Surface Design Awards – Complete

• LIGHT + SURFACE - EXTERIOR 
  The innovative use of light and the way it is inextricably linked to surfaces, whether it’s the effect the light has on the surrounding surfaces or the materials used to create the light. 

Located in Bengaluru, India, this Additive manufacturing facility is the first development within the recently developed Bengaluru Airport City. Envisaged as a sustainable and innovative district, the Bengaluru Airport City is a 560-acre development consisting of Business Parks, Retail Dining, Entertainment Village, Concert Arena and an Exhibition Centre adjacent to the city’s International Airport. This 1-acre site is located at the edge of the Airport City - prominently visible as one approaches the airport.
Tasked with housing the world’s largest quartz silica 3d printing machine, the facility is also required to host a design centre, an experience centre, a space for public outreach and symposiums. The requirements of the production process determined the layout of this facility. Occupying centre stage, the shop floor is designed to have easy access to customers, employees, and services – each separated into distinct circulation paths. There are specific points at the entry an– customer centric areas where visitors can get glimpses of the shop floor and the manufacturing process.
The client – Peekay Steel Castings is a 70-year-old steel company that is making a foray into additive manufacturing. The core design idea was to capture this paradigm shift while remaining recognizable and relatable to the company’s employees and loyal customers. Carrying forward the company’s rich legacy, the new facility’s form is inspired by industrial sheds that are synonymous with steel factories and foundries. The design adapts new technology, materiality along with climate responsive strategies to create a contemporary manufacturing space that is future forward.
Owing to the site’s orientation and profile, the prominent façades of the facility are oriented towards the south and west which posed a considerable challenge as they were susceptible to heat gain and glare. Shading fins in different configurations were designed to mitigate these issues allowing diffused natural light into the shop floors on the south and creating shaded terraces and courtyards along the west. These distinct vertical fins transform into skylights allowing ample natural light into the shop floor. Clad in pre-weathered zinc panels, these fins bring warmth and familiarity to the façade. The standing seam composition with staggered joints highlight the idea of construct which is synonymous with manufacturing.
The west façade mimics the same form with a series of porous fins made of expanded aluminium mesh. These fins add layers of light and shadow into the public and customer facing areas creating an enjoyable spatial experience. Moreover, these screens adjoin landscaped courtyards that directly open into the customer areas and workspaces creating engaging volumes and experiences with light, texture and greenery.
The facility is designed with a focus on employee well-being. The workspaces and the design centre overlook the shop floor creating volumes that allow uninterrupted visual access. The landscaped open terrace on the third level houses a lounge and recreation areas where employees can experience the joy of watching aircrafts take off and land on the adjacent runway.
Adding to muted yet dynamic exterior, the interior spaces also reflect the clean lines and warm highlights of the exterior. Sustainability and energy efficiency is built into the design through active and passive features. Continuing the idea of build and construct, the unique light installation in the lobby and board room highlights the innovation in design that this facility hopes to inspire. This is further enhanced by the experience centre which showcases the company’s history to customers through an immersive experience.

Cost : 320,000,000 Indian Rupees (3,159,807 GBP)
Completion Date: July 2022
Project Architect : Dhiraj Chilakapaty

Pre-weathered zinc sheets take centre stage as the predominant material used across the façade of this project. The choice of zinc was driven by its ability to accentuate the building's geometry, whether it be the bold fins that transform into skylights, or an expansive wall punctuated by openings. The standing seam detail with staggered joints not only provides structural integrity but also highlights the façade's intent without relying on multiple materials. This approach ensures that the façade is not viewed as a separate entity but rather as an extension of the building itself, seamlessly integrated into the overall design.
Another dominant material featured in the design is expanded aluminum mesh. The inherent perforations serve to shade the western side of the building while allowing uninterrupted views to the outside. This not only enhances the building's performance in terms of energy efficiency but also provides a comfortable and visually engaging experience for its occupants.
The mesh is designed to mimic the form of the fins on the southern side of the building. This deliberate design choice adds another layer to the façade, enriching its visual complexity and architectural depth without competing with the primary material, zinc. One of the most distinctive features of the expanded aluminum mesh is its function as a canvas for creepers to thrive. This innovative approach creates a dynamic and ever-changing vertical landscape on the building's façade. As the creepers grow and change with the seasons, they add a unique and evolving dimension to the building's exterior.

Passive design principles form the foundation of this project. The constraints of a small site and strict building bylaws, coupled with an unalterable process line, necessitated innovative approaches to maximize sustainability. Despite limited options for changing the building's orientation, the project cleverly addresses solar exposure. The dominant south and west-facing aspects of the structure prompted the creation of a unique saw-tooth profile along the south facade. This design not only shades interior spaces but also allows diffused light to permeate, reducing the need for artificial lighting and thus energy consumption.

Furthermore, on the west side, a secondary screen with a similar geometry was introduced away from the building. This screen not only provides additional shading for the structure but also defines landscaped courtyards. These courtyards serve as a natural buffer between the interior and the external environment, enhancing thermal comfort and minimizing the building's reliance on mechanical climate control systems.

The choice of zinc as the predominant material for the facade enhances the project's sustainability. Zinc is known for its excellent recyclability, ensuring that the building's materials can be repurposed in the future, reducing waste and the need for new resources. This commitment to using recyclable materials aligns perfectly with sustainable construction practices, contributing to the long-term environmental viability of the project.

CO2 / m2 = 3.55 kgCO2 / sqm/ year
Sustainability Ratings: Applied for LEED & IGBC Gold (Certification awaited)

In our pursuit of a contemporary yet relatable design, we consciously broke away from the conventional overuse of glass. Instead, we opted for pre-weathered zinc sheets for the façade, a decision that came with its own set of challenges.
Firstly, cost considerations were a major hurdle. Zinc sheets are relatively expensive compared to traditional construction materials. Additionally, the need for specialized labour, skilled in working with this material added to the expenses. Moreover, in the sub-continent, it was uncommon to use pre-weathered zinc sheets, which raised concerns about sourcing and expertise.

Despite these challenges, the decision was driven by the material's sustainability credentials, longevity, and the unique aesthetic it offered. It created a value proposition that aligned with our architectural vision.

The limited site area forced us to heavily rely on off-site prefabrication, which required meticulous planning and coordination. Time constraints were equally demanding, with a strict 12-month construction timeline in place to commence production. To meet this deadline, we strategically sequenced the construction process, enabling us to begin commissioning and testing the 3D printer nine months into construction. This timeline was only achievable by utilizing steel for its efficiency and flexibility.