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This Online Learning Seminar is available through a professional courtesy provided by:
Cosentino North America
355 Alhambra Circle, 10th Floor
Coral Gables, FL 33134
Office Phone: 786-686-5060
Web: https://www.cosentino.com/
©2017, 2020 Cosentino North America. The material contained in this course was researched, assembled, and produced by Cosentino North America and remains its
property. “LEED” and related logo is a trademark owned by the U.S. Green Building Council and is used by permission. The LEED® Rating System was authored by and
is the property of the USGBC. Any portion of the Rating System appearing in this course is by permission of the USGBC. Questions or concerns about the content of this
course should be directed to the program instructor. This multimedia product is the copyright of AEC Daily.
Ultracompact Surfacing:
Redefining Boundaries of Interior and Exterior Spaces
powered by
Toronto, Canada
(647) 923- 8957
blair@facadesystemsinc.com

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To ensure the current status of this course, including relevant association approvals, please view the course details here.
Ultracompact Surfacing:
Redefining Boundaries of Interior and Exterior Spaces
The American Institute of Architects
Course No. AECXXX
This program qualifies for 1.0 LU/HSW Hour
Course Expiry Date: MM/DD/YYYY
AEC Daily Corporation is a registered provider of AIA-approved continuing education under Provider Number J624. All registered AIA CES
Providers must comply with the AIA Standards for Continuing Education Programs. Any questions or concerns about this provider or this
learning program may be sent to AIA CES (cessupport@aia.org or (800) AIA 3837, Option 3).
This learning program is registered with AIA CES for continuing professional education. As such, it does not include content that may be
deemed or construed to be an approval or endorsement by the AIA of any material of construction or any method or manner of handling, using,
distributing, or dealing in any material or product.
AIA continuing education credit has been reviewed and approved by AIA CES. Learners must complete the entire learning program to receive
continuing education credit. AIA continuing education Learning Units earned upon completion of this course will be reported to AIA CES for AIA
members. Certificates of Completion for both AIA members and non-AIA members are available upon completion of the test.

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AEC Daily Corporation has met the standards and requirements of the Registered
Continuing Education Program. Credit earned on completion of this program will be
reported to RCEP at RCEP.net. A certificate of completion will be issued to each
participant. As such, it does not include content that may be deemed or construed to be
an approval or endorsement by the RCEP.

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Purpose and Learning Objectives
Purpose: Sinterization is a specialized manufacturing process that uses extreme heat and pressure to create a unique
product called ultracompact surfacing material. This cutting-edge material can be used in ways that natural stone, solid
surface, or quartz material cannot. This course examines the advantages of ultracompact surfaces in terms of life cycle
environmental impact, strength, durability, chemical resistance, absorption, abrasion resistance, and ASTM testing.
Design flexibility with ultracompact surfaces in terms of color, texture, and format is also discussed and possible
interior/exterior application options are considered.
Learning Objectives: At the end of this program, participants will be able to:
• discuss the evolution of surfaces and the various types of surfacing material for interior and exterior applications
• define ultracompact surfacing (UCS) and discuss the innovative production process that creates superior tile
properties and reduced environmental impact
• discuss the advantages of compact surfaces in terms of strength, durability, chemical resistance, absorption,
abrasion resistance, and ASTM testing
• discuss selecting UCS in terms of life cycle environmental impact, color, texture, format, and general design flexibility,
as well as the various possible interior and exterior applications, and
• identify key attributes of UCS, explaining how they influence material performance, safety, durability, and
sustainability.

