A Groundbreaking Innovation in Sustainable Masonry
In 2024, after two years of intensive research and development, NEUF architect(e)s, Webster & Sons, and Permacon introduced DUAL, a revolutionary concrete brick designed to address one of the construction industry’s most urgent challenges: carbon emissions. The new brick, developed in Canada, reduces life-cycle carbon emissions by more than 20%, establishing a new standard for sustainable building materials.
The innovation comes in response to an alarming global statistic: the construction sector is responsible for nearly 40% of carbon emissions worldwide. Recognizing this, NEUF architect(e)s — one of Canada’s most respected architectural firms — launched a research collaboration in 2022 with the well-established masonry company Webster & Sons and Permacon, Canada’s largest producer of concrete products. The mission: to create a more environmentally responsible brick without sacrificing performance, cost-effectiveness, or aesthetic appeal.
The DUAL Brick: Material and Design
The DUAL brick is unlike conventional concrete blocks. Its performance advantages and sustainability credentials lie in both its composition and structure:
- Material Innovation: The bricks incorporate recycled materials and are manufactured in a way that significantly reduces cement usage, one of the most carbon-intensive components of concrete. This contributes directly to the reduction of over 20% in carbon emissions across the product’s life cycle.
- Honeycomb Geometry: The brick features a unique honeycomb structure, which uses nearly one-third less material than traditional bricks. This not only conserves resources but also reduces the weight of each brick, improving transport efficiency and ease of installation.
- Dual Surface Texture: Each brick has two finish options — one side is smooth, while the other is grooved — providing aesthetic flexibility for different architectural expressions. This dual surface enables designers and architects to create visual contrasts or blends, without needing multiple product lines.
- Available Formats:
- Metric Norman: 57 x 90 x 290 mm
- Metric Jumbo: 90 x 90 x 290 mm
- Color Options:
- Zurich (gray)
- Petra (yellow)
- Belfast (red)
Each variation offers unique design potential while maintaining the same environmental credentials.
Environmental Certification and Industry Standards
The DUAL brick has been issued a certified Environmental Product Declaration (EPD). This internationally recognized certification confirms that the product meets stringent environmental impact standards across its entire lifecycle. In addition to the EPD, the DUAL brick is compliant with CSA (Canadian Standards Association) standards for concrete masonry units, ensuring reliability, durability, and safety in real-world construction applications.
This combination of certified performance and third-party sustainability validation positions the DUAL brick as a pioneering choice for architects, developers, and builders who are committed to low-carbon construction.
The Collaboration Behind the Brick
The success of the DUAL brick project lies in the strategic alliance between three leading Canadian companies:
- NEUF architect(e)s: As Canada’s most diversified architectural firm, NEUF played a leading role in defining the design criteria and sustainability goals for the project. Hugo Gagnon, Partner Architect and Sustainability Manager, emphasized the importance of developing a product that is both carbon-conscious and fit for purpose in real-world construction.
- Webster & Sons: This family-owned business brought decades of experience in masonry and construction logistics. Their input ensured that the DUAL brick would not only meet design expectations but also improve on-site handling, boosting productivity and worker efficiency.
- Permacon: With over 70 years in concrete product manufacturing and nine production plants across Canada, Permacon offered the industrial scale and technical expertise required to bring the DUAL brick from concept to market. Their newly established R&D facility in Anjou played a central role in the material testing and optimization phases.
A Localized, Scalable Solution for Global Impact
A key strength of the DUAL brick is its scalability. Unlike niche eco-products, the DUAL brick is designed to be economically competitive and widely applicable, making it suitable for:
- Residential buildings
- Institutional architecture
- Commercial developments
- Public infrastructure projects
This ensures that the product doesn’t remain an experimental alternative, but rather becomes a mainstream building solution.
Furthermore, with nine local Permacon plants manufacturing the bricks, the carbon emissions associated with transport and logistics are significantly reduced. Local production ensures quicker delivery times and lowers the project’s overall environmental footprint.
Shaping a Sustainable Future
The launch of DUAL is more than a product release — it’s a statement about the future of construction. It exemplifies how cross-sector collaboration, design innovation, and ecological responsibility can intersect to create a next-generation building material.
“We’re acting today to protect the future and to build the foundations of a more sustainable world for coming generations,” said Lucas Vallon, President of Permacon.
By offering a solution that balances aesthetic value, structural integrity, and sustainability, the DUAL concrete brick represents a benchmark for eco-conscious construction. It provides a clear path forward for how building materials can be reimagined in the age of climate change.
As the demand for carbon-neutral and circular construction practices grows, innovations like DUAL will be pivotal in reshaping the industry from the ground up.
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