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Mexican “Intuitive dome building” at Hosur, Nov 2019

Thanks to my apprenticeship with Maestro Andres Flores Castañeda of Toluca, Mexico. This blog is the first of a series of my domes no 57-59, (total number of independent vault and dome structures built). After 5 years in Mexico, these are the first domes in India, which are baby steps in the exploration of the vast art of intuitive dome building.

Rational methods of dome building as propagated by the Auroville Earth Institute / Block research group at ETH Zurich, “seem” to use computational methods for the “analysis of masonry structures, graphical analysis and design methods, computational form finding and structural design, discrete element assemblies, and fabrication and construction technologies.” In my humble opinion, this rational method depends on the use of a form work (support for the masonry during construction), or a series of guiding systems to maintain the accuracy of the curved involved. It also needs parametric cutting /shaping of blocks, Pre-calculated to fit on the curve.

The challenges of the above method is that it becomes a mere academic exercise that is hard to replicated in the real field by the common man. It is expensive due to the technology and the high quality of the materials involved. While innovative asymmetric shapes can be developed, it remains as art with little functional purpose.

However, Maestro Andres practices a generational skill, which involves imagination, familiarity and a deeper state of intuition for the realization of curved masonry structures. His “method”, that is very precise but cannot be explained. However it allows him the capacity to span over a range of shapes of plan. It does not use any kind of formwork / guide, nor does it depend heavily on the quality of materials, in fact, it uses skill to celebrate the variations in materials, both brick and mortar. A wabi-sabi, becomes the core principle of the product.

FB_IMG_1515207278989 (A dome over an irregular T shaped plan, developed by Andres Flores in Tepoztalan, Mexico).

In Hosur, a low cost project of earth sensitive architect Vivek, of studio Twasar, introduced us to his project which had two regular rectangles and an irregular quarter circle base that needed a brick roof. He allowed me the flexibility to develop the form, and the opportunity to build it. While the two rectangular units , measuring 12′ x 13′, was a familiar task, the curved plan at a staircase was to be an exploration of the intuitive method. Without using any formwork or guides the dome developed structurally locking into the the two walls.

Notice the herringbone bond patterns diagonally along the dome, that allows easy locking into the side walls and distributes forces along the curve while the dome is bring built.

IMG-20191222-WA0027

IMG-20191221-WA0012

The two intuitive domes were built as a two week workshop with two groups of 7 apprentices each signing up. None of them had prior experience with masonry. Thanks to the easily transferable intuitive method of building, they were able to complete all three domes in a span of two weeks.

The project was a win-win situation for all, as the client got a quick roof in two weeks. Had to pay less than 150 Rs Per sft of roof area as labor. The workshop participants paid 2500 Rs per week of training and the gains were all dedicated into the further learning and exploration of the method.

As a low cost project for a very ecologically and socially sensitive client, the cost per sft for this kind of dome, including material was about 200 Rs per sft, including material, labor, scaffolding and cleaning. If we include a ferrocement waterproofing and stone / ceramic tiling on top, it will compete with a flat RCC slab in cost. However, that is the least of its intentions. The beauty of exposed brick above ones head, and its hygro thermal properties is priceless! Learning to build with ones own hands.. a totally regenerative process!