay, water, and either feldspar or quartz, resulting in a material engineered for high durability, elegance, and sustainability in various paving applications. The inherent hard-wearing quality of porcelain ensures that the pavers maintain their integrity and appearance over an extended period, potentially outlasting many other construction materials currently available in the market. Furthermore, the raw materials utilized in the manufacturing process of these porcelain pavers facilitate their widespread recycling once they reach the end of their substantial lifespan, aligning with circular economic principles. From an environmental perspective, the production of porcelain reportedly involves lower energy consumption compared to traditional manufacturing techniques. The material's composition also contributes to more efficient thermal conductivity. Ryno explains that porcelain's thermal inertia allows it to absorb and gradually release heat, preventing drastic temperature fluctuations in buildings. This property translates into potential energy savings, positioning porcelain as a significant material for energy-efficient construction systems. The Ryno porcelain pavers are versatile, suitable for both public and private environments. They are offered in diverse patterns and color palettes, catering to various design preferences. The pavers are available with either kerfed or grooved edges, a design feature that allows for secure clamping. This clamping mechanism is crucial for preventing uplift, especially in areas prone to strong winds, ensuring the stability and safety of installations on balconies and terraces. Two distinct styles within the range highlight the design versatility. The Tarvio pavers are inspired by 20th-century Milanese architecture, featuring an intricate, pebble-like appearance. In contrast, the Dapello pavers present a warm, honey-colored hue with a striated pattern that emulates the look of natural raw stone slabs. These design options aim to complement both interior and exterior architectural aesthetics. Ryno advocates for the use of its paving range in projects where energy efficiency, sustainability, and adherence to circular economic principles are key considerations. The company specifically recommends these pavers for new construction projects and for the remediation of existing buildings, emphasizing their long potential lifespan and their ability to enhance the energy performance of structures. #PorcelainPaving #SustainableMaterials #ThermalEfficiency #ConstructionSystems #OutdoorDesign #InteriorDesign #ArchitecturalMaterials #BuildingMaterials

The widespread use of steel as reinforcement in brittle structural materials like concrete and unreinforced masonry (URM) structures has been challenged by issues such as installation waste and corrosion, which impede the progress of the construction industry. Strain-hardening cement composites (SHCC) offer a potential solution for steel-free construction. This review article comprehensively examines the properties of SHCC and its practical applications without traditional steel reinforcement. The paper begins by highlighting the superior properties of SHCC and its structural applications in Reinforced Concrete (RC) structures. Concrete's inherent brittleness under tensile and bending loads often leads to cracking and subsequent steel corrosion, significantly impacting the lifespan of infrastructures like roads, bridges, and water conservancy systems. Furthermore, inadequate concrete ductility contributes to structural damage during natural disasters, such as earthquakes, where RC structures frequently experience concrete crushing and steel bar buckling. The current challenges in civil engineering, including labor shortages, high formwork costs, and environmental sustainability concerns, further emphasize the need for innovative materials. SHCC, particularly those reinforced with polyethylene (PE) fibers, offers significantly enhanced mechanical properties compared to traditional concrete. Designed using fracture mechanics and micro-mechanics principles, SHCC exhibits a tensile capacity exceeding 3% with a fiber volume fraction of no more than 2%, providing approximately two orders of magnitude greater ductility. This material's ability to develop multiple cracks, each smaller than 100 μm, renders it highly resistant to environmental degradation. PVA fiber-based SHCC, while commonly used, often faces challenges with premature fiber rupture due to strong chemical bonding with the cementitious matrix, limiting its strain-hardening potential. Treatments like oil coating and air-entraining agents are employed to mitigate this, though PVA-SHCC typically has a compressive strength below 60 MPa and a lower elastic modulus than regular concrete, leading to greater deformation under compression. Conversely, PE fiber-based SHCC leverages the hydrophobic nature and superior tensile strength of PE fibers, promoting fiber pull-out rather than rupture and leading to ultra-high ductile cementitious composites (UHDCC) with mean tensile strains often exceeding 8% and even 12% in some mixtures. This high ductility is attributed to the ultra-high fracture bridging capability of PE-SHCC, allowing for excellent tensile behavior even with high fracture toughness matrices. Comprehensive studies have explored the tensile qualities of various strength grades of SHCC, as well as size effects and rate-dependent tensile properties, leading to performance-based design concepts that consider mechanical and crack pattern characteristics. SHCC has found significant application in RC structures, improving beam-column connections and infill masonry. Experimental results indicate that SHCC can reduce or even eliminate the need for steel reinforcement in certain conditions, offering practical value in civil engineering. Plain PE-SHCC beams have demonstrated mechanical properties comparable to RC beams with 0.5%–1.5% steel reinforcement ratios, and plain PE-SHCC columns matched RC columns with a 0.8% steel ratio. Shaking table tests on PE-SHCC frames under seismic action showed remarkable crack control and compliance with seismic codes. SHCC is also critical for retrofitting URM structures, which are highly vulnerable