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This CEU is registered with the Interior Design Continuing Education Council (IDCEC) for continuing education credits.
This credit will be accepted by the American Society of Interior Designers (ASID), International Interior Designers
Association (IIDA) and Interior Designers of Canada (IDC).
The content included is not deemed or construed to be an approval or endorsement by IDCEC of any material or
construction or any method or manner of handling, using, distributing or dealing in any material or product.
Questions related to specific materials, methods and services should be directed to the instructor or provider of this CEU.
This program is registered for 0.1 CEU value. The IDCEC class-code is: CC-107023-1000.
• This CEU will be reported on your behalf to IDCEC and you will receive an email notification. Please log in and complete
the electronic survey for this CEU.
• Certificates of completion will be automatically issued once you have submitted the online survey for this CEU.
• Attendees who do not belong to ASID, IIDA or IDC and do not have a unique IDCEC number will be provided with a
Certificate of Completion after this CEU.

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How to Use This Online Learning Course
• To view this course, use the arrows at the bottom of each slide or the up and down arrow keys on your keyboard.
• To print or exit the course at any time, press the ESC key on your keyboard. This will minimize the full-screen
presentation and display the menu bar.
• Within this course is a test password that you will be required to enter in order to proceed with the online test.
Please be sure to remember or write down this test password so that you have it available for the test.
• To receive a certificate indicating course completion, refer to the instructions at the end of the course.
• For additional information and post-seminar assistance, click on any of the logos and icons within a page or any of
the links at the top of each page.

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Contents
Evolution of Surfacing Materials
Ultracompact Surfaces
Manufacturing Process
Attributes of Ultracompact Surfaces
Case Studies
Summary
Click on title to view

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Exterior Design
UCS can move easily from inside to outside, offering a beautiful and seamless look that complements any design.

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Exterior Flooring
Versatile, durable, and functional exterior flooring is able to survive all types of weather conditions and temperature
fluctuations. While interior flooring in large formats can be accomplished with an 8mm thickness, outdoor parameters for
large-format flooring require a thicker UCS material of 1.2cm for long-term use.

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External Cladding
Using ultracompact surfacing materials as exterior cladding offers building
owners increased energy savings, acoustic insulation, protection against
water infiltration, structural wall insulation, and thermal insulation. There are
three types: ventilated, bonded, and curtain wall.
The ventilated façade, as pictured on the right, is a high-performance
solution for building enclosures that takes advantage of mechanical
anchoring elements. Through connections between the cladding material
and the mechanical assembly, design loads are effectively transferred back
to the structural wall, providing a safe and secure façade.

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External Cladding
For bonded façades (on the bottom left) fixed with glue, it is very important to select the appropriate adhesives.
Mechanical tie-backs may also be used where needed.
Spandrel panels (on the bottom right) are used in place of glazing units in curtain wall systems where it is necessary to
hide the edges of floor slabs, ceiling details, insulation, and other building elements.

12.
Ultracompact Surfaces

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Raw Materials
A straightforward way to understand this new product category is to learn
about the raw materials.
All materials are categorized as either organic or inorganic.

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Materials
• UCS uses inorganic minerals not only for the bulk of the product
but also for pigmentation and veining
• More than 20 inorganic minerals are used to create an UCS
slab
• Pigments are mineral based and complement the final product’s
performance characteristics
Olivine
Ca-Plagioclase feldspar Halite
Gypsum
Na-Plagioclase feldspar
Pyroxene
Amphibole
Orthoclase feldspar
Limonite
Biotite
Quartz
Hematite
Calcite
Muscovite

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Green Extraction and Raw Materials
Along with manufacturing, extraction and generation of the raw materials
has one of the largest environmental impacts for this type of material. This
can be mitigated by engaging in sustainable quarry restoration programs
and introduction of recycled materials into the mix.
Also, look for Health Product Declarations® (HPDs) for these products, which
lay out any health impacts of the raw materials.

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The Metamorphic Process in Nature
The metamorphic process is nature’s way of forming minerals into solid rock via high temperature and pressure over
time. Ultracompact surfacing features sintering, a manufacturing process that employs an accelerated version of the
metamorphic process where minerals are exposed to extreme pressure and high temperature, causing a profound
physical and chemical transformation. Basically, ultracompact surfacing mimics what mother nature creates in millions of
years in a fraction of the time. Manufacturing essentially speeds up the metamorphic process.

