250AGA - Amery Calvelli interviews Ronald Rael and Virginia San Fratello

2021

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.”
 …

Autogenerated Transcript from YouTube (if available)

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0:08

um

0:08

so i’d like to begin uh with

0:12

uh ron i i kind of i read an article

0:15

that talked about

0:16

the fact that you grew up in an adobe

0:18

house built by your great grandfather

0:21

in the san louis valley of colorado

0:24

and i also know that there’s this early

0:26

resource

0:27

called earthenarchitecture.org i believe

0:30

that was founded by you

0:32

maybe in 20 2003 so 17 years ago

0:36

um so there’s this deep uh you know

0:39

knowledge about

0:40

uh earth as a material and i’m wondering

0:43

what what are the routes for you where

0:45

does this come from this

0:46

this quest for earth as material

0:52

well in my own personal history it comes

0:54

from

0:56

having lived in buildings made of earth

0:58

and

0:59

not only uh in my lifetime but

1:04

my family has lived in buildings made of

1:06

earth for

1:08

uh perhaps time immemorial whether you

1:11

trace my

1:12

european lineage to southern spain

1:15

or you trace my indigenous ancestry here

1:19

in the pueblos of new mexico

1:21

and so i have that very deep connection

1:24

to earth but i also think that all

1:27

humans have that deep connection to

1:29

living in buildings made of earth and

1:31

they may have been disconnected from it

1:33

in their

1:33

in their recent histories in their

1:36

recent family histories

1:37

but for 10 000 years humans have lived

1:42

primarily in buildings constructed of

1:44

earth in every continent

1:45

on on the planet except for one of

1:47

course which is too cold

1:49

but but i think that we all as humans

1:54

not only have this this deep

1:57

historical connection to earth but i

1:59

think we also have

2:00

a biological connection to earth in that

2:03

we

2:04

like some other animals on the planet

2:06

have evolved

2:07

to make those buildings made of earth so

2:09

which means that our own

2:10

physical makeup has allowed us to

2:13

construct those kinds of buildings that

2:15

way we have the building to

2:16

grasp mud and to shape mud and ceramics

2:18

have been some of the

2:20

earliest technologies that we as humans

2:22

have developed and so

2:24

i think that our connection goes beyond

2:26

just

2:27

a connection of memory but it goes to

2:29

connection of biology

2:31

connection of genetics a connection of

2:35

geology right so it’s in our dna

2:38

i believe so in many ways i mean we look

2:41

at

2:42

what creates the the fundamental

2:44

proteins

2:45

for the creation of life it comes from

2:49

molecules that are associated with clay

2:52

interesting we think we think sometimes

2:56

about that as a

2:56

as a kind of biblical story right that

2:58

people come from dust to dust or

3:01

but it’s also a it’s

3:04

a scientific truth that that you can

3:08

create the foundations of life

3:11

by combining certain molecules of clay

3:14

the fundamental

3:15

proteins and amino acids

3:18

yeah i think one of the things that

3:20

really interests me about the

3:21

architecture that the two of you do

3:23

in your practice together is um

3:26

an exploration of materials that are not

3:29

necessarily

3:30

typical for structures salt sugar

3:36

coffee grounds earth maybe being one of

3:39

those or dirt

3:40

but i want to kind of move to emerging

3:43

objects for just a moment

3:44

and um i believe there was

3:48

a smithsonian article that came out that

3:51

talked about the 40 things that you need

3:53

to know in the next 40 years

3:55

and one of those things was the quote

3:57

that

3:58

sophisticated buildings would be made of

4:00

mud and so i

4:01

wonder if we could start from that place

4:04

what sparked your interest

4:06

in that comment and what did that um

4:09

prompt in terms of emerging objects well

4:12

interestingly

4:14

one of the first materials that we

4:16

tested in our binder jet 3d printer was

4:19

clay it was a ball clay if we go

4:22

back to i think 2010 and

4:25

we were experimenting with recipes for

4:28

printing with clay that were open source

4:31

that we had found online and we tested

4:33

ball clays and porcelains

4:37

and then we were invited to participate

4:39

in the bnla of the americas which was in

4:42

denver

4:43

and we decided to 3d print with sand

4:46

so in order to do that we had to hack

4:49

our printer

4:51

and experiment with different sand

4:53

formulations we

4:54

experimented with um eventually adding

4:58

a cement to the matrix that we were

5:00

printing with

5:01

and as we were printing for that exhibit

5:04

we were printing objects that fill

5:08

fit in the build bed of the printer

5:10

which is eight inches by eight inches by

5:12

ten inches

5:13

we were laying them out and we realized

5:15

oh everything’s the same size so we

5:18

started printing

5:19

parts that we could aggregate together

5:21

to make a hole

5:22

so suddenly we we realized oh we can

5:25

stack parts and make something tall

5:27

or something long and then we started

5:29

stacking in both directions and realized

5:31

oh we don’t have to just make models we

5:34

can actually make

5:35

buildings through this technology we can

5:38

make

5:39

building blocks of the future and we can

5:41

make them out of sand

5:43

we can make them out of cement we could

5:45

make them out of

5:47

clay chardonnay etc so that’s

5:50

a little bit of the the origin story for

5:53

us

5:54

and i think when we read that quote we

5:57

realized that we were

5:59

kind of on the cusp of thinking about

6:01

how we might build

6:02

for the future using this nascent

6:05

technology

6:06

with these really old traditional

6:08

materials

6:09

that have proven themselves over time

6:12

you know

6:12

the um earthen construction has

6:16

this flywheel effect of keeping

6:18

buildings

6:19

warm in the interior in the winter and

6:21

cool in the summer in arid environments

6:24

and we can capitalize on just the

6:27

inherent

6:27

quality of the material itself

6:31

one thing about that smithsonian article

