In the era of the Second Digital Turn, designers and engineers have easy and equal access to computational tools across the globe. With the highest development of technology at a global level, the processes of design development and construction are locally contextualised based on the available technology and resources. A craft-based approach to computation and its contribution to support artisans&rsquo; development in India is demonstrated here through ongoing research on customising bricks and utilisation of a computationally generated asymmetrical Catalan Vault. The challenge of constructing the computationally generated form by architecture students is completed by the craftspeople and students of craft. The research elucidates gaps at various levels from design to construction. Craft-based solutions bridging these gaps establish a methodology which makes complex geometry constructible in present-day India when access to digital fabrication methods are still evolving and expensive.Today, designers and engineers have easy and equal access to computational tools across the globe. Data-sharing and advancements in digital fabrication with a six-axis robotic arm have revolutionised design thinking and making. Robots are being trained to sense information, provide feedback on the process and take independent decisions, just as the craftspeople of the preindustrial era. The hands of craftspeople have had cumulative wisdom of materials, tools and techniques. A craftsperson&rsquo;s hands are directly connected to their minds. When craftspeople are introduced to new ideas (in this case, complex geometry), tools and techniques (Catalan Vault), the construction process is as precise as machines. Additionally, a craftsperson posseses the knowledge and sensitivity to material, bringing an inherent quality without any preprogrammed instructions. This feature is a paper that is part of ongoing research on customising brick. It looks at bricks with two simultaneous yet separate approaches. The first approach: parts to the whole, focused on the development of customising a building block (brick). Individual masonry blocks are customised to enhance the quality of the existing brick. The aim is to make construction without mortar and/or add one of the qualities such as acoustics, thermal insulation, light and shadow on the facade, integration of the plantation, and so on. The customisation of the block can also be based on self-assembling complex geometries. The second approach: whole to parts, is based on a funicular structure. Here, the form is computationally generated and the parts are considered as standard blocks available in the market. The focus is to design and build an asymmetrical vault at an affordable cost in India. The project conferred here is built based on the second approach.<img src="https://magarticles.magzter.com/articles/827/381404/5dbac28c60c5e/1572519080134.jpg"" owidth=1282 oheight=855" style="height:534px; width:800px" />Concept Design Form finding The project was conceptualised by students during a three-week-long (Winter School 2016) course, Digital Crafts: Customised Bricks 1.1, conducted at the Faculty of Architecture, CEPT University, Ahmedabad. Students were free to choose a specific site and programme on the Sabarmati riverfront. A bounding box was 30 cubic metres (3 x 3 x 3 m) in volume, with the possibility to stretch the box, keeping the volume constant. This changed to 270 cubic metres (10 x 6 x 4.5 m) while developing the design. RhinoVAULT, which is the Plug-In to Rhinoceros&reg;, emerged from research on structural form-finding using the Thrust Network Analysis (TNA) approach to intuitively create and explore compression-only structures introduced as a generative tool. The number and type of supports were site-specific. Five different designs were generated by students working in groups of two. Out of these, the children&rsquo;s play area was chosen to develop further.<img src="https://magarticles.magzter.com/articles/827/381404/5dbac28c60c5e/1572519081962.jpg"" owidth=1282 oheight=847" style="height:529px; width:800px" />Design developmentThe plan footprint of 9.5 x 6 m with five boundary supports, two central supports and two cut-outs were fixed. Two central supports were used to include the details inspired by the teardrop columns (Frei Otto). The allowable maximum height was limited to 4.5 m. Height in some portions was further reduced to 1.8 m so that the children can climb on the roof and slide down from one of the central supports. The form was iterated until the headroom clearances were achieved with respect to the maximum allowable height, and the aesthetics of geometry were resolved.Prototyping (Scale 1:5) A step-wise sequence of construction was referred from the IaaC pavilion (BRG). Step 1: Making a visual guide using cardboard; Step 2: Constructing boundary curves using scaffolding; Step 3: Building a masonry shell using MDF bricks between the boundary curves with a visual guide only (without scaffolding); Step 4: Begin construction from ground to top from all five outer support points; Step 5: Begin with central support once the masonry work from the outer support has reached the maximum limit of the cantilever without scaffolding; Step 6, Complete the masonry shell on the top. The students agreed to build a scaled prototype (scale of 1:5) following the set sequence of construction to understand shell behaviour during the construction. The cardboard visual guide was removed and the prototype was presented in the exhibition. This marked the end of Winter School.<img src="https://magarticles.magzter.com/articles/827/381404/5dbac28c60c5e/1572519238943.jpg"" owidth=572 oheight=855" style="height:855px; width:572px" />Legal direction: academia to practiceThe outcome of Winter School was presented to the Ahmedabad Municipal Corporation (AMC). The authorities appreciated and encouraged the research by offering land to build a permanent structure at Shahibag Riverfront Park, located on the eastern bank of the Sabarmati. However, the city engineer demanded us to submit the following as regular formalities for building permission:&bull; Structure stability certification along with the report describing load calculations and test results by an authorised engineer. (Dead load, Live load, wind load and seismic load)&bull; Fulfill safety norms for such structures in the public domain.