Father-Daughter Duo Transforms Surfboard Waste into Furniture and Objects

A father-daughter team in Spain is pioneering a novel approach to waste reduction in the surf industry, transforming discarded surfboard materials into functional and aesthetically pleasing furniture and everyday objects. Hall 5 studio, based in Zarautz on the Basque coast, is breathing new life into resin and fiberglass offcuts that are typically generated during surfboard manufacturing.

The initiative, spearheaded by Ignacio Abaitua and his daughter Carlota, explores how these often-discarded materials can be repurposed into practical items that showcase unique colors and textures. Ignacio, with over three decades of experience overseeing production at the Pukas surfboard factory, initiated research into reusing the solidified resin and fiberglass that accumulated in the workshop. By early 2024, their efforts focused on developing an artisanal process that incorporates at least 50% recycled material into each creation.

Essentials Series: Reimagining Resin

The studio’s “Essentials” series exemplifies this commitment to material reuse. High-performance surfboards, often custom-made, present challenges for automated production. During the “glassing” process, excess polyester resin hardens on worktables, forming blocks that are unusable for making new boards. Hall 5 collects both transparent and pigmented resin from these surfaces. The transparent resin, common in performance boards, develops a distinctive bluish hue when layered thickly, while colored resins yield unpredictable combinations based on the factory’s daily production schedule.

For the Essentials series, these solid resin blocks are crushed into granules and mixed with epoxy resin. This composite material can be left uncolored or pigmented before being poured into molds. Reclaimed fiberglass layers are incorporated for added reinforcement. The resulting objects, featuring a dense, terrazzo-like surface, consist of approximately 50% recycled material.

Unic-oh! Pieces: One-of-a-Kind Designs

Pushing the boundaries of unique design, the “Unic-oh!” pieces utilize larger fragments of colored resin. These fragments are manually broken with mallets and hammers, then artfully arranged within molds and bound with epoxy. Because the available colors are intrinsically linked to the surfboards produced at the factory, each “Unic-oh!” creation is inherently a one-of-a-kind piece. These singular objects can contain up to 70% recycled material, with the visual remnants of surfboard production becoming the defining characteristic of each design.

The studio’s workspace is where these reclaimed materials are transformed by hand. The H5 x Auzmendi table, for instance, was specifically designed for a shop window in San Sebastián, highlighting the potential of these reworked materials. Candle holders and corner lamps are among the other items showcasing the varied colors and textures achievable through this innovative process.

Impact on Sustainable Design

Hall 5’s work directly addresses the growing need for sustainable practices within the design and manufacturing sectors. By diverting waste from landfills and giving it a new purpose, the studio not only reduces environmental impact but also creates desirable products with a compelling narrative. The unpredictable nature of the recycled materials ensures that each piece possesses a unique aesthetic, appealing to consumers seeking original and eco-conscious designs. This venture also underscores the potential for small-scale, artisanal processes to contribute significantly to the circular economy.

Key facts

The work of Hall 5 is a compelling example of how creative reuse and material innovation can lead to beautiful and functional design. For readers interested in sustainable architecture and design, this project highlights a practical and inspiring application of upcycling within the context of sports-related manufacturing.

Source: https://www.designboom.com/design/surfboard-offcuts-furniture-objects-hall5/