to seismic activity due to limited shear strength and ductility. Common failure modes in URM buildings include in-plane cracking and out-of-plane collapse. Traditional strengthening methods using reinforced mortar layers, while effective to some extent, suffer from incompatibility with masonry substrates, low reinforcement material utilization, and excessive thickness for indoor applications. SHCC, with its multi-cracking and strain-hardening properties, offers a superior alternative. Studies show that SHCC strengthening can increase shear strength by 1.8–5.7 times and energy dissipation capacity by at least 35 times, significantly mitigating brittle failure. Double-sided strengthening provides even greater improvements in strength and ductility, and the strong bond between SHCC and masonry ensures effective composite action without interface stripping. SHCC layers can also enhance out-of-plane strength and ductility, preventing collapse during disasters. Furthermore, spraying SHCC simplifies construction while maintaining reinforcement quality. Shaking table tests on SHCC-strengthened masonry buildings demonstrate improved damage patterns, deformability, and overall stiffness, outperforming steel-grid-reinforced mortar layers. The review also explores the advancements in 3D concrete printing (3DCP) with SHCC. Extrusion-based 3DCP is a widely used technique due to its simplicity and suitability for lightweight structures. SHCC materials are well-suited for 3DCP, requiring specific fresh properties like pumpability, extrudability, and buildability. Studies confirm that SHCC exhibits respectable workability in 3D printing, with fibers and nanoparticles enhancing rheological characteristics. Printed SHCC typically shows better in-plane properties than cast SHCC, maintaining micro-cracking and strain-hardening characteristics. Fiber alignment during printing improves mechanical performance, allowing for thinner 3D-printed structures with reduced or eliminated steel reinforcement. Printed PE-SHCC also exhibits superior deformability and energy dissipation. The multi-layer structure of 3D-printed SHCC introduces anisotropy in mechanical properties, which has been investigated, revealing both challenges and advantages, such as enhanced ductility and toughness in nacre-inspired designs. The use of SHCC in 3DCP holds significant promise for future steel-free construction. In conclusion, SHCC's high ductility and toughness facilitate the development of structures without steel reinforcement across various applications, including RC structures and URM retrofitting. The integration of SHCC with 3DCP technology further advances the potential for automatic and steel-free construction. Future research should address interface properties, full-scale structural behaviors, seismic response, workability, and shrinkage of 3DCP-SHCC to fully realize its engineering applications and unlock its true value when coupled with theoretical models. This will pave the way for automated, steel-free construction in the future. The development of nacre-inspired 3DCP-SHCC demonstrates enhanced mechanical behavior, particularly in ductility and toughness, further validating the potential for reinforcement-free 3DCP-SHCC structures. These explorations, combined with theoretical models, will highlight the true value of auto-construction without steel reinforcement. #StrainHardeningCementitiousComposites #SHCC #SteelFreeConstruction #UnreinforcedMasonry #URM #3DConcretePrinting #PEFibers #StructuralApplications #SeismicRetrofitting #MaterialScience

The Acme Brick, Tile and Stone location in Florence serves the entire Florence and Tri-Cities metropolitan area, offering a comprehensive range of building materials for residential and commercial projects. This outlet provides a wide selection of bricks from various manufacturers, including Acme Brick, Belden Brick, Old Carolina Brick, Cherokee Brick, Columbus Brick, Lawrenceville Brick, Lee Brick, Meridian Brick, Palmetto Brick, Pine Hall Brick, Ragland Clay, and Sioux City Brick. Customers can choose from different brick sizes such as King, Queen, and Modular, as well as Thin Brick and surplus inventory options. Beyond bricks, the Florence showroom features an extensive collection of flooring materials, including hardwood and tile sourced globally. It also offers a variety of stone products, including cast stone and natural stone from numerous manufacturers and suppliers like Coronado Stone, Horizon Stone, MStone, Majestic Stone, ProVia Stone, and Stonebrook Thin Veneer. The facility also showcases architectural features such as cladding, fireplaces, glass accents, and iron doors. For outdoor living spaces, the Florence location provides outdoor furniture, pool coping, turf, grills, kitchen components, and outdoor heaters. These offerings allow customers to create integrated culinary and entertainment areas. Acme Brick, Tile and Stone in Florence is committed to providing resources and support for architects, designers, and builders. This includes architectural services, environmental product declarations (EPD), innovative building products, and a project inspiration gallery. Technical resources like the Pocket Guide to Brick Construction and Technical Services Digests are also available, alongside Health Product Declarations (HPD). Educational and support services include continuing education programs, case studies, and access to The Acme Technical Center. The company also offers virtual reality tools such as Virtual Mason, Masonry Designer, and Revit for design visualization. The showroom highlights a variety of specific brick products, including Abbeville – Queen – Heritage, Academy – Modular – Heritage, Aden Blend – Queen – Heritage, Adobe Wells – King – Heritage, Allendale – King – Heritage, Allendale Rustic – Queen – Heritage, Allentown – King – Velour, Allentown – Modular – Velour, Alluvial Light – Modular – Ruff, Alluvial Light – Modular – Velour, Alluvial Medium – Modular – Ruff, Alluvial Medium – Modular – Velour, Alpine – King – Heritage, Amaretto – Estate – Velour, Amaretto – King – Velour, Amaretto – Modular – Velour, Americana – Modular – Heritage, and Ansley Park – Modular – Heritage. The store operates Monday through Friday, with Saturdays and Sundays being closed. Detailed store information indicates a focus on providing diverse options for both indoor and outdoor applications, catering to various design preferences and construction needs. #BuildingMaterials #HomeDesign #InteriorDesign #ExteriorDesign #ConstructionSupplies #Flooring #StoneProducts #OutdoorLiving #ArchitecturalFeatures

