Dual, a new concrete brick for carbon neutrality

The construction sector generates nearly 40% of carbon emissions worldwide, and to find effective solutions, Canada’s largest and most diversified architecture and design firm, NEUF architect(e)s, launched a research project in 2022 together with Webster&Sons and Permacon — a collaboration that led to the innovative DUAL concrete brick.

The former is a family company that has contributed to quality building in Eastern Canada over the years, often through specialized products. Permacon is Canada’s largest concrete product manufacturer, with more than 70 years of experience. “In this partnership, our role was to ensure that a product responds to all end-use needs, while aiming to reduce carbon emissions by 20%,” explains Hugo Gagnon, Partner Architect and Sustainability Manager at NEUF.

The collaboration began in 2022 intending to find a solution to reduce the environmental impact of each company in the construction sector. The focus was on designing a new approach to brick production, to create a product that is environmentally and socially responsible while remaining economically competitive. After two years of research at Permacon’s new facility in Anjou, the new DUAL concrete bricks are ready for the market. With the help of product experts, the composition and physical properties of the model have been optimized, and new studies are already underway to further reduce the carbon footprint of concrete products.

Thanks to its innovative honeycomb structure, DUAL reduces the amount of materials used by nearly one-third compared to traditional concrete. The product conforms to CSA standards and comes with a certified Environmental Product Declaration (EPD), indicating a reduction of over 20% in carbon emissions during its lifecycle, thanks to the inclusion of recycled materials in its composition.

The DUAL brick series is available in three natural tones – Zurich (gray) / Petra (yellow) / Belfast (red) – and two models, Metric Norman (57 x 90 x 290 mm) and Metric Jumbo (90 x 90 x 290 mm). Each of the six options features two surfaces, one smooth and one grooved, which can be varied and adapted to any project. The dimensions and structure of DUAL also simplify on-site handling, making installation faster and more efficient.

“With more than a hundred years of collaborating with masonry companies, we understand the importance of designing materials that facilitate use and productivity. Through its unique aesthetic and innovative approach to sustainability, the new DUAL concrete brick completely reflects the mission and vision of Webster & Sons.” notes William Webster, President of the company.

Lucas Vallon, President of Permacon adds: “With nine local plants, we develop innovative, sustainable solutions that help reduce carbon impacts. We’re acting today to protect the future, and to build the foundations of a more sustainable world for coming generations. The new DUAL concrete brick is the perfect product for this ambitious vision.” Thanks to its properties and innovative design, the DUAL concrete brick is more sustainable than current standards and sets a new benchmark for the construction industry.