&bull; Detail 2D working drawings including the cross-section detail showing multiple layers of construction and material specification. The submission requirement is based on conventional construction and a socio-cultural context.<img src="https://magarticles.magzter.com/articles/827/381404/5dbac28c60c5e/1572519240388.jpg"" owidth=629 oheight=419" style="height:419px; width:629px" />Challenges At this pont in the research process, there were three challenges: firstly, getting a detailed structure design and certification by an authorised engineer; secondly, find craftspeople to build the Catalan Vault without scaffolding; and thirdly, limited funds.<img src="https://magarticles.magzter.com/articles/827/381404/5dbac28c60c5e/1572519241065.jpg"" owidth=631 oheight=420" style="height:420px; width:631px" />Detailed structure design and certification by an authorised engineer Funicular structure is a very well-taught theoretical concept among engineering schools in the country, yet uncommon and risky to certify in practice. The Auroville Earth Institute has excelled detailing structure design and construction of a symmetrical catenary vault in compressed earth blocks. The only simultaneous ongoing project of this time in the country was by sP+a which used RhinoVAULT to generate asymmetrical form. It&rsquo;s construction also faced similar challenges. For a detailed analysis and for verification, the mesh of the generated geometry was transferred to STAAD.Pro &mdash; a software most commonly used by engineers in India. The results were found common and safe, yet there was a doubt because there was no such structure built and tested. Thus, the engineer who verified calculations did not certify the design for structural stability.<img src="https://magarticles.magzter.com/articles/827/381404/5dbac28c60c5e/1572519302223.jpg"" owidth=1284 oheight=973" style="height:606px; width:800px" />Finding craftspeople to build the Catalan Vault without scaffolding and reinforcementMasons have excelled constructing domes by corbelling bricks, and this technique is mastered over generations. Very few masons can build shallow domes using the Catalan Vault techniques. This involves construction within a continuous boundary condition. Such domes don&rsquo;t rise above eight inches. These are most commonly used to construct brick slabs. Finally, Philippe Block (from Block Research Group) was contacted by the author to guide construction. The answer was, &ldquo;[The] construction of the Catalan Vault without a scaffolding and reinforcement is highly dependent on skilled masons. If one doesn&rsquo;t find [them], one has to train them&rdquo;.<img src="https://magarticles.magzter.com/articles/827/381404/5dbac28c60c5e/1572519304202.jpg"" owidth=955 oheight=717" style="height:601px; width:800px" />Limited Funds So far there are have been no dedicated funds to conduct research in architecture, specifically in the domain of computational design and digital fabrication. CEPT University funded the project, but the amount was less than USD 10,000. Therefore, neither the appointment of international experts as consultants for structural certification nor importing master masons to show construction techniques was possible. Resolving these challenges took almost six months.<img src="https://magarticles.magzter.com/articles/827/381404/5dbac28c60c5e/1572519620753.jpg"" owidth=1282 oheight=861" style="height:537px; width:800px" />Craft: Bridging the Gap The solution to these challenges was found at the Craft Institute, Hunnarshala Foundation, located domus November 2019 in Gujarat. The institute was also researching on Catalan Vault construction during that period. Masons of Karigarshala were trained to build smaller (1.5 x 1.5 m), symmetrical vaults. The failure pattern was studied by physical load-testing. Joint research between the two institutes was also established.<img src="https://magarticles.magzter.com/articles/827/381404/5dbac28c60c5e/1572520281_loc.JPG"" owidth=550 oheight=515" style="height:515px; width:550px" />Data transferAlong with the 3D model, a set of 2D drawings were given to the team. One of the interns at Hunnarshala was also trained to design 3D models in Rhino. The curvature of each section was studied for structural analysis.<img src="https://magarticles.magzter.com/articles/827/381404/5dbac28c60c5e/1572519521249.jpg"" owidth=960 oheight=629" style="height:524px; width:800px" />Material and Construction detail The first change was the choice of material. It was recommended to use thin clay tile (fired) measuring 230 x 75 x 12 mm instead of the standard brick module which is 230 x 115 x 75 mm. This was simply to reduce the dead load of the structure. An assumption was made that a minimum of three layers of construction will be required. The first layer would comprise clay tiles and gypsum mortar to achieve the desired shape. This will be plastered with 25mm-thick cement mortar on both sides. The second and third layer of tiles on the top and the bottom was to be constructed with fine cement mortar (ratio 1:2) to achieve the desired strength and to protect the first layer from weathering or collapsing. More layers could be added, if required, after load-testing.<img src="https://magarticles.magzter.com/articles/827/381404/5dbac28c60c5e/1572519730417.jpg"" owidth=629 oheight=481" style="height:481px; width:629px" />Prototype (Scale 1:1) The decision to build a prototype (scale 1:1) to train the masons as well as for physical load-testing was to follow. The construction sequence pursued by students to build a prototype (scale 1:5) was explained to the team of craftspeople and students of the craft school. Referring to the Drone Port Pavilion, the making of the visual guide differed from the earlier one made in cardboard. The advantage of the visual guide made of pipes was that it allowed workable space from the bottom.