Cast on Cast in the United Kingdom

Efficient fabrication system for geometrically complex building elements

Cast on Cast in the United Kingdom

Efficient fabrication system for geometrically complex building elements

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    Cast on Cast - Efficient fabrication system for geometrically complex building elements

    Pavilion (Surface).

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    Cast on Cast - Efficient fabrication system for geometrically complex building elements

    Stacked components.

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    Cast on Cast - Efficient fabrication system for geometrically complex building elements

    The handover event included a PechaKucha-style panel discussion (l-r): Paul King, CEO, UK Green Building Council (moderator); Andy Von Bradsky, Chairman, PRP Architects; Rory Bergin, Head of Sustainability, HTA; Paul Hinkin, Managing Director, Black Architects; Peter Fisher, Associate Director, Bennetts Associates Architects; Patrick Bellew, Director, Atelier Ten; and Ryan Dillon, Design Research Lab Programme Coordinator, AA School of Architecture.

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    Cast on Cast - Efficient fabrication system for geometrically complex building elements

    Congratulating Global Holcim Innovation 3rd prize winners (l-r) : LLuis Enrique and Carlos Piles is Alain Bourguignon, CEO, Aggregate Industries UK.

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    Cast on Cast - Efficient fabrication system for geometrically complex building elements

    The Holcim Innovation prize trophy is constructed from a low carbon concrete which produces about 95% less CO2 than traditional Portland cement. Viewing the trophy (l-r): prize winner LLuis Enrique together with his mother Maria Monzo.

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    Cast on Cast - Efficient fabrication system for geometrically complex building elements

    Ryan Dillon, Design Research Lab Programme Coordinator, AA School of Architecture.

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    Cast on Cast - Efficient fabrication system for geometrically complex building elements

    Global Holcim Innovation 3rd prize winners (l-r): Povilas Cepaitis, LLuis Enrique, Diego Ordoñez and Carlos Piles.

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    Cast on Cast - Efficient fabrication system for geometrically complex building elements

    Presenting the winning project, “Cast-on-cast: Efficient fabrication system for geometrically complex building elements”, project author, LLuis Enrique.

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    Cast on Cast - Efficient fabrication system for geometrically complex building elements

    Presentation of the Holcim Innovation 3rd prize (l-r): prize winners Povilas Cepaitis, LLuis Enrique, Diego Ordoñez and Carlos Piles with Rolf Soiron, Chairman of the Board of the Holcim Foundation and of Holcim.

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    Cast on Cast - Efficient fabrication system for geometrically complex building elements

    Presentation of the Holcim Innovation 3rd prize (l-r): Alain Bourguignon, CEO, Aggregate Industries UK; prize winners Povilas Cepaitis, Diego Ordoñez, LLuis Enrique and Carlos Piles; Lucy Musgrave, Co-director, Publica; Ryan Dillon, Design Research Lab Programme Coordinator, AA School of Architecture and Rolf Soiron, Chairman of the Board of the Holcim Foundation and of Holcim.

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    Cast on Cast - Efficient fabrication system for geometrically complex building elements

    Presentation of the Global Holcim Innovation 3rd prize trophy (l-r): prize winner Carlos Piles with Lucy Musgrave, Co-director, Publica and member of the Holcim Awards jury Europe 2008 and 2011.

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    Holcim Awards 2011 Europe ceremony - September 15, 2011 - Milan, Italy

    Representatives of all "Next Generation" prize winners for the Holcim Awards 2011 Europe (l-r): Elisa de los Reyes Garcia (2nd); Eduardo Mayoral (3rd); and Povilas Cepaitis, Diego Ordoñez, LLuis Enrique, and Carlos Piles (1st).

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    Holcim Awards 2011 Europe ceremony - September 15, 2011 - Milan, Italy

    Receiving the Holcim Awards "Next Generation" 1st prize 2011 Europe for Efficient fabrication system for geometrically complex building elements, London, UK (l-r): Povilas Cepaitis, Diego Ordoñez, LLuis Enrique, and Carlos Piles, AA School of Architecture, United Kingdom from Alain Bourguignon CEO Aggregate Industries UK.

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    Cast on Cast - Efficient fabrication system for geometrically complex building elements

    Cast on Cast components assembled in surface.

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    Project entry 2011 "Efficient fabrication system for geometrically complex building elements", London, United Kingdom

    Cast on Cast process.