17.
Manufacturing
Process

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Manufacturing Process
The manufacturing process takes a number of hours, but a
plant can produce up to 1500 slabs a day. From start to finish
the process includes the following steps:
1. Decontamination of raw material
2. Mixing of materials
3. Addition of pigment
4. Distribution of materials on conveyor belt
5. Volume decoration process
6. Compaction
7. Drying and secondary decoration
8. Sinterization

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Decontamination and Mixing
The manufacturing of UCS materials is a multi-step process beginning with the
decontamination of raw materials. Once they are cleaned, the materials are
mixed together. The materials are kept in large hoppers prior to mixing.
It is important to note that the materials are essentially milled to a similar small
particle size that allows the rounded particulates to interact at a molecular level.
The same particle size feature of UCS helps to create a zero-porosity material,
free of the micro-defects that cause tension or weak spots in other surfacing
materials.
Pigments are similar in size and consistency to the milled base materials and
are added in a dry format to the existing dry bed of milled minerals. These
pigments are added randomly or uniformly, depending on the desired
appearance of the UCS material. Inside the pigment machine, the heat reaches
1022° F. The milled/processed raw material mixture is dry “sprayed” with a dry
pigment. The result is that small, colored mineral spheres are introduced to the
UCS material-in-process. Some colors are through-body, while some designs
are only surface due to the extreme density of the UCS material.

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Volume Decoration Process
The volume decoration process uses multiple devices similar to large printers to create patterns in and/or on the slab
and provide the color-through feature of UCS. The random nature of this process reduces the chances of visual repeat
patterns. Different combinations of colored mineral spheres are used to produce different colored UCS products. At this
stage, the material feels light, like a talc. Pictured here is a gray-based sheet. Every slab goes through this process, and
this is where the pigments are introduced to the product.

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A Multi-Step Process: Compaction
Compacted using a unique press made specifically for the manufacturing of ultracompact surface panels
Ultracompact Surface Panel
=

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Drying Process
The drying process ensures the panels are completely dry and
free of moisture
This is very important as it sets up the right conditions for the
next heat step—the sinterization process
Second Decoration Process (when needed), for surface
printing and design, after the drying process is completed

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• The kiln is about 180 meters or 196 yards long
• Temperature reaches approximately 1,250° Celsius
(2,300° Fahrenheit)
• Total resonance time is about 4 hours
A Multi-Step Process: Sinterization

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Sinterization Process
Below is a flow chart of the sinterization process.
Materials are
compacted
Minerals crystallize Crystal network in
drying kiln, 392° F
Heat increased in
in sinterization
kilns to 2192° F
for 4 hours,
materials liquify
Heat decreases and
material slowly
resolidifies into UCS

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Green Strategies
Many ultracompact manufacturers are concerned about the environment and have integrated several energy-saving
procedures into the manufacturing process. Some energy-saving strategies are listed below:
• water recovery and reprocessing
• dust recovery and reprocessing
• raw material waste recovery and reuse
• heat recovery from furnace, saving 5% of fuel (natural gas) consumption
• use of renewable energy
• automated transport system used throughout logistic centers, reducing emissions and fuel consumption
Check with your manufacturer to see if environmentally efficient techniques are being implemented in the creation of the
products used in your project.

26.
Review Question
UCS can be used as exterior cladding. List the
three types.

27.
Answer
Ventilated, bonded, and curtain wall.

28.
Attributes of
Ultracompact
Surfaces

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Key Attributes
The key attributes of ultracompact surfacing
materials include:
• limitless design possibilities
• dimensional stability
• extremely flat
• UV and thermal resistance
• scratch resistance
• low coefficient of thermal expansion
• color stability
• high heat resistance
• high abrasion resistance
• high stain resistance
• low porosity
• durability, and
• sustainability.