<img src="https://magarticles.magzter.com/articles/827/381404/5dbac28c60c5e/1572519731107.jpg"" owidth=629 oheight=478" style="height:478px; width:629px" />Training Masons Due to the asymmetric geometry and sharp curves in the form, it was further required to increase the precision of the visual guide. Therefore, the plan grid at 600 x 600 mm was revised to 300 x 300mm. The perpendicular distance from the ground to the required surface was given at the intersection of the grid. Arches were built first, followed by the surface, starting from all five outer ground points at the same time. Tiles were precisely cut and shaped wherever required to achieve accurate double-curved surface. Preparation of small portion of gypsum mortar was vital to hold tiles in their locations. The construction of teardrop-shaped columns required a special set of drawings to build the geometry. A total of six tonnes of load using 300 sandbags weighing 20 kg each were uniformly distributed over the surface area of the structure. Measuring tools were set at the centre of each arch and at regular intervals inside the structure to monitor deflection. The set-up was left undisturbed for seven days. A deflection of 3mm was documented. The same was confirmed to have matched with the computational model. The entire process from the foundation to load-testing was documented on a daily basis. An extensive structural report was made for the local corporation.<img src="https://magarticles.magzter.com/articles/827/381404/5dbac28c60c5e/1572519774887.jpg"" owidth=470 oheight=716" style="height:716px; width:470px" />On-Site Construction Area of intervention was barricaded for safety of people visiting park on daily basis. The construction on site followed exact same sequence as earlier. Individual foundation for each support was done in brick with a waterproof plaster.<img src="https://magarticles.magzter.com/articles/827/381404/5dbac28c60c5e/1572519774273.jpg"" owidth=304 oheight=316" style="height:316px; width:304px" />On-Site Decisions Decisions regarding the orientation of the pavilion in the park with respect to Sabarmati river, the view from a nearby bridge, the entrance area and an adjoining pathway were made on site. Addition of seats, details for rainwater drainage from the teardrop-shaped column, the surrounding landscape, and pockets for lighting were also made on the site. All the additions made were due to the experience of craftspeople, building from just a sketch. No working drawings, models or details were produced for this.<img src="https://magarticles.magzter.com/articles/827/381404/5dbac28c60c5e/1572519773604.jpg"" owidth=631 oheight=475" style="height:475px; width:631px" />The Way Forward Construction Industry and Cultural Acceptance Though India is known for its contribution to information technology, it takes a decade or sometimes, even more, to percolate technological advancements in architecture and the construction industry when compared globally. India is now in the first digital turn yet is a labour-intensive construction industry. The cost of digital fabrication is still too high when compared to the cost of manual labour (craftsmanship). Often, the time taken to complete a project is not considered as the biggest resource. At present, it is most efficient to establish a balance between digital fabrication and craftsmanship to build a project with complex geometry.<img src="https://magarticles.magzter.com/articles/827/381404/5dbac28c60c5e/1572519923422.jpg"" owidth=634 oheight=425" style="height:425px; width:634px" />Architecture, Engineering and Craft Education Awareness of the advancements in technology and shared tools among designers/architects in India is relatively on par with the world. Architecture and design schools conduct full-time courses and/or specialisation in the field. Architectural practices also began to accept the digital turn positively. However, there is a clear demand for updating civil and structural engineering education. Analytical methods taught and practised by the engineers are extensive, accurate yet not enough to be able to share mutually between designers and engineers. These methods are limited to symmetrical shapes. To be able to calculate the structural behaviour of asymmetrical free-form without digital tools today will demand alternative methods, similar to the one used by Antoni Gaudi, Frei Otto and Felix Candela. <img src="https://magarticles.magzter.com/articles/827/381404/5dbac28c60c5e/1572519924865.jpg"" owidth=627 oheight=424" style="height:424px; width:627px" />Vocational training imparted by Industrial Training Institutes (ITI) in India and skill-development schools like Hunnarshala must include construction craftsmanship like masonry, fabrication, carpentry and other related subjects. Skilled labour and educated craftspeople can change the face of the construction industry in India.<img src="https://magarticles.magzter.com/articles/827/381404/5dbac28c60c5e/1572519925596.jpg"" owidth=956 oheight=606" style="height:507px; width:800px" />AcknowledgementsCEPT University: Shehzad Irani, Avishek Das, Arunima Sen, Ekta Samani, Naindeep, Faisal, Parv Modh, Chaitali, Sudarshana Babu Students of Digital Crafts: Customised Bricks 1.1 (Winter School 2016); Hunnarshala Foundation and students of Karigarshala: Kiran Vaghela, Tejas Kotak, Sunil Dheda, Bharat Chauhan, Pangu Sinh Bamania, Jignesh Gor, Itesh Dhadhar Students of Karigarshala (batch of 2017-18).<img src="https://magarticles.magzter.com/articles/827/381404/5dbac28c60c5e/1572520116346.jpg"" owidth=955 oheight=608" style="height:509px; width:800px" />

Bridging The Gap: Computation For Construction In India

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