Rethinking Architecture with Honeycomb Panels| Hexpressions

In an era where sustainability is emerging as a way of life, Hexpressions pioneers an innovative material for socially impactful design.

Focussed on sustainability and community well-being, founders Shilpi Dua and Abhimanyu Singh use honeycomb panels to create cost-effective, modular homes.

Inspiration and Intent: As architectural students, the routine act of making models from paper sparked deeper interest in studying paper’s properties and potential as a durable building material. Research led them to develop honeycomb panels from recycled paper. Using paper honeycomb as the core, and either cement board, wood, or stone as the outer face material, these composite panels have not only brought to life an unconventional construction material that is sturdy and has significantly reduced environmental impact, but also one that has drastically reduced construction time and conserves water by an impressive 90%. This solution especially aims to support underserved communities with permanent shelter, empowering people to build their own homes and live a dignified life.

Efficiency and Adaptability: One of the most remarkable aspects of paper honeycomb structures is their rapid assembly. With the help of trained local builders, paper homes can be constructed in just a month, far quicker than traditional methods, and boast a lifespan of approximately 30 years. Moreover, they are flexible, versatile and have amazing acoustical and insulation properties. These panels are designed to function optimally in a broad temperature range, from -15°C to over 50°C, making them suitable for diverse climatic conditions.

Due to their lightweight nature, these panels are especially beneficial in hilly terrains, where conventional construction materials can pose logistical challenges. During the COVID-19 pandemic, Hexpressions demonstrated the scalability of the material by producing honeycomb beds in large quantities for emergency use.

Material features: Each panel undergoes rigorous testing to meet local building codes and safety standards, ensuring fire resistance and structural integrity. Customisation is another key feature, with thickness options ranging from 10mm to 150mm. To minimise waste, window and door dimensions are carefully planned based on panel sizes.

Manufacturing of the panels involves a heating process that makes them inherently termite and water resistant. Additional waterproofing treatments using specialised paints and sprays further enhances their longevity. All materials used are non-toxic, ensuring good indoor air quality and eliminating harmful chemicals from production.

Durability remains a critical focus. Structural reinforcements enhance performance in extreme conditions, and recent tests have demonstrated stability even against high winds and heavy rainfall. Ongoing research continues to push the boundaries of resilience against natural disasters.

Innovation in Action: A notable project in collaboration with Selco Foundation saw the creation of handicapped-friendly retail shops for low-income workers in Karnataka. This initiative has provided a permanent and stable alternative to makeshift setups, significantly improving the community’s quality of life.

Challenges, however, are part of the journey. Initially, the panels suffered chipping during transportation due to their lightweight nature. Experimentation with protective layers and on-site assembly techniques have eventually resolved this issue. Another major hurdle is market scepticism, with clients hesitant to use unconventional materials, particularly in India.

“It’s crucial to keep innovating and reducing waste, no matter how small the action may be,” emphasises Shilpi. As they look ahead, the duo hopes for greater acceptance of such innovative materials, envisioning a future where we grow in harmony with the planet.

Fact File:
Design Firm: Hexpressions, Jaipur
Founder and Principal Architects: Shilpi Dua and Abhimanyu Singh
Photography courtesy of the architects.