Dunya Home Design, based in Huntingdon Valley, is revolutionizing the surface material industry with its focus on unique luxury products. The company's name, 'Dunya,' which means 'world' in Arabic, reflects its broad vision for innovative design solutions. Chief operating officer Mike Sobolewski highlights that Dunya's product offerings significantly distinguish them from competitors, aiming to establish the brand as the leading U.S.-based company for distinctive surface solutions, driven by an essence of exclusivity. A key product in Dunya's portfolio is FLEXMARBLE, a groundbreaking surface technology crafted from 100% real crushed marble. This material maintains the authentic texture and visual richness of natural stone but introduces an unprecedented level of flexibility. This characteristic allows architects and designers to apply marble to curved walls, columns, and other unconventional architectural elements, thereby expanding the creative possibilities for incorporating marble's classic aesthetic into modern design. Sobolewski emphasizes that FLEXMARBLE is currently exclusive to Dunya in the U.S., making it a unique, customizable, and flexible stone technology. Once installed and sealed, it is designed to offer lasting beauty coupled with easy installation and adaptability. Beyond FLEXMARBLE, Dunya Home Design continues its commitment to innovation across its product range. The company has recently launched Stone Polymer panels, which are waterproof, UV-resistant, and highly durable. These panels are suitable for diverse applications, from high-humidity environments like spa bathrooms to exterior facades. Dunya is also in the process of introducing a real brick veneer alternative and is actively developing new lines, including stairs, railings, contemporary doors, and aluminum siding. Sobolewski states that every product from Dunya is developed with the intention of disrupting the design world, addressing a perceived stagnation in surface material innovation. The company's showroom is designed to be an immersive experience, functioning more as a creative studio than a retail space. It features full-scale wall installations and carefully arranged vignettes, inviting clients to interact directly with the materials. This setup allows customers to physically touch, view, and envision how these surfaces can transform their spaces, moving beyond simple samples to a more comprehensive understanding of the products. This experiential approach fosters a deeper connection with the design possibilities Dunya offers. Client support is a core component of Dunya's service model, extending well beyond the showroom. The company provides extensive support, including design consultations, digital mockups, installation guidance, and training programs. This ensures that architects, interior designers, and homeowners receive comprehensive assistance throughout their projects, fostering a sense of partnership and commitment. Sobolewski notes that Dunya considers its clients and supporters as an extended family, aiming for this sentiment to be evident in every interaction. The company's future objectives are ambitious, with a stated goal to not merely meet industry standards but to completely redefine them. Through products like FLEXMARBLE and its expanding range, Dunya is actively shaping new ways of experiencing surface materials in interior and exterior design. #DunyaHomeDesign #InteriorDesign #SurfaceMaterials #FLEXMARBLE #StonePolymerPanels #ArchitecturalInnovation #LuxuryDesign #HomeRenovation #DesignTrends

For years, marble has been a dominant force in home design, particularly for kitchen and bathroom surfaces, celebrated for its luxurious feel and robust nature. However, a noticeable shift is occurring in homeowner preferences, with many now gravitating towards an alternative: quartzite. This emerging trend highlights a broader move towards materials that blend practicality with aesthetic appeal, diverging from the traditional constant upkeep associated with marble. Amanda Pendleton, a home trends expert at Zillow, observes a growing desire among homeowners for materials that offer warmth and texture. While designers like Hannah Goldberg of Hannah Charlotte Interiors maintain that marble's timeless beauty ensures its continued relevance, she acknowledges a significant change in how clients balance beauty with practicality. Busy households and those seeking elegance without intensive maintenance are increasingly opting for alternatives that do not demand the same level of care as marble's 'lived-in' patina. Toronto-based designer Golara Ghasemi reinforces this sentiment, emphasizing the importance of selecting materials that demonstrate longevity and resilience. She points out that materials which appear stunning in a showroom might disappoint under the rigors of daily life due to susceptibility to stains, scratches, and constant maintenance. Ghasemi advises prioritizing lifestyle needs first, followed by aesthetic considerations, when making material choices. Six interior designers consulted on this trend unanimously identify quartzite as the material currently gaining significant traction. Kristen Wolff of Brandon Architects notes that clients are increasingly choosing quartzite and quartz, appreciating their ability to mimic the depth and movement of natural stone without the inherent sensitivities of marble. Quartzite, a natural stone similar to marble, offers enhanced user-friendliness. Lauren Saab, a designer based in Dallas, describes quartzite's veining and coloration as akin to fine art, yet perfectly suited for daily use. Reanna Channer, founder of Design to Elevate in Seattle, highlights quartzite's durability and low-maintenance characteristics, specifically its heat resistance, which eliminates the need for trivets when handling hot cookware. However, Katelyn Gilmour of KBG Design