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Limitless Design Possibilities
Ultracompact surfacing is available in a variety of colors and multiple textures, giving designers maximum flexibility when
creating plans for both interiors and exteriors. Some of the more popular finishes include: slate, leather, wood grain,
linen, matte, shine, and natural.
Wood grain textureShine textureMatte texture

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Custom Design Possibilities
Custom design options are available and are added during the volume decorating process and/or the secondary design
process. The secondary decorating process is similar to a CNC (computer numeric control) hard surface system used on
other hard surfaces; however, tooling and set-ups are specific to UCS.

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Custom Design Possibilities: Book-Matching
Here is an example of an ultra-sized custom computer generated design. The large panels have the appearance of large
marble slabs.

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Dimensional Stability
Ultracompact surfacing materials are very consistent in both dimension and
thickness throughout the slabs, which minimizes the need for field corrections. The
unique manufacturing process produces a dead-flat panel as measured by ISO
10545-2, “Ceramic tiles - Part 2: Determination of Dimensions and Surface
Quality.” Using a consistent and dimensionally stable panel provides easier
installation and a uniform flat appearance in the final product.
Many different sizes of slabs are offered including ultra-sized. This extremely large
size opens the door for design flexibility. Being lighter than traditional flooring and
cladding materials, ultracompact surfacing is able to be installed in many diverse
applications.
Typical thicknesses are 2cm (20mm), 1.2cm (12mm), and 0.8cm (8mm), while
panel sizes are 126″x56″.

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Extremely Flat
Ultracompact slabs are incredibly flat mainly due to the manufacturing
process—compaction from a large 50-million-pound press—as compared
to classic porcelain processes that lend themselves to possible doming
and lippage problems. As a result, the ultracompact surface makes it
easier to create a flat surface when installing large-format flooring, or
provide a completely flat look for a façade application.
As you can see from the example on the right, the large, extremely flat
slabs provide a clean, even, uniform appearance for this hotel’s exterior.

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UV and Thermal Resistance
Ultracompact surfaces are highly resistant to ultraviolet (UV) light and will not fade or degrade over time. Outdoor
applications may include wall cladding, kitchens, barbeque areas, swimming pools, tiles, and furniture.

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Scratch Resistance
UCS material is the most scratch-resistant surface on the
market today and while the slip of a knife won’t cause
damage, cutting boards are still recommended to protect your
household utensils.
It is advisable to not cut directly on the countertop using
ceramic utensils because the materials are of similar hardness
and the UCS may dull the knife blade. Always check with your
manufacturer for specific warnings and instructions.

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Low Coefficient of Thermal Expansion
Unlike granite façades where you need to allow for
large expansion joints, ultracompact surfacing has
very low expansion and contraction during
temperature fluctuations as per ASTM C372,
“Standard Test Method for Linear Thermal
Expansion of Porcelain Enamel and Glaze Frits
and Fired Ceramic Whiteware Products by the
Dilatometer Method.”
This allows for extremely tight seams on the floors,
walls, or countertops, providing a cleaner, sleeker
design. Smaller joint surfaces reduce areas for dirt
to stain. The low coefficient of thermal expansion
also means that the surfacing is thermal shock
proof from both extreme heat and extreme cold,
making it extremely durable and perfect for both
indoor and outdoor applications.

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Color Stability
The manufacturer’s control of ultracompact pigmentation and decoration gives better color consistency from slab to slab,
resulting in a long-lasting product that will not fade over time. The surface you install today will maintain the same new
appearance for the life of the product. There are many color variations to choose from and the color is consistent
throughout the entire slab.

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Heat Resistance
Ultracompact surfacing can withstand high temperatures without burning, scorching, or cracking. Hot pots and
appliances like crock pots can be placed directly on the surface with no worry of damage. European Standard testing EN
13501 and ASTM E136, “Standard Test Method for Behavior of Materials in a Vertical Tube Furnace at 750° C,” classify
ultracompact surfaces as noncombustible.
However, while this type of surface can withstand extreme heat, it is always best to avoid direct contact between the
surfacing material and the metal parts of an electric broiler, cooking worktops, or ovens; very high temperature objects
such as chimneys, barbecues, etc.; and contact with flame. Always check with the manufacturer for specific instructions.

