Computer-Generated Surface Textures

In the United States and around the world, a growing design movement is incorporating new computer technology to generate new forms and textures. A progressive group of architects are discovering that mass production can be harnessed to provide affordable, customized and unique design statements for their projects. Three-dimensional gypsum sculptural panels are among a growing new collection of materials that are using a combination of computer aided production techniques with hand — finish craftsmanship.

Three-dimensional wall panels provide firms with a commercial product that can allow professionals to provide unique textural surfaces within a typical design budget and schedule for high-end interiors. They can be finished with textures and flowing patterns that suggest organic and complex textures and patterns. Gypsum three-dimensional sculptural wall panels can also be custom designed and the professional can develop unique patterns that can be applied to projects throughout the world. These panels have environmental benefits that include recycled content, the reduction of waste and increase in efficiency for labor and installation.

According to Daniel Nevitt, chief marketing officer of Armourcoat, “The seamless alternative to pre-cast panels would be a thick layer of plaster applied directly to the wall and sculpted by hand, but this approach is extremely expensive, labor and time intensive. More importantly, the designer has a limited ability to expressly design the wall finish —as this is a creative technique in the hands of the artist.” Recent alternatives to hand plastering techniques include computer generated and routed medium density fiberboard panels which are small in scale and have a low relief; or gypsum wallboards that are directly applied to walls for smaller scale repeating patterns. However, the latest trend includes large-scale three-dimensional gypsum seamless sculptural wall finishes, many without obvious repeats. These panels are constructed from a series of pre-cast panels bonded to a substrate that can create large seamless wall surfaces. They are specified either by selecting a range of pre-manufactured custom patterns and finishes or designed by the professional as a unique pattern. Certified installers are trained to finish these surfaces in handcrafted techniques.

The long, seamless three-dimensional seamless gypsum panel was created using advanced computer technology. The result is a unique flowing background at the Gourmet Burger Restaurant in Spitalfields, London, England. Photo courtesy Armourcoat

Used throughout the rest of the world and the United States in hotels, offices and restaurants, seamless wall surfaces modulate light and create surface textures that reflect both natural daylight as well as interior lighting. They can be placed on curved walls and wrap around internal and external corners. They also have environmental benefits and can easily be incorporated into projects with green building criteria. Panels contain zero Volatile Organic Compounds (VOCs), up to thirty percent recycled material and can be finished with hard, durable, fifty percent recycled marble surface finishes. They meet class ‘A” fire rating and are easy to clean and maintain.

This leaf pattern is used in a restaurant in Chelsea, London and is an example of how a large walls can be sculpted to provide a repeating ornamental design. Photo courtesy Armourcoat

Historic Hotel ABBA and Its High-Tech Addition

New addition to historic Hotel ABBA in Bratislava, Slovakia. Photo courtesy of Ladislav Karkusz Composed of two buildings, Hotel ABBA was designed to combine the richness of a historic building with a new high tech addition. The original building was built in 1891 as the Domicile of the Slovakian Woman’s Union and it is located in the city center, next to the Presidential Palace and within walking distance of shopping and the Danube River. In the original building, renovations of the walls, ceilings and bar areas maintained the historic appearance. In this case, gypsum wall panels were hand finished with traditional gypsum plaster. Although the effect was that of a seamless wall surface, in fact, separate, modular panels were finished to provide the appearance of a historic texture. A highly textured wall surface clad the connector between the two buildings and a modern three-dimensional wall sculpture highlights the main lobby. The exterior of the new annex is modulated and is designed with the new high tech aesthetic that is possible only through new computer animations and integrated design. The interior wall in the main lobby continues the expression of organic flow also by using designs generated by computer and hand finished during the installation process. According to Ladislav Karkusz, CEO of Karki Decorative Products, “Architects chose these products because it enabled them to design within a limited budget in Bratislava and still provide their clients with a high-end finish.” The main lobby of the new annex of Hotel ABBA follows and accentuates the energy of the flowing exterior. Photo courtesy of Ladislav Karkusz

Decorative Panels with Environmental Benefits

Manufactured to be part of a green design palette, three-dimensional gypsum wall panels are mineral based, non-toxic and completely non-combustible. Panels are approximately ¾-inch thick and weight three pounds per square foot. The panels are extremely dense and hard and have a smooth ceramic-like surface. They can incorporate up to thirty percent post-consumer recycled content, which in some cities can be recycled at the end of the product’s life cycle. The panels are designed for interiors and for areas that are not exposed to the elements or large temperature fluctuations.

