Tri Forged Studios

3D Printing - Casting - Mold Making - Production

Gears of War 5 – Concrete Bunker Photo Op (2019)

 
 
 

This project was created as a companion build for the Hive Wall at Toronto Fan Expo 2019. We were asked to design interactive cover props that attendees could hide behind while getting their photo taken.

The full set included:

  • A repurposed steel barrel

  • Two concrete-style bunkers

  • A stack of sandbags

The barrel was an actual steel drum that we distressed using a pickaxe and drill bits to simulate dents and bullet damage. It was painted black, weathered using a mix of dry brushing and rust techniques, and sealed with a matte clear coat for durability.

The bunkers were built from lightweight Styrofoam panels and reinforced with epoxy. We carved in battle damage and finished them with Buddy Rhodes’ vertical concrete mix, tinted and applied directly to the foam to mimic the texture of real concrete. Once cured, they were weathered with black washes and dust for a more realistic, aged appearance. Despite their look, each bunker was light enough to lift with one hand.

To safely replicate exposed rebar, we molded a piece of real rebar and cast it in flexible, pigmented silicone rubber with a bendable metal core. This gave us a realistic effect that was safe for public interaction.

The sandbags were made using burlap sacks filled with packing peanuts to keep them lightweight. We glued them into a stack using construction adhesive and gave them a weathered, battle-worn look with paint and distressing.

This was an incredibly fun build and it was rewarding to see fans interact with the set throughout the event.