points out that quartzite does require annual or semi-annual sealant maintenance due to its porosity, a minor upkeep she believes is justified by its natural beauty. For those seeking even less maintenance, engineered quartz presents a compelling alternative. Golara Ghasemi praises quartz for its ability to deliver timeless elegance without the typical worries. Lauren Saab appreciates quartz's smooth and flawless surface, while Hannah Goldberg commends its consistency, durability, and non-porous nature, which effectively resists staining and etching. While quartz is generally more affordable and requires less maintenance than quartzite, it may not offer the same level of heat resistance as the natural stone. Regardless of the choice, protective measures like trivets are always recommended for countertops. Ghasemi also advises selecting countertops with subtler veining, suggesting that high-contrast patterns or dramatic swirls can quickly become overwhelming or appear dated as design trends evolve towards softer, more organic aesthetics. Overly dramatic patterns can clash with cabinetry, lighting, and decor, creating a restless rather than refined atmosphere within a space. #HomeDesign #StoneTrends #Quartzite #KitchenDesign #BathroomDesign #InteriorDesign #MaterialChoices #Durability #LowMaintenance

The construction industry is experiencing a surge in innovation regarding concrete alternatives, driven by concerns about concrete's significant contribution to global carbon dioxide emissions (8% annually) and the push for more sustainable building practices. While concrete is fundamental to modern civilization, its production is energy-intensive, involving the super-heating of limestone with fossil fuels, and causes environmental damage through quarrying and water consumption. Scientists, government entities, and the concrete industry are actively researching and developing new materials to mitigate these issues. Emerging alternatives offer several advantages. Many provide enhanced crack resistance due to better tensile strength, allowing for more unique architectural designs. Some new technologies, drawing inspiration from traditional earthen building methods like adobe, improve temperature regulation in homes, reducing energy demands for heating and cooling. Furthermore, these alternatives address the environmental impact of traditional concrete by reducing carbon emissions, minimizing landscape disruption from quarrying, and decreasing water usage. Several greener concrete alternatives are becoming more accessible for home building and improvement projects. Hempcrete, made from hemp hurd, lime, sand, and water, is one-eighth the weight of concrete and resistant to mold, insects, fire, and earthquakes. Although not suitable for foundations or load-bearing walls, it excels in interior walls and insulation (R-value of 2.4 to 4.8), serving as a carbon-negative replacement for drywall due to CO2 sequestration during growth and in the final product. While generally more expensive than standard concrete, its environmental benefits are significant. Compressed earth blocks, modernized versions of ancient building techniques, incorporate fibers, bamboo, or rebar for added strength. They are fire-resistant, offer excellent insulation, and can substitute standard masonry products. Environmentally conscious, they are unfired, often made locally from readily available materials, and can be cost-competitive with concrete. Green concretes, such as ashcrete and fiber cement, modify traditional concrete by replacing some energy-intensive components with eco-friendly materials. Ashcrete, using fly ash from coal combustion, can be stronger and cure faster than standard cement, often at a lower cost. Fiber cement, made with wood pulp, resists cracking and warping, making it suitable for roofing and siding panels, though it is slightly more expensive than vinyl siding. Ferrock, a carbon-negative alternative, utilizes 95% recycled materials, combining industrial steel dust and ground-up glass, then exposing them to high CO2 concentrations. This process results in a material up to five times stronger than regular concrete with superior compressive strength and flexibility, making it ideal for earthquake-prone regions, pavers, walkways, and marine projects. Currently, it is not widely available for consumer purchase. Mycelium, or mushroom block, derived from fungi fibers, is a lightweight, versatile, fire, water, and mold-resistant, self-healing material that can be grown into any shape. While not yet mass-marketed, it can be grown DIY for various applications. Fungi and bacteria are also being explored as binders in traditional cements. Straw bales, an ancient building material revitalized in the 1970s, involve tightly baled straw anchored with rebar, bamboo, or wood, then covered with plaster or plywood. These walls provide effective temperature and sound insulation, improved fire resistance, and good earthquake and wind resistance. Straw is a renewable, nontoxic, carbon-friendly, and affordable material, with some building codes and banks now recognizing and financing straw-bale construction. Even the traditional concrete industry is evolving, with current "ordinary Portland cement" already incorporating waste products to reduce its environmental impact. Innovations like polymer fibers, soon to be replaced by solid carbon, are being added to concrete to sequester carbon. #ConcreteAlternatives #SustainableBuilding #EcoFriendlyMaterials #Hempcrete #EarthBlocks #GreenConstruction #CarbonNegative #Mycelium #StrawBaleConstruction