New three-dimensional sculptural wall systems are unique in that they provide the benefits of computer aided design and production, with the advantages of a hand made finish. The design professional can choose among a palette of developed wall patterns or develop a new surface design using a computer aided design (CAD) program. They can also provide a hand-drawn sketch to the manufacturer who will input into the CAD system.

Some designs are made from a sequence of repeating patterns on multiple panels that can be mounted across large surfaces. A multiple panel design allows for a non-repetitive sculptural wall that flows with natural surface changes in texture. No two walls need to be identical and the mounting allows for a seamless view of the entire design.

The profile of the sculptural wall surface is marked and the pre-set contours assure proper alignment with multiple wall panels. Photo courtesy Armourcoat

The process of manufacturing is a unique combination of high-tech production techniques with low-tech hand finishing and controls. To achieve a hand-finished effect the process starts with a basic Computer Numeric Control (CNC) produced panel produced with the contours (peaks and flow lines) already marked. Pre-set contours ensure that the complex alignment of different — but interchangeable — panels work together with precision and provide a match line for joined panels. A craftsperson then uses wet plaster and hand tools to create a natural finish for the 'master' panel, softening the rigid machined surface. Hand tooling provides the finished product with crisp details and a surface that is full of texture and complexity.

From this original master a rubber mold is created to make a negative. It is filled with a wet gypsum plaster casting mix. This mix can incorporate as much as thirty-percent recycled glass as lightweight filler providing an additional environmental benefit. When dry, the plaster panel is pressed out of the mold and allowed to dry fully. The panels are labeled and numbered for installation as a whole three-dimensional surface design to be assembled in place. These are then delivered to site in custom-made reusable transport crates for installation.

The size of an installation is limited by weight and supporting wall bearing loads. A single, seamless sculptural wall should not exceed 400 square feet as the weight of the panel may cause cracking. Individual panels and linear runs should be no longer than thirty feet, as with larger walls there is a risk of small hairline fractures developing between the panels due to slight substrate movement or thermal expansion and contraction. The panels are jointed and placed in sequence on a wall surface. The manufacturing process assures that the panels fit together seamlessly and can even be assembled on a curved wall surface provided they are of a consistent radius. The minimum radius for curved walls is eight feet and all curved panels are custom made for each project to the required radius. Once manufactured, special packing crates are made to support curved panels. Additional costs can be incurred for a curved panel for the mold bases, additional casting time and custom made crates.

Curve Control Reduces Waste

This custom made curved sculptural wall in the lobby of the offices at Colinas Crossing in Dallas Texas was installed during construction to show no seams or breaks in the continuous flow pattern. Photo courtesy SPE PHOTO Highlighting the lobby of the office lobby for Colinas Crossing, a 200-acre mixed-use commercial development in Dallas, is a unique curved three-dimensional wall. This large wall sculpture washed with blue cove lighting suggests the flow of water and provides a natural counterpoint in this otherwise rigid space. The three-dimensional design was constructed from a series of precast panels bonded to the construction wall substrate. The design was created by combining computer-aided design with traditional hand sculpting and created a flow design that fit together with total accuracy yet retained the essence of being hand crafted. The curved wall — with a 21 feet radius — called for custom-made panels to accommodate the curvature of the wall. Amish Desai, Architectural Sales Representative for Southwest Progressive Enterprises described the process as one that met the challenges of working with the curved surface as one that required careful planning but not a high degree of difficulty. Desai notes, “The advantage of this system over other similar products is that there is just one contractor, who measures, installs, seams and finishes so that the final product appears hand finished.” After specifying this product, the architect, supplier and contractor met to review the process for installation. The contractor built the new wall with the proper plywood substrate. After the wall was built, the supplier measured both the circumference and radius and those measurements were used to create the CNC model and final wall panels. After placement, the panel joints were filled and sanded. A final architectural coating with a low sheen and subtle shimmer surface was hand applied to complete the installation with a handcrafted artisan finish. The preplanning for this wall surface reduced labor and waste. The product was delivered in returnable packaging and fit into the surface area.

