Welcome to 250AGA, a weekly exploration into what architects should know. Responding to Michael Sorkin’s outline of 250 things, Amery Calvelli, Adjunct Curator of the Poole Centre of Design, explores “the basics of mud construction.”
This week, Amery catches up with Ronald Rael and Virginia San Fratello who run architecture studio Rael San Fratello.
Explore #250AGA on our website: https://www.youraga.ca/support/our-sp…Welcome to 250AGA, a weekly exploration into what architects should know. Responding to Michael Sorkin’s outline of 250 things, Amery Calvelli, Adjunct Curator of the Poole Centre of Design, explores “the basics of mud construction.”
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um
0:08
so i’d like to begin uh with
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uh ron i i kind of i read an article
0:15
that talked about
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the fact that you grew up in an adobe
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house built by your great grandfather
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in the san louis valley of colorado
0:24
and i also know that there’s this early
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resource
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called earthenarchitecture.org i believe
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that was founded by you
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maybe in 20 2003 so 17 years ago
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um so there’s this deep uh you know
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knowledge about
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uh earth as a material and i’m wondering
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what what are the routes for you where
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does this come from this
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this quest for earth as material
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well in my own personal history it comes
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from
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having lived in buildings made of earth
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and
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not only uh in my lifetime but
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my family has lived in buildings made of
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earth for
1:08
uh perhaps time immemorial whether you
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trace my
1:12
european lineage to southern spain
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or you trace my indigenous ancestry here
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in the pueblos of new mexico
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and so i have that very deep connection
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to earth but i also think that all
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humans have that deep connection to
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living in buildings made of earth and
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they may have been disconnected from it
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in their
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in their recent histories in their
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recent family histories
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but for 10 000 years humans have lived
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primarily in buildings constructed of
1:44
earth in every continent
1:45
on on the planet except for one of
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course which is too cold
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but but i think that we all as humans
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not only have this this deep
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historical connection to earth but i
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think we also have
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a biological connection to earth in that
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we
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like some other animals on the planet
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have evolved
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to make those buildings made of earth so
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which means that our own
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physical makeup has allowed us to
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construct those kinds of buildings that
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way we have the building to
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grasp mud and to shape mud and ceramics
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have been some of the
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earliest technologies that we as humans
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have developed and so
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i think that our connection goes beyond
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just
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a connection of memory but it goes to
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connection of biology
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connection of genetics a connection of
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geology right so it’s in our dna
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i believe so in many ways i mean we look
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at
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what creates the the fundamental
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proteins
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for the creation of life it comes from
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molecules that are associated with clay
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interesting we think we think sometimes
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about that as a
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as a kind of biblical story right that
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people come from dust to dust or
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but it’s also a it’s
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a scientific truth that that you can
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create the foundations of life
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by combining certain molecules of clay
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the fundamental
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proteins and amino acids
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yeah i think one of the things that
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really interests me about the
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architecture that the two of you do
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in your practice together is um
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an exploration of materials that are not
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necessarily
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typical for structures salt sugar
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coffee grounds earth maybe being one of
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those or dirt
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but i want to kind of move to emerging
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objects for just a moment
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and um i believe there was
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a smithsonian article that came out that
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talked about the 40 things that you need
3:53
to know in the next 40 years
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and one of those things was the quote
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that
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sophisticated buildings would be made of
4:00
mud and so i
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wonder if we could start from that place
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what sparked your interest
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in that comment and what did that um
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prompt in terms of emerging objects well
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interestingly
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one of the first materials that we
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tested in our binder jet 3d printer was
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clay it was a ball clay if we go
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back to i think 2010 and
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we were experimenting with recipes for
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printing with clay that were open source
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that we had found online and we tested
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ball clays and porcelains
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and then we were invited to participate
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in the bnla of the americas which was in
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denver
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and we decided to 3d print with sand
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so in order to do that we had to hack
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our printer
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and experiment with different sand
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formulations we
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experimented with um eventually adding
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a cement to the matrix that we were
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printing with
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and as we were printing for that exhibit
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we were printing objects that fill
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fit in the build bed of the printer
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which is eight inches by eight inches by
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ten inches
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we were laying them out and we realized
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oh everything’s the same size so we
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started printing
