This essay from 2023 by Automate Construction focuses on the development of 3D Printed Earthen Architecture by Ronald Rael, WASP, and presents a brief history of Earthen Architecture as it relates to this technological development.
Architecture, Art, Design, and Culture using of mud, clay, soil, dirt & dust.
This essay from 2023 by Automate Construction focuses on the development of 3D Printed Earthen Architecture by Ronald Rael, WASP, and presents a brief history of Earthen Architecture as it relates to this technological development.
The TECLA House is a collaboration between Mario Cucinella Architects (MCA) and World’s Advanced Saving Project (WASP). The name “TECLA” is a portmanteau of “technology” and “clay,” and references Italo Calvino’s Invisible Cities, specifically the fictional city of Thekla, were construction never ceases.
The materials used in the TECLA House include local clay and soil, water, rice husks, and a binder (which constitutes less than 5% of the total mixture). This makes it a true “0km building,” meaning the materials are sourced directly from the site on which the dwelling is built. WASP, an Italian 3D printing firm, brought their technological expertise to the project. Founded in 2012 by Massimo Moretti, WASP unveiled Crane WASP, their flagship 3D printer, in 2018. Mario Cucinella, the principal architect on this project, designed a morphology inspired by the potter wasp and based on the research of the School of Sustainability (SOS), Cucinella’s post-graduate school.
TECLA was built with 350 layers of 3D printed earth. The configuration of the walls was dictated by the humidity and temperature of the climate, and SOS made several infill case studies optimized for different geographical locations.
The TECLA House is the first dwelling built using multiple 3D printers working simultaneously and collaboratively. This project was the proof of concept for the Crane WASP. WASP claims that Crane WASP is an infinite 3D printer, whose print area of 50 square meters can be extended in a modular fashion to cover a printing area of arbitrary size.
The two Italian firms built their prototypical TECLA house in Massa Lombarda, Italy, but the idea is that the house can be reproduced anywhere. WASP advertises their “Maker Economy Starter Kit,” which can be purchased online and fits inside a single shipping container. TECLA can be reproduced in “200 hours of printing, […] 150 km of extrusion, 60 cubic meters of natural materials for an average consumption of less than 6 kW.” Interested parties can also purchase an entire Crane WASP rig for €160,000.
Architects: Alexandre Dubor and Edouard Cabay (see below for full team)
Location: Barcelona, Spain
Year of Completion: 2018
Area: 10 square meters
Digital Adobe is a research project developed by faculty directors Alexandre Dubor and Edouard Cabay at the IAAC (Institute for Advanced Architecture of Catalonia) in 2017-2018 (The rest of the contributors can be found here). The goal was to apply additive manufacturing techniques to the creation of an adobe wall with “highly performative structural and passive/climatic behavior” that could be adapted to the material limitations and climatic conditions of many locations [1]. The project culminated with the design and construction of a wall composed of 3D printed Adobe bricks, assembled by hand. The printed mixture is composed of 43% clay (unusually high for traditional adobe) , 25% aggregate, 13% water, and 1% bio based additives. The mixture was developed and strength tested before being used in smaller scale 3D printed prototypes and eventually the 1:1 wall. Assembly took 5 days [3]. The whole process can be seen in this video produced by the IAAC.
The structural capacity of the wall and its potential for integration with other building materials is demonstrated by the connection of a timber frame platform that bears on the wall. The research team also designed the wall to be self supporting. This is achieved through the tapering profile from 0.7m at the base to 0.2m at the top. This geometry combined with the wall’s own weight provide stability [1].
The other determinant of geometry was passive climactic behavior. The research team aimed to harness the natural properties of adobe, while enhancing them via geometric variation. Hollow bricks allow for cavity ventilation in the final assembly (while also saving material) and protrusions create a self shading effect that limits solar gain. The internal structure and fill of the bricks also vary with differing amounts of earth fill and sizes of cavities. These differences produce a portion of the wall more attuned to passive heat gain and another optimized for ventilation and therefore passive cooling [2].
The wall is significant for its demonstration of enhanced structural capacity with minimal material, and potential adaptability to various locales through enhanced passive heating and cooling made possible by the varied brick profiles. While the production process is likely cost prohibitive for widespread application at time of its construction, the project is an important investigation into how an adobe structure’s performance might be enhanced through the formal possibilities made possible with additive manufacturing.
