A landmark exploration of material, light, and logistics, the Onyx Square project demonstrates how complex natural stone systems can be transformed into precise architectural outcomes. Through an integrated approach to design, engineering, and fabrication, the project redefined the possibilities of onyx as an exterior cladding material, balancing design ambition with technical certainty and risk control.

The brief and context

The Onyx Square was conceived as the central element of a major urban development, designed to create a luminous architectural identity through the use of translucent stone façades.

The design intent required the use of onyx as an exterior cladding material—an unconventional and technically demanding choice due to its inherent fragility, variability, and unpredictability. Unlike conventional façade materials, onyx introduces both aesthetic richness and significant engineering challenges.

The project was inherently global in nature. Design was developed in London, engineering inputs were coordinated internationally, raw material was quarried in Greece, processed across multiple European facilities, and ultimately assembled and installed in the Middle East.

This fragmented supply chain introduced a high level of complexity, requiring precise coordination across multiple stakeholders including designers, fabricators, laminators, and installers. Each stage introduced new variables affecting cost, schedule, and quality.

At the core of the project was the need to protect design intent while navigating technical uncertainty. This required early-stage integration between design, material sourcing, fabrication methods, and installation strategy—moving away from traditional linear workflows toward a more collaborative and reciprocal approach.

Engineering

Stone system design

Façade engineering and material selection

Delivery

From specification to site completion

We specified the stone, designed the fixing details, and managed the installation process to ensure precision and durability.

Solutions

Technical challenges solved

Three critical problems addressed in the façade design

Technical

Material Instability & Performance

Stabilizing structurally inconsistent onyx through resin infusion, lamination with glass, and controlled fabrication processes.

Aesthetics

Extreme Design Complexity & Variation Control

Managing thousands of unique stone pieces with varying cuts, colors, orientations, and positions across multiple buildings.

Precision

Logistics, Tracking & Risk Management

Developing systems to track each stone from quarry to final installation, reducing waste, errors, and program risk.

Timeline

Project phases from design to completion

Concept & Material Strategy

Early engagement to validate the feasibility of onyx as a façade material, including testing, sourcing strategy, and alignment with design intent. Iterative development through physical and digital mock-ups, including backlighting tests, material calibration, and performance validation.

Engineering & System Development

Creation of composite stone-glass systems, integration of LED backlighting, and development of fixing and support strategies.

Digital Tracking & Coordination

Implementation of a custom database and visual interface to map each stone’s position, orientation, and characteristics across the façade.

Fabrication & Installation

Multi-stage fabrication across international facilities, supported by photographic tracking, dimensional calibration, and continuous verification.
Sequenced installation of panels with precise alignment to achieve the intended visual gradient and architectural expression.

Questions

Common questions about this project's approach and execution

How was stone selected?

We examined samples in natural light across seasons. The stone needed to weather predictably in London's climate while meeting the architect's aesthetic vision. Three quarries were evaluated before selection.

Why was onyx considered a high-risk material?

Onyx is structurally unstable, highly variable in composition, and prone to breakage during processing. Its unpredictability makes it difficult to standardize without advanced engineering solutions.

How was consistency achieved across the façade?

Through a combination of material selection protocols, lamination techniques, and digital tracking systems that controlled placement, orientation, and visual continuity.

What made this project unique from a technical perspective?

The integration of design, fabrication, and logistics into a single coordinated workflow—allowing real-time decision-making and reducing risk across the entire supply chain.

What was the key innovation?

The development of a “virtual dry-lay” system that allowed designers to visualize and adjust each stone before fabrication, eliminating traditional limitations and significantly reducing waste.

Need more information?

Reach out to discuss this project in detail

“From material uncertainty to architectural precision.”