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parts that we could aggregate together
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to make a hole
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so suddenly we we realized oh we can
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stack parts and make something tall
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or something long and then we started
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stacking in both directions and realized
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oh we don’t have to just make models we
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can actually make
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buildings through this technology we can
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make
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building blocks of the future and we can
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make them out of sand
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we can make them out of cement we could
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make them out of
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clay chardonnay etc so that’s
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a little bit of the the origin story for
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us
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and i think when we read that quote we
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realized that we were
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kind of on the cusp of thinking about
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how we might build
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for the future using this nascent
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technology
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with these really old traditional
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materials
6:09
that have proven themselves over time
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you know
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the um earthen construction has
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this flywheel effect of keeping
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buildings
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warm in the interior in the winter and
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cool in the summer in arid environments
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and we can capitalize on just the
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inherent
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quality of the material itself
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one thing about that smithsonian article
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that predicted the
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sophisticated buildings of the future
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will be made of earth is that
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uh i always found it interesting that i
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thought that sophisticated buildings of
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the last ten thousand years
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were also constructed and that that
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inherent to earth is construction is a
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sophistication
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and we as humankind have been developing
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that material
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for uh thousands of years and so it’s
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the material that we’ve been working on
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the
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longest it’s fundamentally the most
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sophisticated
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material that we have under our control
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let’s build the environment and so
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because we’ve had such a long time with
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this material what does that allow us to
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do how do we understand it better
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because we’ve been
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working with it or do we maybe we left
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it behind for some time
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well you know i think increasingly we’re
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leaving it
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behind and and it’s unfortunate
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so fewer and fewer people around the
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world are living in buildings made of
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earth because they’re moving
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towards other building materials that
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are extremely resource
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intensive concrete for example
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and i think what what we have not been
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able to do
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with earth is to bring it into
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a capitalistic economy so no one can
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really make money
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building buildings made out of earth but
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certainly building buildings made out of
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concrete or steel those
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are are materials that have a
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capitalistic power
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and earth does not and so it it’s almost
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like the material has resisted itself
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bringing itself into the economy and so
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i think
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given the global crises that we are in
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it’s an opportunity for us to look back
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at the sophisticated technology that we
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have developed
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and begin to use it in our capacity to
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create
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elegant buildings to great housing for
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those who need housing
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there are examples of almost every
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architectural typology man of earth
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around the world there are airports made
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out of earth in yemen for example
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there are museums embassies and so
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i think it’s a building material that we
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should not forget
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and i know you authored a book about
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earth architecture
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in 2008 or 2009 so we’ll include a link
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to that as well so you’ve done a lot of
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studies around
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what’s been built with earth right
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we both have a really nice opportunity
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to travel around the world and look at
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buildings constructive earth
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and the diversity of earth and
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construction around the world and the
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many different kinds of techniques
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that are available to use only
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fundamentally earth and humidity
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may be sometimes mixed with some organic
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material
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to make to make shelter
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so i think in looking at the
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structures that you’ve built using a 3d
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printer
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you describe this printer as old
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technology but in the photograph it
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looks almost robotic
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there’s this long arm that is filling
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earth
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into into sections or into structures
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and i wonder if you could talk about
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what the use of new technology does you
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started to comment about how it might
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change
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economy or the access to building
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with earth but um what is this merging
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of new technology
9:59
with the old material what does it allow
10:02
in your in your views well we we are
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using a
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robotic arm to 3d print with the
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earth and i think um it does a couple of
10:13
things
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it allows us to build more quickly
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than we might be able to by hand