The article explores the innovative technique of fabric-casting concrete, a method gaining renewed interest among designers and architects for its potential to create dramatic, sculptural forms. This process involves pouring cement into a textile mould, which is typically supported by a wooden frame, allowing for unique shapes and textures that traditional formwork cannot easily achieve. The technique has historical roots with pioneers like the University of Manitoba's Centre for Architectural Structures and Technology (CAST) and 20th-century Swiss engineer Heinz Isler, who utilized it for thin concrete building shells. Modern applications, however, are pushing the boundaries, with experimentation extending to sculptural furniture and novel architectural components, even incorporating robotics. One significant advantage of fabric casting, according to engineering and architecture firm Atkins, is its efficiency, potentially reducing concrete usage by up to 40% and requiring less labor. Joseph Sarafian, a designer working on robotic casting methods, emphasizes the scalability of this technique for future construction, envisioning its use for unique building facade elements and even primary structural components. This innovation addresses the growing demand for variation in parametric design, which often faces limitations with conventional construction methods. Several compelling examples demonstrate the versatility and potential of fabric-cast concrete. Ron Culver and Joseph Sarafian's "Fabric Forms" project, conducted at the University of California, integrates robotics into the casting process. They pour a concrete and fiberglass mixture into Lycra sleeves manipulated by six-axis robots, eliminating the need for repeatedly building and dismantling plywood frameworks. This robotic approach significantly streamlines the process and allows for greater design flexibility. The "Augmented Skin" project by Bartlett School of Architecture graduates showcases another inventive application. This technique involves using sticks wrapped in stretchy fabric to create intricate building components. Concrete is poured around these stick-reinforced fabric moulds, forming solid, interconnected structures without external support frameworks. The sticks remain embedded, providing additional reinforcement. While currently applied to smaller prototypes like chairs, the project envisions larger architectural structures such as pavilions and bridges. Japanese studio Schemata Architecture Office employed fabric casting to create a chunky, uniquely textured counter for a Papabubble sweet shop in Tokyo. Unlike the intricate web-like forms often associated with fabric casting, this project used a fabric bag to produce a more robust, yet still organically shaped, concrete element, highlighting the material's adaptability to various aesthetic goals. Similarly, Janwillem Van Maele's "Mass IIII" side table demonstrates the creation of furniture by suspending a fabric net, filling it with cement and gravel, and allowing it to harden, resulting in a distinct, sculptural piece. Further exploration of the technique includes "FattyShell (v.01)" by University of Michigan students, who used stitched rubber sheets tensioned with cables to control the concrete's form, resulting in complex, multi-layered structures. Finally, Florian Schmid's "Stitching Concrete" presents an alternative approach by using concrete-impregnated fabric (Concrete Canvas). This material, consisting of cement layered between fabric and PVC, can be manipulated after soaking and then hardened, offering a different aesthetic and application for items like stools. These examples collectively illustrate the ongoing evolution and potential of fabric-cast concrete as a transformative material in architecture and design. #FabricCastConcrete #ArchitecturalInnovation #ConcreteDesign #RoboticConstruction #SustainableBuilding #ParametricDesign #MaterialExperimentation

Dutch designer Inge Sluijs has developed a novel method to transform landfill waste into a durable, rock-like material she calls 'plasma rock,' offering a potential solution to waste management and a source of sustainable materials. The process involves subjecting waste to extreme temperatures using plasma, which is ionized gas capable of generating intense heat. Waste collected from landfills, particularly coastal ones, is first heated in a gasifier to 800 degrees Celsius, converting it into gas. This gas is then superheated to 1,500 degrees Celsius and blasted with plasma, reaching temperatures exceeding 5,500 degrees Celsius—hotter than the sun's corona. This intense heat breaks down the gasified waste into its atomic elements. The end product of this gasification process is a slag that, upon cooling, solidifies into a vitrified, rock-like material with sharp edges. The chemical composition of plasma rock varies depending on the type of waste processed, but it predominantly consists of silica, lime, and alumina, along with traces of titanium, magnesium, sodium oxide, iron oxide, phosphate, and potassium. Crucially, tests confirm that the process consistently yields syngas (a potential fuel), reusable heat, and the plasma rock, irrespective of the initial waste material, whether it be food scraps, plastic, or even baby diapers. Approximately 100 kg of landfill waste can be converted into 20 kg of plasma rock. Sluijs emphasizes that despite originating from toxic landfill waste, the resulting plasma rock is virtually un-bleachable, meaning any hazardous materials present are rendered inert and will not leach out. This quality makes the material mechanically strong, very dense, and environmentally stable. To showcase the versatility and practicality of this innovative material, Sluijs and her collaborators have created various functional and decorative items. For example, waste from the East Tilbury landfill in Essex, England, has been transformed into 'Tilbury Tiles,' which are sold as souvenirs. Furthermore, Sluijs has crafted glass vases adorned with plasma rock specks, illustrating how discarded landfill materials can be repurposed into aesthetic pieces for home decoration, thereby giving waste a 'second life' and contributing to a more circular economy. #PlasmaRock #SustainableMaterials #WasteManagement #EcoDesign #CircularEconomy #LandfillWaste #EnvironmentalInnovation #MaterialScience