6:33

that predicted the

6:36

sophisticated buildings of the future

6:37

will be made of earth is that

6:39

uh i always found it interesting that i

6:41

thought that sophisticated buildings of

6:43

the last ten thousand years

6:44

were also constructed and that that

6:48

inherent to earth is construction is a

6:50

sophistication

6:52

and we as humankind have been developing

6:55

that material

6:57

for uh thousands of years and so it’s

7:00

the material that we’ve been working on

7:01

the

7:02

longest it’s fundamentally the most

7:04

sophisticated

7:05

material that we have under our control

7:09

let’s build the environment and so

7:11

because we’ve had such a long time with

7:13

this material what does that allow us to

7:15

do how do we understand it better

7:17

because we’ve been

7:18

working with it or do we maybe we left

7:21

it behind for some time

7:24

well you know i think increasingly we’re

7:26

leaving it

7:27

behind and and it’s unfortunate

7:30

so fewer and fewer people around the

7:33

world are living in buildings made of

7:35

earth because they’re moving

7:36

towards other building materials that

7:39

are extremely resource

7:40

intensive concrete for example

7:43

and i think what what we have not been

7:46

able to do

7:47

with earth is to bring it into

7:50

a capitalistic economy so no one can

7:53

really make money

7:55

building buildings made out of earth but

7:57

certainly building buildings made out of

7:59

concrete or steel those

8:02

are are materials that have a

8:04

capitalistic power

8:06

and earth does not and so it it’s almost

8:09

like the material has resisted itself

8:11

bringing itself into the economy and so

8:14

i think

8:15

given the global crises that we are in

8:19

it’s an opportunity for us to look back

8:21

at the sophisticated technology that we

8:23

have developed

8:24

and begin to use it in our capacity to

8:27

create

8:27

elegant buildings to great housing for

8:29

those who need housing

8:32

there are examples of almost every

8:34

architectural typology man of earth

8:35

around the world there are airports made

8:37

out of earth in yemen for example

8:39

there are museums embassies and so

8:42

i think it’s a building material that we

8:44

should not forget

8:47

and i know you authored a book about

8:48

earth architecture

8:50

in 2008 or 2009 so we’ll include a link

8:53

to that as well so you’ve done a lot of

8:55

studies around

8:56

what’s been built with earth right

9:00

we both have a really nice opportunity

9:02

to travel around the world and look at

9:03

buildings constructive earth

9:05

and the diversity of earth and

9:08

construction around the world and the

9:10

many different kinds of techniques

9:12

that are available to use only

9:14

fundamentally earth and humidity

9:18

may be sometimes mixed with some organic

9:20

material

9:21

to make to make shelter

9:25

so i think in looking at the

9:29

structures that you’ve built using a 3d

9:31

printer

9:32

you describe this printer as old

9:34

technology but in the photograph it

9:36

looks almost robotic

9:37

there’s this long arm that is filling

9:40

earth

9:41

into into sections or into structures

9:43

and i wonder if you could talk about

9:46

what the use of new technology does you

9:49

started to comment about how it might

9:50

change

9:51

economy or the access to building

9:54

with earth but um what is this merging

9:58

of new technology

9:59

with the old material what does it allow

10:02

in your in your views well we we are

10:05

using a

10:06

robotic arm to 3d print with the

10:09

earth and i think um it does a couple of

10:13

things

10:13

it allows us to build more quickly

10:16

than we might be able to by hand

10:20

right so we can design something in the

10:23

computer

10:24

and then the robot is able to well we

10:26

have a continuous hopper

10:28

that pumps the earth up to the robot and

10:31

the robot

10:32

puts it in place so we can make complex

10:35

structures

10:36

um we can work more quickly

10:39

um i think you know for someone like me

10:42

i might not be able to lift a 40 or a 50

10:45

pound adobe

10:46

over my head and stack it but the robot

10:49

can can build higher than i am tall

10:52

right

10:52

so i think the limitations that

10:55

might traditionally be there are negated

10:59

by using the robotic arm i mean

11:02

what’s what we’re discovering which is

11:04

really interesting and it was our theory

11:06

that’s

11:07

that’s proving to be true is that

11:10

we could create a printer that’s smaller

11:12

than the object that we’re creating

11:14

and so and so we can print a very large

11:17

object

11:18

and also right now there are primarily

11:21

just

11:22

two people at a time on the building

11:24

site

11:25

and the tasks are

11:28

to sift mud to sift dirt

11:32

to mix to make mud and to press the

11:35

button on the printer

11:37

and so if you think about that as well

11:40

there are times when

11:41

when only one person could actually

11:44

execute this job

11:45

to construct a very large structure so

11:48

these are the largest structures that

11:49

we’ve

11:50

made this summer and they are 12 feet

11:53

tall

11:54

and they are large as a as a small room

11:57

so they’re really occupiable and two

11:58

people could sleep in

12:00

in one of the rooms that this printer

12:01

can make

12:03

and the printer itself is very

12:04

lightweight and so

12:06

i think one of the things this process

12:08

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

12:29

just a couple of people using mud have

12:31

made buildings with their own hands

12:34

but i think what this also does it

12:36

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

12:58

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

13:10

uh i can see years and years of

13:13

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

13:21

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

13:32

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

13:39

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

13:48

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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