「建築設計和建造充滿着複雜並矛盾的關係，建築師的任務之一正是把它們適當結合。南豐 AIRSIDE 團隊通過早期與製造商 MINIWIZ 進行細緻研究和不同版本的再生材料生產嘗試，成功地為中庭空間特製了獨特的 「新布料」。」

How to achieve Architectural Resilience through Bold through Experimentations?

Architectural design is equipped with all the tools and gadgets that encourage experimentation and exploration, yielding greater creative expression that architects desperately seek. It also needs to be resilient to bridge the gap with construction and fabrication limitations. However, this has always been the dilemma to find a point where the two can meet gracefully. [01]

[01] “Detail and interior view of the AIRSIDE, showing the intertwining of fabric in space.”. Source: Vanessa Ma, Nan Fung

In 2019, the AIRSIDE design and project team was given the task of paying homage to Nan Fung Group’s textile legacy in Hong Kong. Snøhetta proposed a concept that intertwines “New Fabric” and “Waste Reduction” as key themes for the atrium space. By boldly introducing an upcycled fabric finish, it would soften how the space receives daylighting at different times of the day, whether through the skylight or vertical cracks. The duality expresses the physical continuity between floors with a prominent ambience that celebrates textile heritage while exploring upcycled material to symbolize a new direction that demands new fabrication technology. [02, 03]

[02] “Close up of the fabric”. Source: Nan Fung

[03] “Atrium section from 2/F to 6/F.” Source: Brice Wong

From Waste to Fabric
We partnered with MINIWIZ from Taiwan in early 2020, as they shared the same vision that materials can be reused again and again into new materials or products, to significantly reduce CO2 emissions from our industry. At the time, MINIWIZ already had experience with turning sneakers into retail shop furnishings and re-engineering post-consumer plastic product wastes into components for installation or pavilion. Adopting a new product from overseas is always controversial in Hong Kong, but the team embraced the potential with open mind and total commitment together with MINIWIZ.

From Fabric to Space
We embarked on a two-year R&D journey by collecting plastic bottles from local sources like hotels and convention centres during the pandemic. They were cleaned, shredded into flakes, weighted by colour, and spun into fibres before being mixed. These fibres were rolled to form layers and stacked onto each other to create a batt. The thick batt was compressed to a denser, thinner sheet and repeatedly needle-punched to entangle the felt web before being heat-pressed with an embossed pattern. The result was a non-woven architectural textile upcycled from over 100,000 PET plastic bottles, measuring 1.4 meters wide and considerably long. [04, 05]

[04] ” The Taiwan factory processes.” Source: MINIWIZ

[05] “Pattern design iterations - Sample pattern tests from drawings to fabric.” Source: Nan Fung

With the production sequence established, the next challenge was to select the perfect colour range and design the pattern. Since the atrium balcony steps back as they ascend to amplify sunlight penetration, only a warm-toned fabric can echo and generate a complementary effect. Countless colour samples were made, each mixed from 6 to 8 different colour fabric shreds with varying weights to achieve a unique shade. Based on the recorded weights, the final approved fabric colour could be produced with consistency. [06, 07]

[06] “Colour range samples by different weights.” Source: Nan Fung

[07] “Different embossment depth and pattern process.” Source: Nan Fung

The next task was to create an interweaving pattern onto the fabric for a more robust and recognisable identity, with yet a practical function to enhance the visual alignment at flat and curved panels and single to double-curved corner nosing joints. The interlocking lattice-inspired pattern proved to be more visually striking than the orthogonal one, which plays down the verticality and horizontality at panel junctions. Rigorous studies on the size and depth of the pattern took many 1:1 trial mounting attempts in the Taiwan factory and then on-site so that distortion could be test-stretched on concave and convex panels to ensure benchmark quality control and prepare contractors for site assembly. [08, 09]

[08] “Typical edge section.” Source: Brice Wong

[09] Single fabric piece trial mounting on concave, convex spandrel. Source: Nan Fung

In parallel, we addressed technical and safety aspects, including flame retardant classification, water and liquid repellency, anti-mold and anti-bacterial qualities, low-VOC content, and abrasion resistance tests. While these are standard off-the-shelf product performances, we invested hours in the testing lab for a new material.

With AIRSIDE’s grand opening in September 2023, the fabric-wrapped atrium space was not only well-received by fellow architects but also demonstrated to the public and community members that the conventional linear manufacturing process can be shifted into the circular economy. Adopting something that seemed experimental initially was made possible by the designer and team’s willingness to exchange and engage in trials and iterations with the fabricator. [10]

[10] “Fabric with skylight.” Source: Hip Hing Construction

Brice WONG is an architect and HKIA Member, Project Manager and Executive Architect of AIRSIDE
黃世豪 建築師及香港建築師學會團員, AIRSIDE策劃經理及執行建築師

1. Project Name

   AIRSIDE

2. Project Type

   Mixed-used Commercial Development

3. Design/Built Year

   2023

4. Site Area

   17.767sqm

5. Building Area

   177,670sqm

6. Location

   2 Concorde Road, Kai Tak, Kowloon

7. Client

   Nan Fung Development Limited

8. Design Architect

   Snøhetta
   

9. Project Architect

   Ronald Lu & Partners (Hong Kong) Ltd
   

10. Consultant

    J. Roger Preston Ltd
    Ove Arup & Partners Hong Kong Ltd
    Urbis Ltd
    Arcadis Hong Kong Ltd