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    Project entry 2011 "Efficient fabrication system for geometrically complex building elements", London, United Kingdom

    Waste in building processes.

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    Project entry 2011 "Efficient fabrication system for geometrically complex building elements", London, United Kingdom

    a-b-b-c logic.

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    Project entry 2011 "Efficient fabrication system for geometrically complex building elements", London, United Kingdom

    Assembly.

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    Project entry 2011 "Efficient fabrication system for geometrically complex building elements", London, United Kingdom

    Angle logic.

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    Project entry 2011 "Efficient fabrication system for geometrically complex building elements", London, United Kingdom

    Pavilion (Towers and Surface).

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    Project entry 2011 "Efficient fabrication system for geometrically complex building elements", London, United Kingdom

    Simplifying complex geometries.

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    Project entry 2011 "Efficient fabrication system for geometrically complex building elements", London, United Kingdom

    Design, fabrication, storage/transportation and assembly.

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    Project entry 2011 "Efficient fabrication system for geometrically complex building elements", London, United Kingdom

    Cast on Cast components fabricated in towers.

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    Project entry 2011 "Efficient fabrication system for geometrically complex building elements", London, United Kingdom

    Hexagon logic.

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    Project entry 2011 "Efficient fabrication system for geometrically complex building elements", London, United Kingdom

    Team picture.

  • Awards Innovation 3rd prize 2011–2012 Global
  • Next generation Next Generation 1st prize 2011–2012 Europe
Cast on Cast is an efficient and sustainable fabrication process, focused on the development of a smart but simple methodology to design and prefabricate building elements with complex geometries, which is resource efficient and considerably reduces construction waste.

By Povilas Cepaitis, Diego Ordoñez, Carlos Piles - AA School of Architecture, London, United Kingdom; Lluis Enrique Monzo - Swiss Federal Institute of Technology (ETH Zurich), Zurich, Switzerland

This system is composed of two complementary parts: a novel manufacturing technique of precast stackable building components, and a new geometric method for the design of freeform shapes by means of stackable solid tiles. 

The main advantage of the system is that it eliminates the need of costly molds, making the production of freeform shapes in concrete more efficient and sustainable. Furthermore, the method has also delivers advantages in the storage and transportation of the components to the construction site.

Cast on Cast

Project authors

  • Povilas Cepaitis

    AA School of Architecture

    United Kingdom of Great Britain and Northern Ireland

  • Lluis Enrique Monzo

    Swiss Federal Institute of Technology (ETH Zurich)

    Switzerland

  • Diego Ordoñez

    AA School of Architecture

    United Kingdom of Great Britain and Northern Ireland

  • Carlos Piles

    AA School of Architecture

    France

Project entry 2011 "Efficient fabrication system for geometrically complex building elements", London, United Kingdom

Cast on Cast components fabricated in towers.

Project updates

November 23, 2018 | Project Update | Zurich, Switzerland

First prototype at ETH Zurich proves viability of CASTonCAST system

Project Update November 2018 – CASTonCAST

Construction of the first real-scale CASTonCAST prototype at the Swiss Federal Institute of Technology (ETH Zurich) was completed successfully. Lluís Enrique Monzo, postdoc at the Chair of Structural Design and author of the LafargeHolcim Awards winning project, is keen to point out that his recent investigation “proved the viability of applying this innovative production system for concrete elements at a real scale”.

Read full article
June 15, 2017 | Expert update | Paris, France

Pursuing passion for innovation

The Holcim Awards gives many projects the boost to achieve realization and is part of countless success stories being written by aspiring and established professionals. A prize in the competition opens new doors for many of the winners, like the Spanish architect Carlos Piles. Thanks to two prizes from the Holcim Foundation, he has made an exciting step in his career – to Holcim!

Read full article
October 21, 2016 | Project Update | Zurich, Switzerland

Casting an eye on precast design

Project update October 2016 – Cast on Cast: Efficient fabrication system for geometrically complex building elements, London, United Kingdom

Research to develop the Holcim Awards winning CASTonCAST system has continued at the Swiss Federal Institute of Technology (ETH Zurich). Project author Lluis Enrique is completing a PhD that examines structural concerns in the fabrication system for the design of shell structures built from precast stackable components. His multidisciplinary research in building technology brings together the fields of architectural geometry and manufacturing, with the aim of producing architectural freeform shapes in an economically efficient and sustainable manner.