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High Abrasion Resistance
According to ASTM C1243, “Standard Test Method
for Relative Resistance to Deep Abrasive Wear of
Unglazed Ceramic Tile by Rotating Disc,”
ultracompact surfaces are even more resistant to
abrasion than granite, making them the ideal
surface for flooring in commercial applications and
other high traffic areas. While other surfaces show
wear over time, the ultracompact surface finish will
last for the life of the product and never needs to be
resurfaced or refinished.
As with any product, designers must always check
with the manufacturer’s instructions as product
performance will vary. While this type of surfacing
material has a very high abrasion resistance, it is
advisable to not polish the surface using metal
sponges or use abrasive particles unless otherwise
directed.

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High Stain Resistance and Low Porosity
Drips or splashes of common household chemicals like bleach,
drain cleaners, or oven degreasers will not harm the surface. The
low porosity of the slab means it never needs to be sealed. It
naturally prevents liquids and gasses from penetrating the surface,
making it a low-maintenance surface that is easy to clean.

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Countertop Maintenance
For everyday cleaning of these countertops, gentle soap and hot water are recommended. In the case of aggressive
stains, either from products that are resistant to normal cleaning agents or because they have remained on the work
surface for a long time without being removed, using more specific products such as solvents (acetone or universal
solvent type) is usually recommended. The accompanying table shows the various types of stains with their
corresponding cleaning products. Acid cleaning products can include any product that contains acid or descaling agents,
etc. Alkaline products include basic cleaning agents, ammonia, etc. Solvents can include products such as universal
solvents, turpentine (white spirit), acetone, alcohol, etc. Oxidants include products such as hydrogen peroxide and
diluted bleach.
Stain Cleaning Product
Grease, oil Alkaline detergent/solvent
Ink, tire rubber, resin/nail polish, candle
wax, epoxy adhesive, grouting, tar
Solvent
Rust, limescale, residual cement, gesso Acid
Wine, coffee Alkaline detergent/acid
Ice cream Alkaline detergent
Cola, fruit juices Oxidant
Nicotine Solvent/oxidant

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Flooring Maintenance
For everyday dry cleaning (of dust) of ultracompact surface flooring, use a dry mop without additives, or a conventional
vacuum cleaner, or broom. For everyday wet cleaning with a mop, use a neutral, soapy cleaning product and follow the
manufacturer’s instructions. For everyday wet cleaning of non-slip flooring and paving, use a neutral, soapy cleaning
product with a cotton mop (not a microfiber one) and follow the manufacturer’s instructions.
The regular use of other common cleaning products such as bleach, hydrogen peroxide, or caustic soda—commonly
used in commercial establishments, hospitals, veterinary clinics, industrial sites, and other public spaces—is perfectly
compatible with ultracompact surfaces without any precautionary measures required beyond those indicated by each
manufacturer.

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Flooring Maintenance
The chart below recommends the most suitable cleaning products to use to eliminate stubborn stains .
Stain Cleaning Product
Liquids and organic residues Conventional detergent and grease remover
Grease, oil, rubber, tar Degreaser
Resin, putties, silicone residue, dyes Solvent, acetone
Traces of cement adhesives Acid
Plaster Plaster remover, acid
Nicotine Abrasive cleaning product, solvent, acetone
Rust Hydrochloric acid

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ASTM Standards and Testing
Test Standard Determination Units
Typical
Ultracompact
Material
Moisture expansion ASTM C370 Average moisture expansion % 0.02
Breaking strength ASTM C648 Average breaking strength ft·lbf 3962
Flexural properties ASTM C674 Average modulus of rupture psi 10828
Water absorption, bulk density, apparent
porosity, and apparent specific gravity
ASTM C373 Average water absorption % 0.03
(impervious)
Static coefficient of friction (skid resistance) ASTM
C1028
Static coef. friction dry
Static coef. friction wet
-
-
0.08
0.66
Wet dynamic coefficient of friction (DCOF) ANSI A126.1
section 9.6.1
Average DCOF - 0.57
Relative resistance to wear (Taber abrasion) ASTM C501 Average abrasive wear index 182.2
Thermal shock resistance ASTM C484 Defects - No defects
Bond strength ASTM C482 Average bond strength psi 423
Resistance to chemical substances ASTM C650 Common household cleaning chemicals - Not affected