Acme Brick, Tile and Stone's El Paso facility serves the entire El Paso metropolitan area and the Southeastern region of New Mexico. The showroom offers a comprehensive selection of building materials for both interior and exterior applications, catering to diverse design preferences and construction needs. For exterior projects, the showroom displays samples of Acme Brick and distinctive natural stone. The building's exterior itself showcases split-face concrete masonry units, complemented by the Acme/IBP Fast Track Stone system, providing inspiration for clients. The outdoor patio area features manufactured concrete pavers, inviting visitors to envision and design their own relaxing outdoor spaces, complete with built-in fireplaces and fire pits. The store categorizes its extensive product range into several key areas, including Brick, Building Materials, Cladding, Concrete Masonry Units (CMU), Fireplace components, Landscape materials, Masonry, Outdoor products, Stone, and Thin Brick. Within the 'Brick' category, customers can explore various sizes such as King, Queen, Modular, and Thin Brick, along with surplus inventory options. The 'Flooring' section includes a wide array of materials like brick, thin brick, tile, pavers, stone, and wood, allowing for versatile interior design choices. The 'Stone' offerings encompass different types such as Cast Stone, Coronado Stone, Horizon Stone, MStone, Majestic Stone, ProVia Stone, and Stonebrook Thin Veneer. Architectural Features include Cladding, Fireplaces, Glass Accents, and Iron Doors, providing elements to enhance a property's aesthetic and functional appeal. For outdoor living spaces, the store provides Outdoor Furniture, Pool Coping, and Turf. Culinary spaces are addressed with Grills & Kitchens, Outdoor Grills, and Heaters, facilitating the creation of complete outdoor entertaining areas. Acme Brick, Tile and Stone also offers specialized products for architects and designers, including various brick types, thin brick, cladding, Featherlite Concrete Masonry Units, tile, glass accents, and stone. The product listings on the website further detail specific brick products like 'Abbeville – Queen – Heritage', 'Academy – Modular – Heritage', 'Aden Blend – Queen – Heritage', 'Adobe Wells – King – Heritage', 'Allendale – King – Heritage', 'Allendale Rustic – Queen – Heritage', 'Allentown – King – Velour', 'Allentown – Modular – Velour', 'Alluvial Light – Modular – Ruff', 'Alluvial Light – Modular – Velour', 'Alluvial Medium – Modular – Ruff', 'Alluvial Medium – Modular – Velour', 'Alpine – King – Heritage', 'Amaretto – Estate – Velour', 'Amaretto – King – Velour', 'Amaretto – Modular – Velour', 'Americana – Modular – Heritage', and 'Ansley Park – Modular – Heritage'. Each product entry includes an image and a link to its dedicated product page, allowing for detailed exploration of individual materials and their characteristics. #BuildingMaterials #Brick #Stone #Tile #Cladding #Fireplaces #OutdoorLiving #HomeDesign #ConstructionMaterials

Acme Brick Company, established in 1891, has significantly expanded its product offerings beyond traditional brick to become a comprehensive source for residential and commercial building materials. The company now provides a diverse range of products designed to enhance homes of all sizes and locations, reflecting a strategic evolution from its brick-centric origins. This expansion includes various innovative and traditional materials for exteriors, interiors, and outdoor living spaces, catering to both aesthetic preferences and functional requirements in contemporary construction and design. For exterior applications, Acme Brick offers a wide selection of thin brick products, which are hard-fired from natural clay. These thin bricks are notable for their versatility, cost-effectiveness, and ease of installation, requiring no additional wall support due to their light weight. They are suitable for both exterior facades and interior accent walls, with an extensive color palette available from brands such as Cherokee Brick, CityScape, English Cottage Series, Fusion, King Klinker, Marion Ceramics Vee Brick, Metro Brick, Old Carolina, Pacific Clay, Pine Hall Brick, and Royal Thin Brick. Installation methods include traditional tiling or specialized support systems like SpeedyMason. The company's cladding systems encompass a broad array of modern and proven options. These include terra cotta panels with diverse colors, textures, and shapes from Agrob Buchtal; an Acme-developed support system for panels made from natural stone and manufactured stone; durable steel panels that mimic the look of natural wood; embossed steel panels in lap and board-and-batten profiles from Quality Edge; high-pressure laminate panels with a proprietary installation system from Pura NFC for both residential and commercial use; high-density fiber cement from KØL in natural colors; and natural slate panels from CupaClad with multiple installation options for stone exteriors. Acme Brick also supplies advanced fireplace systems, offering lightweight, pre-engineered, modular units that surpass traditional scratch-built fireplaces in thermal efficiency and application range. These systems are available from leading manufacturers like Earthcore (Isokern), MFI (Mason-Lite), and Stone Age. For outdoor living areas, the product line includes a variety of landscape products such as elegant BrickTile fired clay pavers and pool coping from Marion Ceramics, traditional solid paving brick from brands like Pacific Clay, Pine Hall, Whitacre Greer, and Yankee Hill, economical concrete pavers and retaining walls from Keystone Hardscapes, porcelain and natural stone paving units from Savannah Stone Source, and low-maintenance synthetic turf from GrassTex. Interior and entrance enhancements are also a key focus. Acme showrooms feature a broad range of porcelain tile, mosaics, hardwood flooring, and luxury vinyl plank options for both flooring and wall applications. The company also provides robust and aesthetically pleasing iron doors from "Love That Door," "Exclusive Iron Doors," and "Stately Iron Doors," with options for single or double designs and accompanying hardware. Furthermore, for secure package delivery, products like the Box Gobbler from MB Sentinel are offered, featuring numeric keypads to deter theft. Finally, Acme Brick collaborates with regional producers to offer natural stone, cast stone accents, and manufactured stone products. These include cladding options from MStone and the Stonebrook line of veneer thin stone, with partners such as Apex Stone, Coronado Stone, El Dorado Stone, Horizon Stone, Jacobs Stone, Kirby Stone, Quality Stone, Scott Stone Supply, Semco Stone, and Texas Stone Design. This expanded portfolio positions Acme Brick as a comprehensive provider of high-quality building and design materials. #BuildingMaterials #HomeDesign #ThinBrick #CladdingSystems #FireplaceSystems #LandscapeProducts #Flooring #IronDoors #NaturalStone