Read full article
September 10, 2012 | Innovation Jury Report | Zurich, Switzerland

“Overcoming the dilemma of high materials use to achieve a sculptural dialog” – Holcim Innovation Prize Jury

This project received the special interest of the jury for a variety of reasons. Students of the Architectural Association (AA) in London presented an approach to a fundamental problem of contemporary architecture: while designing complex geometric shapes has become increasingly easier, it is their construction that is the tricky bit. With its plasticity and flexible molding, concrete is actually a material that lends itself well to a sculptural language.

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September 10, 2012 | Global Innovation prize handover | London, United Kingdom

Towards waste-free concrete fabrication without conventional molds

A research project, from students at the Architectural Association (AA) School of Architecture, to fabricate complex concrete elements without conventional molds was presented with an inaugural 2012 Global Holcim Innovation prize at an event held at Kent House Knightsbridge in London. The prize-winning project considers simultaneously the design of free and ambitious shapes, as well as the material efficiency and economic performance of the construction process.

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March 29, 2012 | Announcement of Global Winners | Zurich, Switzerland

Prizes for materials and technology breakthroughs

Cast on Cast – Innovativ, effizient und nachhaltig

A team of four students from the AA School of Architecture in London, UK, won the Holcim Innovation 3rd prize for their research project on an efficient cast concrete fabrication system for geometrically complex building elements. This approach considers simultaneously the design of free and ambitious shapes, as well as the material efficiency and economic performance of the construction process.

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September 15, 2011 | Winners for Europe Announced | Milan, Italy

“Next Generation” prizes for post-graduate student visions

The Holcim Awards competition recognizes the importance of engaging tomorrow’s professionals on the theme of sustainable construction, and sharing their visions and ideas at a conceptual level. The “Next Generation” category was open to student projects. The first prize was awarded to a team of four students from the AA School of Architecture, UK, for their research project on an efficient cast concrete fabrication system for geometrically complex building elements.

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June 23, 2011 | Regional Jury Report – Europe | Zurich, Switzerland

“Innovative new method of designing and fabricating geometrically complex building elements” – Holcim Awards Jury

The jury commended this project which innovatively challenges new methods of designing and fabricating geometrically complex building elements and in addition provides efficiency improvements in terms of materials, storage, and transportation. Overall, the project presents a way that considers simultaneously the design of free and ambitious shapes, as well as the material efficiency and economy of constructions.

Read full article

Related information

Related information

Location

pin London, UK

London, UK

News

Project Update November 2018 – CASTonCAST

Project Update

First prototype at ETH Zurich proves viability of system

Zurich, Switzerland

Expert update

Pursuing passion for innovation

Paris, France

Project update October 2016 – Cast on Cast: Efficient fabrication system for geometrically complex building elements, London, United Kingdom

Project update

Lluis Enrique, On Making Complex Things Simple

Zurich, Switzerland

Project update October 2016 – Cast on Cast: Efficient fabrication system for geometrically complex building elements, London, United Kingdom

Project Update

Casting an eye on precast design

Zurich, Switzerland

Innovation Jury Report

“A new approach to production of complex geometric shapes that overcomes the dilemma of high materials use to achieve a sculptural dialog” – Holcim Innovation Prize Jury

Zurich, Switzerland

Global Innovation prize handover

Towards waste-free concrete fabrication without conventional molds

London, United Kingdom

Awards 2012

Integrated solutions in Burkina Faso, Brazil and Germany win top awards in sustainable construction

Zurich, Switzerland

Holcim Foundation Awards

Sustainable place making and materials innovation

Milan, Italy

Regional Jury Report – Europe

“Innovative new method of designing and fabricating geometrically complex building elements” – Holcim Awards Jury

Zurich, Switzerland

Project Entry & Details

London, United Kingdom

Videos

Holcim Awards Innovation 3rd prize winners on their project and the Holcim Awards

A concept that allows complex architectural forms at lower cost and with less waste.

Holcim Awards Innovation 3rd prize winners on their project and the Holcim Awards

A concept that allows complex architectural forms at lower cost and with less waste.

Carlos Piles

From Holcim Awards prize winner to leading product development in France.

Carlos Piles

From Holcim Awards prize winner to leading product development in France.