1.Digital Adobe. IAAC. (2019a, April 30). https://iaac.net/project/digital-adobe/
2. Digital Adobe – additive manufacturing with adobe towards passive habitats. IAAC Blog. (2018, August 11) https://www.iaacblog.com/programs/digital-adobe-additive-manufacturing-adobe-towards-passive-habitats/
3. IAAC, Digital Adobe, IAAC Open Thesis Fabrication (2018; Barcelona) Video https://www.youtube.com/watch?v=sTug99TUYcw&list=PLrJLvlOA1ReATJ-qyTKT5tFWdBVbYCuM-&index=10
Gramazio and Kohler is a research group based in ETH Zurich, Switzerland, who consider the “interlinking of data and material and the resulting implications for architectural design” [gramaziokohler.arch.ethz.ch]. Working between material, manufacturing logic, and the design process, the group uses technology, robots, and programming as a means to define a new architectural expression.
Interrogating methods and workspace limitations of the construction/build process, Remote Material Deposition literally builds from afar; “remote material”, as in material situated at a distance, and “deposition” as the ejection, depositing, and/or build up of a material.
A robotic catapulting device, which is hooked up to a camera sensor installed at a birds-eye view, is installed within in a confined workspace. The catapulting device is loaded with loam projectiles, a composite soil made of clay, sand, and silt. The material in this process must be able to adhere to its fellow material upon impact, and harden after. For this reason loam (mud, earth) was chosen as the primary building material. The loam is shaped in cylinders, as to maximize the colliding forces of impact in order to adhere to the existing materials that were “shot” before it. Below is a diagram of the workspace.
Since uncertainties are bound to occur with the depositing, or lack of depositing, of the loam projectiles the over head sensor captures the mistakes, uncertainty, and data from the build, sends that information back to the design system (computer), and adjusts for the next round of projectiles. Although a defined proposal for design is used to set up and initialize the machine, the construction and build process becomes the design process; the two are linked in a feedback loop.
The use of earth/loam in this context is necessary for the method of construction applied, the adherence of projectiles, however the material and concept of this application can exist independently. What would the process of “ballistic architecture” look like at a much larger scale, if material were not a condition?
Consider the word “ballistics”: missiles, bombs, destruction. Countries such as Palestine and Afghanistan (and so many more) have had entire historical and cultural identities destroyed through ballistic warfare and destruction of their architecture and built infrastructure. It is an incredible thought to place Gramazio and Kohler’s work in the context of ballistic creation. Instead of destroying each other through missiles and projectiles, can countries and nations build each other instead?
Size: 12 m × 12 m and a ceiling height of 7 m (interior construction space)
Year: 2014
Photos: ETH Zurich, Gramazio and Kohler, Michael Lyrenmann
Architects: Gramazio and Kohler
Students: unknown
References:
[1] https://gramaziokohler.arch.ethz.ch/web/e/lehre/277.html Gramazio Kohler website
[2] https://www.researchgate.net/publication/317340911_REMOTE_MATERIAL_DEPOSITION Conference Paper
[3] https://vimeo.com/100784860 Production video
For centuries, Ukrainians have utilized the earth to create diverse and resilient dwellings. While wood played a role in certain regions, earthen construction techniques were widespread, particularly in the steppe and forest-steppe zones where wood was scarce. One of the most common methods was wattle and daub, employed as far back as the Neolithic Trypillian culture (5500-2750 BC). This involved creating a woven lattice of wood (“wattle”) and then applying a mud or clay mixture (“daub”) to form the walls. This technique, while simple, provided sturdy and well-insulated structures. While the actual structures haven’t survived, the archaeological evidence provides insights into their building techniques. Museums like the Museum of Folk Architecture and Way of Life of Central Dnieper Ukraine in Pereiaslav preserve examples of traditional building techniques, including earthen structures. The museum is part of Pereiaslav National Historical and Ethnographic Reserve. It was created in the 1960s and is the first open-air museum in Ukraine. The skansen (open-air) area on the picturesque Tatar Mount is divided into several sections: a pre-Soviet Ukrainian village of the Middle Cis-Dnipro Region, crafts and trades of a reformed Ukrainian village, windmills, and the earliest period section. Its total area of 25 hectares contains about 300 items, 122 of which are folk architecture monuments from the 17th to 19th centuries. They include 20 households with dwelling houses and outbuildings, presenting over 20,000 artifacts, such as works of folk craftsmen, lobar tools, household items, archaeological materials, documents, and photos.