Smartstone, a prominent Australian supplier of engineered surfaces, has significantly expanded its product offerings with the introduction of the Sintered Collection. This new range of surfaces is designed to meet the evolving demands of both residential and commercial projects, providing enhanced performance characteristics alongside sophisticated aesthetics. The Sintered Collection features materials known for their extreme durability, resistance to high temperatures, UV stability, and scratch resistance, making them suitable for a wide array of applications, including kitchen benchtops, splashbacks, outdoor entertaining areas, and high-traffic commercial spaces. The collection is initially launching with three distinct designs: Bianco Angelico, Nero Puro, and Taj Mahal. Bianco Angelico presents a luminous white surface with subtle grey veining, designed to mimic the classic elegance of natural marble while offering superior practical benefits. This design is particularly well-suited for creating bright, expansive interiors and can serve as a versatile foundation for various design palettes. Nero Puro, on the other hand, offers a deep, uniform black surface that exudes sophistication and modernity. Its rich, consistent tone provides a striking contrast or a bold, monolithic statement, ideal for contemporary and minimalist designs. The third addition, Taj Mahal, captures the warm, creamy tones and intricate veining of its natural quartzite namesake, offering a luxurious and inviting aesthetic that can complement both traditional and transitional design schemes. Smartstone emphasizes that the Sintered Collection is manufactured using advanced technology that subjects natural minerals to extremely high pressures and temperatures, replicating the Earth's natural processes of rock formation. This manufacturing method results in a non-porous material that is highly resistant to stains, chemicals, and impact, ensuring longevity and ease of maintenance. The surfaces are also designed to withstand direct heat exposure, making them ideal for areas around cooktops and fireplaces, and their UV resistance prevents fading, even when used in outdoor environments or spaces with abundant natural light. Beyond their functional advantages, the new surfaces are presented as a solution for designers and homeowners seeking materials that combine high performance with refined beauty. Smartstone’s expansion into sintered surfaces reflects a commitment to innovation and a response to market trends favoring durable, versatile, and aesthetically pleasing materials. The company anticipates that the Sintered Collection will be particularly appealing for high-end residential projects and demanding commercial applications, where both visual impact and long-term durability are paramount. This launch reinforces Smartstone's position as a comprehensive supplier of engineered surfaces, now offering a broader spectrum of choices to cater to diverse design requirements and project scales. #Smartstone #SinteredCollection #EngineeredSurfaces #ArchitecturalMaterials #InteriorDesign #KitchenDesign #OutdoorLiving #BuildingMaterials #ProductLaunch

This article showcases the range of cement and aggregate products available at Wickes, a prominent retailer of home improvement and building materials. The selection includes various types of cement, catering to different construction needs such as general purpose, rapid setting, and fire cement. Customers can filter products based on type, size, colour, brand, and package type, ensuring they find the right material for their projects. The available cement types include Cements, Fire Cements, Post Concrete, Rapid Setting Cements, and Slablayer Concrete, indicating versatility for different applications from foundational work to specialized repairs. Product sizes range from small 1kg and 2.5kg packs, suitable for minor repairs or DIY tasks, to larger 20kg and 25kg bags, ideal for more extensive building projects. The colour options primarily feature grey and light grey cements, with one cream option for specific aesthetic requirements. Brands stocked include Blue Circle, Holcim, and Wickes' own brand, offering customers a choice between established manufacturers and value options. Packaging varies, with products available in paper bags, plastic bags, and tubs, each offering different benefits in terms of storage, handling, and protection from moisture. The article highlights several popular products, such as Blue Circle Ready To Use Postcrete, Blue Circle General Purpose Cement, and Blue Circle Mastercrete Cement, along with Wickes' own Rapid Setting Ready Mixed Cement. Customer ratings and pricing information, including per kilogram costs, are provided for each product, allowing for informed purchasing decisions. Special offers, such as '30 for £210' on certain cement types, are also advertised, appealing to bulk buyers and trade professionals. Additionally, the page suggests related products like Bostik Cementone Colours for Cement, STS NoMorePly Tile Backer Floor Board, Knauf Square Edge Plasterboard, and Soudal Repair Express Cement, indicating a comprehensive range of complementary building materials. Beyond product listings, the article emphasizes Wickes' commitment to providing diverse building solutions and support. The inclusion of cement dyes, tile backer boards, plasterboard, and repair solutions illustrates the breadth of materials available for various construction and renovation tasks. The detailed product descriptions, alongside practical filters, aim to simplify the selection process for both professional builders and DIY enthusiasts. The information presented underscores the importance of choosing appropriate materials for specific applications, ensuring durability and structural integrity in construction and home improvement projects. The focus on comprehensive product details, competitive pricing, and accessibility to a wide array of related building essentials positions Wickes as a convenient source for construction materials. #Cement #Aggregates #BuildingMaterials #HomeImprovement #Construction #DIYProjects #BuildingSupplies #Wickes #RapidSettingCement