Computer Numeric Control (CNC) Machines and Design Efficiency

The bar code imagery on this three-dimensional gypsum wall sculpture is a reflection of its generation by CNC machines creating a modern twist to a technique derived from Venetian plaster. Photo courtesy Armourcoat Manufacturing techniques common to the automotive and engineering trades in the nineteen fifties have continued to strongly influence the design world. Recently, affordable opportunities to select unique designs for each project is possible due to a number of new uses of CNC technology in building products and materials. A CNC machine combines Computer-Aided Designs (CAD) with Computer Aided Manufacturing (CAM) programs. The designer inputs a design that is interpreted through a computer file to a production machine. Tools, drills, saws, routers are all orchestrated to create a material that meets the unique instructions of the design. In the late 1950s, General Motors and IBM created a partnership to design and build truck parts initiating the first step toward an expansion of CNC into all manufacturing systems. Later advances in technology and less expensive machinery allowed manufacturers to explore new products. Architects like Zaha Hadid and Frank Gehry, among many others, are generating new forms using complex rendering and CAD systems. They are sending entire building plans and specifications direct to manufacturers who are developing components unique to each project. In the nineteenth century, Arts and Crafts critic Ruskin and artist William Morris argued that all machine made products were less valuable because they dishonored the labor of workers, and did not convey the quality and complexity of nature. For Ruskin, hand made objects reflected the hand of the maker and conveyed a greater aesthetic value. In the twentieth century, modernist architects such as Eero Saarinen and Ray and Charles Eames countered that mass-production was the means to bring great design to all classes. For the past fifty years, designers have been constricted to large runs of mass produced objects of identical design. Ceiling tiles, wall surfaces, window trim, and the design of most building products were limited by the cost of manufacturing individual and unique alternatives. Today, the use of the CNC machine has changed the design of building products. Manufacturers can easily produce unique designs using the CNC machine without increasing production time, cost or material waste. There are both environmental as well as aesthetic benefits to the use of CNC manufacturing. The best of these material processes individualizes the design process and uses nature as a guide to adjust molds, select color palettes and use environmentally beneficial materials. Automation of the design process with an attention to the details of hand-craftsmanship provides new opportunities for mass customization by 21st century designers.

Installation Basics That Ensure Waste Reduction

Three-dimensional gypsum wall sculptures are designed to reduce waste both during the manufacturing process as well as during installation. Most three-dimensional gypsum wall surfaces are designed as flat panels installed as part of a typical construction timetable to fit exactly into the desired location. These are manufactured to the exact size and pieced together by hand rather than cut and joined. Designing a wall with a radius requires the construction of the wall is completed before the wall is manufactured to assure that the wall system meets the required substrate conditions. After the curved wall substrate is completed, the wall is measured in place and the panel is manufactured to the exact curvature of the constructed wall.

Most installations usually are completed within five days from finish to start based on a wall surface of approximately 400 square feet. The construction substrate should be designed for the wall panel surface. Good communications before walls are constructed between the architects, the contractor and the installer will assure that this product is installed correctly and will meet all necessary requirements for attachment to the proper substrates.

One advantage to some of these systems is that the supplier is also certified as an installer and finisher. The installer must establish a completely straight datum line at the bottom of the wall and build the panels progressively up from this point. Errors in matching and placement can occur if the installer relies on the floor or any existing skirting being sufficiently straight or true. For a precise measurement, a datum board should be firmly fixed to the substrate ensuring that it will not move or flex when the panels are rested onto it.