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right so we can design something in the
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computer
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and then the robot is able to well we
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have a continuous hopper
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that pumps the earth up to the robot and
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the robot
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puts it in place so we can make complex
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structures
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um we can work more quickly
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um i think you know for someone like me
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i might not be able to lift a 40 or a 50
10:45
pound adobe
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over my head and stack it but the robot
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can can build higher than i am tall
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right
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so i think the limitations that
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might traditionally be there are negated
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by using the robotic arm i mean
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what’s what we’re discovering which is
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really interesting and it was our theory
11:06
that’s
11:07
that’s proving to be true is that
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we could create a printer that’s smaller
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than the object that we’re creating
11:14
and so and so we can print a very large
11:17
object
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and also right now there are primarily
11:21
just
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two people at a time on the building
11:24
site
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and the tasks are
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to sift mud to sift dirt
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to mix to make mud and to press the
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button on the printer
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and so if you think about that as well
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there are times when
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when only one person could actually
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execute this job
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to construct a very large structure so
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these are the largest structures that
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we’ve
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made this summer and they are 12 feet
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tall
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and they are large as a as a small room
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so they’re really occupiable and two
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people could sleep in
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in one of the rooms that this printer
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can make
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and the printer itself is very
12:04
lightweight and so
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i think one of the things this process
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does is allow for
12:11
someone with very little skill in
12:14
robotics for example
12:15
or computer modeling or construction
12:19
to actually participate in the making of
12:21
a building
12:22
now having said that that’s not that is
12:25
not necessarily novel
12:26
again for thousands of years uh
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just a couple of people using mud have
12:31
made buildings with their own hands
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but i think what this also does it
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allows for the deposition of mud to
12:39
occur
12:40
in ways that might not be so easy to
12:43
do by hand and that’s pretty exciting
12:46
and i think
12:46
while this research is fairly new to us
12:50
we’re discovering that we can make uh
12:52
stairs we can make
12:53
insulated wall cavities we can make
12:56
surfaces that have micro shading we can
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make
12:58
structures that are very thin but very
13:01
strong
13:02
we can use less material so there’s
13:04
there’s i mean this is research that’s
13:06
just beginning over the last couple
13:07
years printing these very large
13:09
structures but
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uh i can see years and years of
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continued research on what’s possible
13:16
using this method
13:17
one thing that you know where as ron
13:19
said we’re at the very beginning
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one thing that i really like about um
13:24
this traditional adobe house that
13:27
uh is in juan’s family is that the
13:29
interior of each room is plastered with
13:31
a different color earth
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and i love that i think it’s so
13:34
beautiful and i love the notion that we
13:36
might be able to
13:37
3d print with different color earths to
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get different effects
13:41
on the interior or for example we’ve
13:44
been
13:45
digging wild clays in the mountains of
13:47
northern new mexico
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and the clay has mica in it so we could
13:51
have a kind of
13:52
shimmer right or reflectivity in the
13:54
material and
13:55
and so we’re just at the cusp of of
13:58
thinking about
14:00
the expanse of materials that we could
14:02
print with and how they might transform
14:05
this process as well or affect the
14:07
process so
14:08
yeah this really opens up the
14:10
possibilities it’s very fascinating
14:12
yeah i’d love to end with just a
14:14
question about
14:16
i know we were supposed to talk about
14:17
the basics of mud construction and we
14:19
have been essentially talking about that
14:21
but i’d like to ask
14:23
uh about if we think about rammed earth
14:26
or
14:26
mud or adobe structures a lot of times
14:29
they are
14:30
um assumed to be uh designed with fewer
14:33
means if we have less means we design in
14:35
that
14:35
in that material and so i i’m interested
14:38
in the social dynamics of mud
14:40
and what that means you know how how are
14:44
you confronting
14:45
that perception in a different way if
14:47
you feel that you are
14:49
oh yeah you know earth has
14:53
a long history
14:56
of being considered a material for the
14:58
poor
15:00
um and that has flipped occasionally and
15:02
so the history of earth and construction
15:04
in in new mexico and southern colorado
15:06
is actually that uh there became a point
15:09
in
15:10
in time when building codes
15:14
made it prohibitive for someone
15:17
for someone who was poor to build the
15:19
houses they had built for centuries
15:21
for different reasons right the code
15:23
might have said well now you need a
15:25
foundation that goes below the frost
15:26
line uh and
15:28
walls of adobe are can be two feet thick
15:30
so imagine now you have to build a
15:31
concrete foundation two feet thick that
15:33
goes
15:34
six feet deep and you also need a a bond
15:37
beam
15:38
above the wall to stabilize it when
15:40
traditionally you would use small pieces
15:42
of wood
15:42
to stabilize the wall from from lateral
15:45
forces
15:47
so at that same time that the poor could
15:50
no longer build
15:51
the buildings made out of earth the
15:53
wealthy
15:54
begin especially in santa fe and other
15:56
cities in new mexico
15:58
they begin desiring these buildings made
16:01
out of earth because
16:02
of their romantic connotations and
16:04
historical connotations and so there are
16:06
grand you know
16:08
uh homes in new mexico
16:12
made out of adobe and there’s there’s
16:14
actually
16:15
i mean given what i said about earth
16:16
entering the realm of capitalism there
16:18
is
16:19
the largest adobe yard in the world in
16:21
new mexico that produces up to 25 000
16:23
adobe’s a day for sale around the world
16:28
and um
16:31
and and so there there are these
16:32
preconceptions about
16:34
wealth and poverty that have also
16:36
affected and impacted the populations
16:38
who
16:39
would build these buildings
16:40
traditionally so
16:42
you know back to your question which was
16:44
how are we how are we dealing with this
16:46
phenomena of the preconceptions of earth
16:48
being the building material for the poor
16:50
i i think this largely has to do with
16:53
with design and and the elegance of of
16:56
the production of a building and so
16:59
you know people travel all around the
17:01
world to see
17:03
the wondrous structures that have been
17:04
built over the centuries made out of
17:06
earth and
17:07
and in some cases we’re finding these
17:09
are major tourist sites where people pay
17:11
a lot of money to stay in the hotels
17:13
and so if we can design with with
17:16
elegance
17:17
but also with a certain degree of
17:20
um
17:24
maybe the word might be
17:28
that it could be both inexpensive and
17:31
beautiful
17:33
then i think we can we can tread into
17:36
the realms where it could be more
17:37
culturally acceptable
17:39
again yeah yeah we call this project
17:43
mud frontiers because of course we’ve
17:45
been
17:46
printing at the frontier between the
17:47
united states and mexico and we’re also
17:49
at a technological frontier
17:51
but we also think of of it as
17:54
connecting to mobility because the
17:56
printer is so lightweight
17:57
ubiquity because soil is everywhere
18:01
right and democracy because we’re
18:03
developing this
18:04
um software app called potterwear which
18:06
runs in the cloud
18:08
which means that anyone can
18:11
develop files for 3d printing you don’t
18:13
have to know how to model anything
18:16
so it’s it’s immediate like a an 8th
18:18
grader can do this
18:20
in a day right right there’s also
18:23
a real special connection to the actual
18:26
place because the soil comes from the
18:28
local area
18:29
so different structures will have
18:31
different colors and
18:32
tendencies i imagine based on where
18:34
they’re built exactly
18:36
yeah yeah well i want to thank you so
18:39
much
18:40
for this wonderful conversation about
18:43
mud and construction and i really
18:45
applaud the
18:46
research that you’ve been doing and
18:48
we’ll look forward to following it as it
18:50
continues
18:51
and um thanks so much for your time yeah
18:54
thank you
18:54
thank you
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