Links:
Neolithic Trypillian culture, Museums like the Museum of Folk Architecture and Way of Life of Central Dnieper Ukraine in Pereiaslav, Pyana Hata restaurant, Ukrainian hata Wiki, Ukrainian hata, Mazanka, Museum of Folk Architecture and Folkways of Ukraine
Neolithic Trypillan settlements, Southeastern Europe1914
Ukrainian traditional houses were generally built facing south to maximize sunlight for warmth. This often resulted in houses being positioned at various angles to the street, especially in hilly areas with complex terrain, creating a charmingly haphazard village layout. In flatter regions, houses were more likely to be aligned with the street.
In rural areas, the tradition of earthen construction continued to flourish, shaping vernacular architecture. Homes, outbuildings, and even churches featured cob walls made from a mix of clay, sand, and straw. This readily available material created thick, insulating walls that were well-suited to the Ukrainian climate.
Another prominent technique was the construction of mazanka houses. This type of house got the name mazanka from the word mazaty (Ukrainian: мазати; to smear, to grease, to plaster with clay mortar). These structures usually utilized a wooden frame filled with clay mixed with straw or reeds, brushwood, or woven willow branches. The walls were then plastered with a clay mixture and whitewashed, creating a distinctive and practical dwelling. The choice of technique often depended on the availability of local materials. They dominated areas with limited wood, clay, and straw, while regions with more forests might incorporate more timber framing. This adaptability is a hallmark of Ukrainian earthen building traditions, reflecting a harmonious/sustainable relationship between builders and their environment.
The architectural appearance of the folk dwelling – “khata” – and its internal organization in its main features are common throughout Ukraine. Khata is a rectangular, somewhat elongated building in plan, covered with a hipped roof; the ratio of the width of the building to the length ranges from 1:1.25 to 1:2.25.
The living space itself approaches a square – the most economical rectangular shape of a room, in which the perimeter of the walls and the cooling of the room are the smallest. A large entrance hall and a pantry attached to the living space lengthen the plan. If the hut is built for two independent living spaces with an entrance hall between them, then the building is stretched along the main facade and acquires an elongated shape.
The most typical roof design in Ukraine was a hipped roof with four sides and sloping ends supported by rafters. These rafters were either attached to the top of the log walls or to longitudinal beams laid on top of the walls. In the Polissya region, a gable roof (two-sided) was also common, constructed in a few different ways: with a log covering, using supports shaped like chairs, or with posts supporting a main beam and the entire roof.
Roofs were typically covered with straw, either bound in sheaves or spread loosely. In forested and mountainous areas, the log structure of the house was left exposed, showcasing the craftsmanship of the interlocking logs. In the steppe and forest-steppe zones, houses were usually whitewashed inside and out, regardless of the building material, creating a striking contrast against the surrounding greenery. Colorful accents around windows, doors, and the base added a cheerful touch.
The simplest Ukrainian hut had two rooms: a large entrance hall used for storage and a warm living area. The stove dominated the living space, serving as a cooking area, storage space, drying rack, and even a bed! Kitchenware was kept near the entrance, while the sleeping area was located at the back, away from the windows.
The floor was made of earth in the early periods and later also had a special clay base. Only in some regions of Ukraine was the floor made of wood.
These time-tested techniques, passed down through generations, not only provided shelter but also shaped the unique character of Ukrainian villages. The whitewashed walls of mazanka houses, nestled among gardens and fields, created a picturesque landscape that continues to define the rural Ukrainian identity. Though modern materials have become more prevalent, the legacy of earthen construction remains an important part of Ukraine’s architectural heritage.
Here, you can check out a contemporary documentary film about the vernacular architecture of Ukraine filmed during the war, where multimedia platform Ukraïner and film studio Craft Story have teamed up for a special five-part documentary series entitled ‘STRIKHA’ (meaning ‘the roof’ in Ukrainian). Based on a long-term expedition throughout all regions of war-torn Ukraine (except those occupied by Russia), the series portrays the country’s authentic and vernacular architectural ‘treasures,’ particularly those hidden in distant villages, away from the main road.