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ASTM Standards and Testing
Test Standard Determination Units
Typical Ultracompact
Material
Resistance to chemical
substances
ASTM C650 Common household cleaning chemicals:
Acetic acid, 3%, 10% (v/v), Ammonium chloride, 10g/L, Citric
acid solution, 30g/L, Citric acid solution 100g/L, Lactic acid,
5% (v/v), Phosphoric acid, 3%, 10%, (v/v), Sulfamic acid,
30g/L, Sulfamic acid 100g/L, Swimming pool chemicals,
Sodium hypochlorite solution, 20mg/L, Acids and bases,
Hydrochloric acid solution 3%, 18% (v/v), Potassium
hydroxide, 30g/L Potassium hydroxide, 100g/L
- Not affected
Absorption and bulk gravity ASTM C97 Average weight percent absorption
Average density
%
lb/ft3
0.02
156
Modulus of rupture ASTM C99 Average modulus of rupture - dry conditions
Average modulus of rupture - wet conditions
psi
psi
8128
7490
Flexural strength ASTM C880 Average flexural strength - dry conditions
Average flexural strength - wet conditions
psi
psi
6840
6205
Compressive strength ASTM C170 Average compressive strength - dry conditions
Average compressive strength - wet conditions
psi
psi
34409
17823
Abrasion resistance ASTM C1353 Average index of abrasion - 349

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Environmental Impact of Installation, Use, and Maintenance
According to one manufacturer’s
Environmental Product
Declaration, during the installation
phase of the UCS life cycle, there
is no impact on environmental
performance, use of resources,
and waste management.
The maintenance phase does
have a small impact due to use of
water and cleaning products.
Lastly, recycling of part of the UCS
waste as a raw material for other
products gives rise to a positive
effect as this prevents the impact
of using virgin raw materials.
Environmental performance per functional Unit (1.000 kg UCS)

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Green Material and LEED® Credits
With its zero porosity and high strength, UCS products are durable. This durability means replacement and repair will be
minimal and use of new raw materials limited.
Manufacturers who incorporate green practices to mitigate the environmental impacts of raw materials acquisition and
production contribute to further lowering the environmental footprint of UCS.
UCS products are available with transparency documents, like Health Product Declarations and Environmental Product
Declarations, along with green building certifications for low emissions, like GREENGUARD.
These green initiatives contribute to green building program credits—for instance, credits within the USGBC’s LEED v4
Materials and Resources category and Indoor Air Quality category.

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GREENGUARD Certification
An ultracompact surfacing material that has earned GREENGUARD
Certification has met rigorous and comprehensive standards for low
emissions of VOCs. The GREENGUARD Gold standard limits emissions of
more than 360 VOCs and total chemical emissions, and ensures that the
UCS material is acceptable for use in healthcare facilities.
Always check with your manufacturer to see if the UCS material in your
project has GREENGUARD or GREENGUARD Gold certification.

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NSF
NSF International is a non-profit, non-governmental organization that works with regulators and companies to issue
certification in the areas of health, hygiene , and the environment. It is currently the most recognized entity in these fields
and is endorsed by the US Food and Drug Administration (FDA) and the World Health Organization (WHO). It is the only
entity of its kind that is fully accredited by the American National Standards Institute (ANSI).
Many ultracompact surfacing materials have been tested and evaluated by NSF under NSF/ANSI 51. Always check with
your manufacturer to see if the ultracompact surfacing material in your project has NSF certification.