Detail of a wall section of a sculptural three dimensional wall surface with a protected corner detail. Image courtesy Armourcoat

The non-combustible panels and the substrate to which they are attached must be constructed in accordance with the minimum fire ratings required for the project. For a successful installation, one that will not crack over time, it is necessary to be able to screw or fix the panel directly into the substrate. Substrates should be inherently stable and not affected by changes in temperature or humidity. One layer of ½-inch plywood followed by a layer of ½-inch foil backed drywall is recommended as an ideal substrate. Panels are mechanically fixed at sixteen points and bonded to the substrate with a low-VOC adhesive.

Using a foil-backed drywall ensures that the moisture for the bonding adhesive does not permeate into the plywood causing it to expand or move. An alternative is to apply an oil-based primer to the plywood at least 24 hours before fixing the plasterboard. In addition, glass-mat cladding boards can be used as a replacement for a foil backed drywall board.

After the wall is built to specifications, the installer applies a low VOC adhesive to the substrate with a notched trowel. Panels are then placed into position upon the bonded surface and screwed to the substrate until it is aligned along the entire edge with the adjoining panel. Panels can be cut to size with a jig saw fitted with carbide grit blades or an angle grinder, although panels are designed to be placed with minimal cutting on site. Once the panels have been installed and the adhesive has set, the seams between all the panels must be filled flush with a repair filler or drywall jointing compound by the installer and sanded to create a smooth continuous surface.

Turning the corner with a sculptural wall is possible and was an elegant solution for the elevator lobby of this private apartment building in Coral Gables, Florida. Photo courtesy SPE PHOTO

Corners and Edge Conditions

When specifying a sculptural wall in situations where there are multiple changes of surface planes within a small area additional planning is required. It is not possible to run a sculptural wall around an entire room and have the pattern join up to itself without some modifications. As shown in the image, designers in Florida, clad elevator cores in a sculptural wall surface panel to express motion and direction and emphasized the elevators as large sculptures in space. The pattern was joined and mitered at both exterior and interior corners to create seamless edge conditions wrapping the elevator cores with an expressive design statement.

To create external corners an installer will cut and miters each panel to and around the corner. Approximately 1/16-inch is lost in the cutting and mitering process. This gap is filled with bond filler and sculpted by the installer to meet the adjacent surface. The nose of the corner is also hand shaped with a rasp file or sandpaper to create a pencil round that reflects the sculptural shape of the corner.

Mitering panels to the intersecting wall forms internal corners. In this process, a section of the design may be lost and consequently the sculpted lines of the surface may not align. To create an internal corner, the installer uses two panels that are cut to fit together at the proper match line. Corner installations do lead to additional waste, but pre-planning reduces the losses significantly.

Decorative Surfaces with Durable Code-Rated Finishes

This three- dimensional sculptural wall panel is durable and resistant to nicks and scratches even when used on the base of a bar counter at the Hard Rock Café in Florence, Italy. Photo courtesy Fuse Studios

Three-dimensional wall sculptures can provide unique surfaces that can be produced and finished for both contemporary and traditional designs. For interior design at the Hard Rock Café in Florence, Italy, UK based Fuse Studios, used a stylized floral pattern. Special lighting was used on the main bar front that highlighted the additional depth and character of the pattern. Additional wall-to-ceiling cast relief patterns were also used in the interior design of the restaurant.

They used sculptural wall panels on the walls, stage front, and on the bar front of the main island bar at the centre of the venue. As Dave Matthews, Assoc. AIA, ARB, RIBA, director at Fuse Studio explains, “We chose this sculptural wall panel product because we wanted a durable finish that had a relief pattern that would ‘pop’ when edge lit by a linear LED light source. Originally, we were going to do a more rustic cast concrete finish but in the end, this product was more economical. The product has proved to be extremely durable. Despite its location on the front of the bar where it is constantly kicked and scratched, it has stayed in superb condition.”