Here’s an example of a contemporary take on Ukrainian earthen building utilizing the wattle, daub, and cobb techniques. The Ukrainian architecture firm of architect Yuriy Ryntovt built the restaurant Pyana Hata in Kharkiv in 1999 (literal translation: “drunk house,” but now you know that khata/hata means not just a house but an earthen plus wooden structure) that may playfully resemble an ancient Neolithic Trypillian culture aesthetics. The building area is 350 m2, and the site area is 0.4 hectares.
Yuriy Ryntovt is born in 1966. Head of the creative workshop Ryntovt Design (Kharkov), specializing in architectural design, furniture, and interior design. Co-founder and artistic director of the theater and concert club “RODDom.”
Open Thesis Fabrication is a six-month applied research program for postgraduates at the Institute for advanced architecture of Catalonia.
The program focus is on combining additive manufacturing with construction technology to create sustainable architecture with key areas of research in robotic manufacturing, material research, and performance-based design.
The program works with non-governmental organizations to develop designs for use in African humanitarian contexts and is comprised of architects, engineers, designers, and professionals with previous knowledge of digital fabrication and computational design.
It’s learning objectives are for program participants to:
This is achieved through the implementation of three phases, Exploration, Prototype Design Charettes, and Prototype Construction.
Examples of projects that have been completed include:
For more information regarding tuition fees, how to apply, grading systems, etc., be sure to check out IAAC OTF resource guide: https://iaac.net/wp-content/uploads/2019/07/OTF_Booklet_2019-22-07-2.pdf
The project located in Boulogne-Billancourt in the Parisian suburbs, involves a building with eight social housing units, a caretaker’s lodge, and a shop on the ground floor, with a raw earth facade on the street side, a stone base and a wooden facade on the garden side. It is driven by a desire for restraint in design and the use of natural, bio-sourced, and local materials without ever losing sight of comfort for the occupants.
The building rises on five levels including a ground floor, four floors of housing and a green roof. It is structured around a central circulation core including an elevator and a staircase serving all levels. The search for optimization, transversality and independence of spaces guided our design.
The façade at street level is made of raw earth blocks, thus following the precepts of the “cradle to cradle” concept based on two principles: zero pollution and 100% reusability. The rammed earth used in the project comes from local sources, specifically from the excavation of the Greater Paris metro. This reduces carbon emissions from transportation and follows the circular economy principle.
Rammed earth bricks are prefabricated , differing from the traditional on-site method. This technique speeds up construction and ensures consistency and quality control, and offers flexible installation in complex urban settings. Rammed earth bricks are placed on a stone base ensures both structural integrity and environmental sustainability.
Location: Boulogne-Billancourt, France
Completion: 2023
Project Area: 350 m2
Budget: €1,700,000 excluding VAT
Architect(s): Déchelette Architecture
REFERENCES
https://www.dechelette-architecture.com/quatre-cheminees/
https://www.facebook.com/dechelettearchitecture/?locale=ms_MY
Located in the town of San Jose de Garcia in Michoacan, Mexico, Casa Nandi is a collaborative project between architect Fino Lozano and the firm Moro Taller de Arquitectura. This two-story residence is designed to blend with its natural environment while offering views of the landscape. The home employs rammed-earth construction techniques combined with concrete elements such as casting, creating a balance between traditional and modern building methods. The design aims to respect the local context while providing a functional and aesthetic living space.
Architects: Fino Lozano, Moro Taller de Arquitectura
Area: 1345 ft²
Year Built: 2022
City/State: San Jose De Garcia, Michoacan
Country: Mexico
By making the most of its orientation to create a bright, intimate space, the residence also emphasizes the simplicity of its surroundings. Its natural ventilation which is derived from its forms, creates moments of release within the home that allow for contemplation of not just the environment but of self-embracing elements of harmony and tranquility for the inhabitants.