51.
Review Question
Label this diagram to show the sinterization process.

52.
Answer
.
Materials are
compacted
Minerals crystallize Crystal network in
drying kiln, 392° F
Heat increased in
in sinterization
kilns to 2192° F
for 4 hours,
materials liquify
Heat decreases and
material slowly
resolidifies into UCS

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Case Study: Spain Pavilion Expo Milano 2015/Flooring
Almost 1000m2 of innovative ultracompact surfacing material was placed
in the Spain Pavilion of Expo Milano 2015. The material was applied on
the floors of the public space, exhibition area, multi-purpose room,
vegetable garden, workshops, and restoration areas. Designed by the
Fermin Vazquez Studio, the Spain Pavilion aims to be a benchmark for
excellence in Spanish architecture.
Ultracompact surfacing material has many advantages for interior and
exterior flooring and stairs. Functionally, its hardness, high resistance to
abrasion, easy maintenance, and size versatility make it a perfect
product for spaces that receive heavy foot traffic.
One of the most innovative interior design features at the pavilion was
the recreation of the tomato genome, printed using ink jet technology on
the floor. This amazing floor design was created using ultra-large UCS
slabs sized 3200mm x 1440mm. Because of the innate abrasion
resistance in the floor, there was no worry that the design would rub off.

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Case Study: Spain Pavilion Expo Milano 2015/Worktops
UCS material was used as countertops in the kitchen and bar areas of the expo because of its excellent heat and scorch
resistance. The very low porosity of UCS material and its high hydrolysis resistance enabled it to be used in the
vegetable garden as well.

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Case Study: Cajamar Group Building in Almerίa
The ultracompact surfacing material selected allowed for a uniform design to be created on the exterior of the building,
making all the walls appear as if clad in a single covering. The low thermal expansion and dimensional stability of the
slabs contributed to the success of the overall design. Additionally, qualities such as its high resistance to ultraviolet rays,
resistance to frost and thawing, color stability, and high stain resistance are essential properties for exterior façades.
This building used a hidden longitudinal fastening system, which works using compression exerted by the system on the
back of the tile. The precision of the UCS material along with the metal structural support used to attach the UCS panels
contributed to its ease of installation.

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Case Study: The Chares, Atlanta, GA
The Charles is a 22-story mixed-use building that utilized
UCS from grade to the top of the building using 1.2cm slabs
for a total of 12 500ft2. The ground floor retail space had a
custom pattern designed by the architect.
When planning the exterior in an urban area, the architect
loved the superior performance of UCS, its dead flatness,
graffiti resistance, and wide color palette. UCS’s durability
will ensure this building will maintain its beautiful façade for
many years.

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Case Study: LUMA Hotel, New York, NY
The LUMA Hotel, designed by Peter Poon Architects, used UCS
slabs in 1.2cm and 2cm for a total of 900ft2 for its ventilated façade.
The slabs are attached to the CMU (concrete masonry unit)
substrate using a mechanical assembly and adhesives.
The UCS cladding is used both as a rainscreen and as a decorative
element to tie the design of the overall hotel entry together. The
UCS material was used to continue the modern, flat appearance
into the lobby for stair treads and large format flooring.
The finished façade is sleek and sophisticated. Even though this
hotel is in a busy city center, the durability, stain and graffiti
resistance, thermal shock resistance, UV stability, and other
attributes, will keep this façade looking new for many years to come.

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Case Study: LUMA Hotel, New York, NY

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Case Study: University of Missouri Stadium, Columbia, MO
In conceptualizing the University of
Missouri south endzone stadium
entrance, the architect wanted to
create a stunning aesthetic with an
extremely durable product. A custom
design was created to match the
team’s iconic diamond pattern using
1.2cm slabs in a black gloss and black
matte finish.
Additionally, UCS offered the following
benefits: stain/graffiti resistance, a
matte and gloss finish, zero-porosity,
UV resistance, and dimensional
stability.

