We designed a bench: architectural terra cotta beyond building

Pelli Clarke & Partners took part in the 2024 Architectural Ceramic Assemblies Workshop (ACAW), presented by Boston Valley Terra Cotta (BVTC), Carnegie Mellon School of Architecture (CM SoA), and the University at Buffalo School of Architecture and Planning (UB SAP).  

For nine years, the annual workshop has supported architects’ hands-on research and development of innovative uses with terra cotta in large scale building assemblies. Following three months of design and four months of preliminary fabrication, ACAW is a weeklong event that features factory tours, lectures, and a hands-on experience for teams to assemble their respective projects in the UB Fabrication Workshop. This has been the fourth year the PC&P team has participated in ACAW.

Bridging the gap

For ACAW 2024, the PC&P  team proposed continuing its 2022 research to address an increasing need with buildings to have beautiful and durable outdoor work and play places. The issue has grown prominent in PC&P’s own work, as the scope of architectural design extends further beyond façades and interiors, as it did with 2100 Pennsylvania Avenue, to exterior spaces that can benefit with time-tested materials like terra cotta.  

Refining previous designs

At ACAW 2022, while finishing construction administration for 2100 Pennsylvania Avenue, PC&P sought ways to enhance the project’s outdoor spaces with in-the-round seating using terra cotta assemblies and explored design variations through slip casting. Upon this experience, the workshop proved the case that glazed terra cotta might be an excellent material choice for sustainable, resilient, and self-supporting outdoor furniture. BVTC encouraged PC&P to continue developing the modular bench design by seeking improvements to the existing design forms and incorporating new beneficial features. 

2024 ACAW goals

At ACAW 2024, the team aimed to advance the 2022 design with greater variations in module shapes and specific features: 

• Modular fastening and securing systems 
• Integrated Lighting
• Planting
• Ribbed Texturing

For the surface glaze, the team studied warm, lustered bronze, alluding to traditional bronze figures and sculptures that animate many of the world’s most celebrated urban landscapes. 

ACAW workshop

The weeklong workshop took place at the University of Buffalo School of Architecture and Planning, which included hands on collaboration on the team’s design as well as informative interactions with industry professionals who shared their research and experiences with terra cotta. In addition to the valuable workshop time, the team participated in educational and inspiring tours at the Boston Valley Terra Cotta, Silo City, and Frank Lloyd Wright’s Martin House.  

The workshop gives PC&P team members hands-on experience with the terra cotta and fastening systems. The workshop effort included assembling the various modular terra cotta pieces with different fastening systems, inserting 3D printed planter linings, and plantings. The modular assembly allowed the team to explore a wide variety of configurations in real time on the University of Buffalo’s campus. 

A modular terra cotta bench

To illustrate the modularity and potentials of the bench design using only 8 pieces in total (4 with backs and 4 with planters), the team explored configurations both digitally and physically on-site. The goal was to design a market-ready product that could be used to adapt to the requirements of the site with minimal production pieces.  

Details

Shape

The pieces were designed to have ergonomic sloping edges for comfort when sitting. This was an intended improvement from the 2022 ACAW design that featured a linear seat and back. 

In plan, the pieces are shaped in both wide nose and narrow nose shapes to allow for both linear and circular aggregations. 

Arch

To allow access panels to service any connections or the light fixtures, the pieces feature a textured arch design that allows for wider footing and a hidden access panel.  

Planter

Planter pieces were created to be attached to the bench pieces in both narrow and wide sizes. These planter pieces also feature 3D printed inserts to allow for planting and drainage.  

Texture

Textured ribbing helps with the support wall’s structure and gives the bronze lustered glazing a rippling light effect, alluding to traditional bronze sculptures of urban landscapes. 

Lighting

A channel under the seat nose houses a concealed linear light fixture, serviceable through the access panel at the underside of the bench piece. 

Connections

The design features connection points to attach the planter pieces to the bench seats through screws and fasteners. To attach the seat pieces together, the design features horizontal connection points aligned to allow seats connections with screws and fasteners. These connection points can be serviced through various access panels on the underside of the bench pieces.