For use in these high-end interiors, designers specified panels that met the following criteria:

• Noncombustible
• Rated as Class A for flame and smoke development when tested to ASTM E84 and Class 0 according to BS 476 part 6 and 7
• Compressive Strength = > 33Mpa as per ASTM C109M “Standard Test Method for Compressive Strength of Hydraulic Cement Mortars
• Flexural Strength => 10 Mpa as per ASTM C-348 “Standard Test Method for Flexural Strength of Hydraulic-Cement Mortars
  

These durable gypsum wallboards can add texture and character to areas of high occupancy and movement as seen in the Hard Rock project. The final finishes of the sculptural surface can be completed with protected coatings, including those for food areas in restaurants. Some coatings can be applied that allow for steam cleaning as needed for health care facilities. If the wall surface is scratched or scuffed in a high traffic area, they are easily touched up with paint by maintenance staff.

Coatings can be specified with zero VOCs and use as much as sixty percent recycled material if finished with plaster products incorporating recycled marble. When choosing a coating particularly for low VOCs, Armourcoat’s Daniel Nevitt recommends that the architect guard against undocumented claims about paints and adhesives having low-VOC finishes. Some finishes are labeled low VOC but do not meet the appropriate testing for all pigment choices of the base color. There is also a difference in how the standards are applied and measured for the North American market versus the European and International Market. (See sidebar.)

The Psychology of Awareness: Nature, Organic Forms and Perception

Using natural imagery can heighten awareness of nature. Image courtesy Armourcoat

Designers are finding many reasons to choose custom finishes that are hand crafted. They are also combining materials that are mass-produced along with aesthetic properties based in natural images. This aesthetic is based on new research documenting responses to nature. Studies are revealing that visual attention and focus can be heightened by complexity in design, images of nature and daylight. These studies have led environmental designers to search for new products that are sustainable in appearance as well as in material composition. Designers are customizing their projects by using computers to provide unique finishes and new patterns that have an organic feel or replicate a natural system.

In addition, new color palettes, brighter surfaces with complex finishes are now being selected and preferred for the design of assisted living facilities as well as for the hospital and hospitality market. Psycho-neuro-immunologists are finding that there is a relationship between the brain and the material world. Designers are using the studies of brain and material relationships to create new spaces that are balanced, colored and textured to provide an atmosphere similar to that of an experience of nature. They are generating new forms, textures and design experiences based on science using new technologies. Manufacturers are assisting them in this new trend, by combining the process of computer-aided design with unique finishing techniques. In addition, they are also responding to the need for green and sustainable building materials. The results are new products like sculptural three-dimensional gypsum wall finishes that are now being used by progressive designers throughout the world.

To highlight the hotel name, this sculptural wall was finished in an intense dark color. Photo courtesy Ladislav Karkusz

Architect Celeste Allen Novak AIA, LEED AP specializes in sustainable design and planning in Ann Arbor, Michigan.

Fom luxurious polished (Venetian Stucco) and textured plaster wall finishes, high performance architectural coatings, stone-effect cast products, to stunning seamless wall systems, Armourcoat is a global powerhouse in decorative surface finishes.  Most products have low or zero VOC content, and incorporate pre and post consumer recycled material, qualifying for inclusion within LEED® projects. www.usa.armourcoat.com

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Learning Objectives

At the end of this course you will be able to:

Discuss decorative computer-generated three-dimensional gypsum wallboard surfaces that are durable, contain recycled content and have a handmade finish. Specify correct substrates to enhance performance and maintenance of three-dimensional sculptural gypsum wallboards. Discuss decorative low-VOC finishes that meet Green Seal criteria for all pigment variables. Select a decorative wall surface that reduces labor, product waste and meets green building rating performance values.

This course was approved by the GBCI for 1 GBCI credit hour(s) for LEED Credential Maintenance.

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