Agoprene represents a novel biodegradable foam designed for sustainable padding applications, primarily composed of Norwegian kelp, mineral fillers from seashells, and cellulose feedstock from the paper industry. This innovative material stands out in the padding sector due to its high biogenic composition, reaching up to 85%, significantly surpassing traditional fossil fuel-derived expanded foams and more sustainable variants that typically contain only 20-30% bio-based material. Agoprene was developed as an alternative to polyurethane (PU) foams, offering a 100% biodegradability based on internal studies, further enhanced by the complete absence of harmful or petroleum-based chemicals in its formulation. The production process involves mixing kelp, mineral fillers, and paper industry by-products to create a paste. This paste then undergoes an expansion process utilizing water injection and air foaming, which imparts the foam with its characteristic lightness, elasticity, and porous structure. The current manufacturing of this bio-foam is manual, adopting an artisanal approach. However, the company is actively engaged in a scale-up phase, focusing on integrating automated systems to optimize production flows and standardize formats. The immediate goal is to produce ready-to-use sheets, which will streamline application phases and reduce overall processing times for various industries. Agoprene's versatility allows for its application across multiple sectors, including furniture upholstery, padding for accessories and textiles, and the packaging industry. The foam is typically supplied in rolls or standard sheets, with a width of 2 meters and thicknesses ranging from 2 millimeters to 5 centimeters. Thicker applications, up to 10 centimeters, can be achieved by stacking multiple layers. Furthermore, the material has demonstrated workability with molding techniques, although potential shrinkage may impose limitations on shape design and production rates. An internal Life Cycle Assessment (LCA) has revealed that Agoprene boasts a carbon footprint approximately one-third smaller than that of conventionally manufactured polyurethane foam. This significant environmental advantage positions Agoprene as a forward-thinking option for designers and creatives seeking to integrate eco-conscious materials into their projects. The start-up's commitment to sustainability offers a compelling alternative in the market for technical components used in furniture and interior design, providing solutions for both flat cushioning surfaces and flexible, curved structures. It bridges the gap between creative design, technical demands, and ecological responsibility. #MaterialsAndSurfaces #InnovationDesign #InnovativeMaterials #SustainableDesign #EcoConsciousDesign #BiodegradableFoam #FurnitureUpholstery #GreenTechnology

Design & Detail, a fabric and furniture showroom with locations in St. Louis and Kansas City, is expanding into a new market category by becoming the exclusive North American showroom for Casadenza, a line of ultra-thin, flexible real stone veneers. Casadenza, a product of a partnership between Esspex Corporation of Japan and Vesna Inc. of India, has been available in Asia for nearly 15 years but is new to the North American market. Ivan Moses, a veteran of the door industry, introduced the product to a select group of showroom owners, including Melinda Klinghammer, owner and founder of Design & Detail. Klinghammer was so impressed with the product, which is available in over 70 stone varieties, that she accepted Moses’ invitation to partner with him in bringing Casadenza to the U.S. and Canada. Casadenza veneers are produced in India by applying a sealant and backing to a slab of stone and then peeling it in layers. Due to its thin profile, the veneer is not suitable for flooring or countertop surfaces but is ideal for vertical applications, both indoors and outdoors. The fiberglass-backed version is waterproof, allowing it to be used on walls, fireplaces, showers, and cabinet or island fronts. It is also certified for exterior building applications up to 40 feet high. The lightweight and flexible fabric-backed version can be applied like wallpaper or fabric, enabling it to wrap around curved surfaces such as columns, where traditional stone would be impractical due to weight. The product's efficiency extends to its use in unique environments, such as 25-passenger planes, for which it has received FAA approval. Casadenza is also a more affordable alternative to traditional stone, with a price point comparable to high-quality wallpaper or tile. While relatively easy to install, proper application requires a skilled trim carpenter. To ensure quality installations, Design & Detail is collaborating with the Masonry Association to train its members on the product's application. Design & Detail plans to establish a new Casadenza showroom on the second floor of its St. Louis location. Ben Klinghammer, Melinda's son and the company's sales manager, will lead Continuing Education Unit (CEU) classes to educate architects and other professionals about the product. The introduction of Casadenza represents a new venture for the Klinghammers and their company, moving beyond their traditional focus on residential furniture and fabric to embrace commercial applications. The product has already garnered interest from various commercial entities, including casinos and businesses looking for elevator and retail store displays. Residential interior design clients have also shown enthusiasm, particularly for using the veneers on kitchen cabinets and for accent walls. Ben Klinghammer, who will oversee Casadenza sales, expressed his excitement about the product's potential and its niche in the market. He looks forward to educating people about Casadenza and its diverse applications in various projects. This expansion marks a new challenge and opportunity for Design & Detail. #CasadenzaStoneVeneers #DesignAndDetail #ArchitecturalMaterials #InteriorDesign #HomeRenovation #BuildingMaterials #ProductLaunch #StLouisBusiness #FlexibleStone