Constructed upon pine wood beams, the building also features handcrafted mud bricks supporting a concrete slab that indeed displays the underlying natural elements for an effortlessly elegant yet raw appearance. As previously indicated, the walls that make up the house are a combination of modern concrete techniques and traditional rammed earth, providing a juxtaposition that emphasizes how timeless architectural building practices can be. This combination offers acoustic and thermal insulation in addition to structural support.
Every material used in the home is on display, allowing each texture and color to contribute to a visual experience that authentically reflects the surrounding landscape. Rammed earth construction is popular in conveying the essence of Mexican architecture and Casa Nandi is a great example due to its rosy pink walls of local mud, creating a seamless connection between the home and its environment. “Casa Nandi, in that spirit, stands out yet settles in the place it belongs to” (Zohra Kahn).
References:
Caballero, Pilar. “Nandi House / Fino Lozano + Moro Taller de Arquitectura.” ArchDaily, ArchDaily, 7 June 2024, www.archdaily.com/1017433/nandi-house-fino-lozano-plus-moro-taller-de-arquitectura?ad_medium=gallery.
Khan, Zohra. “Casa Nandi in Its Muted Rammed Earth and Concrete Form Stands out yet Settles In.” STIRworld, STIRworld.com, 15 July 2024, www.stirworld.com/see-features-casa-nandi-in-its-muted-rammed-earth-and-concrete-form-stands-out-yet-settles-in.
FRANÇOIS COINTERAUX: THE ARCHITECT OF THE ‘AGRICULTURAL PROLETARIAT’ is an essay by Anja Segmüller who writes on the history of the French Architect Francois Cointeraux who is known for his focused attention on “the possibilities of ‘pisé’ (rammed earth) as a construction technique and to teaching the agricultural working class how to construct their own cost-effective, fire-resistant, and ‘dignified’ dwellings, founding several educational institutions”.
Will Bruder is an American architect known for his innovative use of materials and site-specific designs. Born in Milwaukee, Wisconsin, in 1946, Bruder’s background spans art, sculpture, and architecture. He studied at the University of Wisconsin-Milwaukee, earning a degree in Fine Arts, and later apprenticed under visionary architect Paolo Soleri, which significantly influenced his work in the desert Southwest.
Bruder’s work focuses on creating architecture that integrates with the natural environment, using innovative material choices and architectural forms. His approach prioritizes materials that connect the building to its surroundings, as seen in his use of adobe for the Matthews Residence.
The Matthews Residence, designed by Will Bruder, was built between 1979 and 1980 and received the 1983 Environmental Excellence Award for its innovative design. The residence is a 2,800-square-foot adobe home. The primary material of this residence is adobe brick, a traditional earth material made from sun-dried bricks, which is able to blend into the natural landscape. Adobe also offers excellent thermal properties, helping regulate temperature in the desert climate.
Inspired by the traditional Southwestern courtyard house, the design features curving adobe walls, strategically shaped to reduce exposure to the intense Arizona sun. The house spans a large double cul-de-sac lot in a suburban area of west Phoenix.
The layout creates a dynamic interplay between expansive and more intimate spaces, enhanced by the flowing geometry of its curves. The design’s sense of light, compression, and openness is carefully crafted, with a long skylight running from the entrance, introducing a play of light that highlights the contrast between rougher materials like adobe and concrete floors and the more refined details of oak and galvanized steel.
A key inspiring aspect is how Bruder masterfully combines adobe with modern materials like steel and wood, which creates a dynamic contrast between natural, traditional, and modern industrial materials. This combination enriches the architectural narrative by blending the old with the new. The combination of modern architectural design with natural, sustainable materials makes the Matthews Residence a source of inspiration for architects interested in sustainability and regionalism.
Interestingly, this is the only known Bruder house constructed from adobe, making it a rare and distinctive project. The way adobe is used in this design adds to its uniqueness, and it remains one of the most intriguing examples of Bruder’s residential work.
Matthews ResidenceCitations:
AZ Architecture. “Matthews Residence – Will Bruder Architect – Adobe.” AZ Architecture, https://azarchitecture.com/architecture-guide/matthews-residence-will-bruder-architect-adobe/. Accessed 23 September 2024.
USModernist. “Will Bruder.” USModernist, https://usmodernist.org/bruder.htm. Accessed 23 September 2024.
Rael, Ronald. Earth Architecture. Princeton Architectural Press, 2009, pp. 120-121.