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Case Study: University of Missouri Stadium, Columbia, MO

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Rafa Nadal Academy, Manacor, Mallorca
Rafa Nadal Academy by Movistar, came into
being in 2016 with the aim of becoming a
benchmark centre in the world of tennis at an
international level. The architectural project
consists of more than 24 000m2 located
throughout a range of facilities including the
halls of residence, training school, hotel, sports
courts, changing rooms, bar, clinic, and
outdoor common areas.
The project was fitted with more than 40 000
m2 of UCS panels of all thicknesses and for
different applications, such as facades,
flooring, interior wall cladding, countertops,
stairs, baseboards, swimming pools.

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Rafa Nadal Academy, Manacor, Mallorca
The ventilated façade of the Rafa Nadal Academy is composed mainly of UCS large format panels and glass. The
qualities of UCS, such as its high resistance to ultraviolet rays, its resistance to frost and thawing, its color stability and
high stain resistance are essential properties for its use outside and the result is visually spectacular.
David Iglesias, Architect: “The best feature of [UCS] is something which we architects love: its format. It allows you to
play with large dimensions and with different forms of quartering. It is very easy to work with [UCS] and the result is
perfection.”

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Case Study: Porsche Design Boutique, Oak Brook, IL
In conceptualizing the Porsche Design boutique,
architect Eric Styer of DXU Architects sought a
façade material that would embody the client’s
design philosophy and that would set it apart from
adjacent storefronts in an upscale retail
development.
The design concept required a material that would
achieve a minimalist, homogeneous look, with
understated detailing. Key considerations such as
budget, performance, and aesthetic eliminated
initial materials including stone, tile, and fiber
cement board. However, the zero-porosity, UV and
freeze/thaw resistance, and dimensional stability
characteristics of UCS made the material an ideal
solution for the installation.

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Case Study: Porsche Design Boutique, Oak Brook, IL
The façade was applied as a rainscreen that is structurally
independent from the base building structural system,
allowing for water and air to circulate behind the 1.2cm
thick, 320cmx144cm (approx. 5ftx10ft) UCS slabs,
installed using a railing system. The large format size of
UCS slabs minimizes the number of visible joints on the
façade, creating a sleek, sophisticated appearance that
mirrors the brand identity of Porsche.
Additionally, the durability of the façade was a key
consideration. The storefront is located at a high-traffic
corner in the retail development so the material must be
able to stand up to day-to-day wear and tear without
damage. Foot-traffic concerns aside, the climate is highly
varied from season to season, so the freeze/thaw
resistance and stability offered by UCS is essential in
ensuring the façade’s integrity.

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Case Study: Case Study: ToHa Project, Tel Aviv, Israel
This project combines more than 300 000ft2 of
UCS in ventilated facades, flooring, elevators,
ceiling, and interior wall cladding.
From the functional point of view, this ambitious
project inverts the organization of the conventional
office block, placing all the infrastructure and
machinery on the first floors enabling the roof to
become a public space, accommodating an
upscale restaurant with views of Tel Aviv and the
Mediterranean Sea.
The offices start on the seventh floor, allowing the
occupants to take advantage of natural daylight
and beautiful views.

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Case Study: ToHa Project, Tel Aviv, Israel
Using eleven different colors and four different thicknesses: 4, 8, 12, and 20mm. This project reflects the unlimited
design potential of ultracompact surfacing.

67.
Summary

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Summary
Using ultracompact surfacing materials in building projects
gives designers and architects many options for both the
exterior and interior.
The UV resistance, dimensional stability, and low thermal
coefficient allow UCS materials to be installed in almost
any climate, providing the builder with a uniform, flat
external appearance for cladding and durable, scratch-
resistant external flooring.
Using UCS materials inside can lend a continuous look for
internal floors and stairs. Its scratch- ,scorch-, and mold-
resistant surface makes it a perfect choice for kitchens and
bathrooms. Because of the many textures available, such
as leather or wood grain, UCS materials will enhance any
décor.

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Conclusion
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