Low Carbon Construction Training Report

Orissa-Artisan Training Report

Artisans – Orissa

6th – 15th March 2013

Orissa-Artisan Training Report

1. Contents

1. Background ...... 2 2. Training Approach ...... 3 3. Training Process ...... 3 4. Observations and Lessons learnt ...... 12 5. Annexure 1 : List of Participants ...... 13 6. Annexure 2 : Drawings ...... 14

Orissa-Artisan Training Report

2. Background

A mason training on Low Carbon Construction techniques was held from 6th to 15th March 2013 at the ASHRAYA Building Materials Services Bank. It was organised by Co-operation for Rural Excellence (CORE) in collaboration with the Development Alternatives Group, New Delhi and supported by the Climate and Development Knowledge Network (CDKN), UK. The twelve day workshop aimed to build capacities of artisans and masons and demonstration of low carbon cost effective construction techniques in coastal spaces like Orissa. The training was attended by 25 skilled and semi-skilled masons from Orissa. The masons trained were from Grudighatia,Choudwar, Biratbazar and Daptari areas of Cuttack District. Climate change impacts are now being felt at a local and global level. The construction sector sustainably contributes to this. Simultaneously, it also bears the brunt of these impacts. The practices in the construction sector of Orissa that aggravate climate change need to curb their impact on the local environment by,

 Reducing ecologically detrimental methods of sourcing building materials.  Using more energy efficient construction technologies.  Ensuring minimum amounts of energy used in the operation of buildings constructed.

Alternate technologies and materials offer a solution to deal with this challenge. The Government of India has recognised the need for action in the Low Carbon, Climate Resilient (LC-CR) sector. However, there is a lack of attention towards the 70 million strong rural spaces and small towns which are emerging as areas of high growth. This training workshop aimed to bridge this gap by generating knowledge support for LC-CR solutions for small towns and rural spaces to build capacity for masons and artisans. The training is part of a larger initiative that seeks to generate knowledge support for LC- CR solutions for small towns and rural spaces by building capacity at three levels, viz. Policy Makers, Building Professionals and Artisans. It also attempts to influence policies and building practices in response to imminent climate change trends and need for low carbon construction. The objective of the workshop were to :

 Understand concepts and dynamics of climate Figure 1: Coastal settlements of Orissa change and the construction sector  Learn about alternate building materials and technologies  Demonstrate these technologies and gain hands on experience.

Orissa-Artisan Training Report

3. Training Approach

The ASHRAYA BMSB has a long history in the production and use of alternate technologies in Orissa since the super cyclone of 1999, when it was set up. This workshop utilised the building material production set up at the centre to put together a demo structure that would be usable by the ASHRAYA team later. The approach adopted for the training workshop was participant centred, with an emphasis on practical learning. In order to bring conceptual clarity on subject matter, the training began with expert lectures followed by discussions on low carbon building materials and technologies. Each of the technologies were demonstrated and the masons were encouraged to try this out while building a life scale structure. Within this structure the team aimed to showcase and train the masons in as many technologies as possible that were avaliable and relevant to the coastal belt of Orissa. The master masons were Khadim Sek and Sasmita Sahoo, while Anjan Jena and Prasanta Bisoei supervised the trainings. The technologies demonstrated during the 10 day training were: Walling:  Interlocking Compressed Earth Blocks  Fly ash brick  Hollow concrete blocks  Solid concrete blocks  Rat trap masonry Roofing:

 Ferro-cement Channels  Plank and Joist roofing Figure 2: Discussion with the team  MCR tile roofing  Bamboo roofing understructure

4. Training Process

Over the ten day period, the DA and ASHRAYA team worked closely together to work out a step by step training process where a structure that would be useful to the BMSB in the future would be constructed and through its process of construction, the masons would be trained in the technologies employed. Naturally, a foundation to roof approach was followed in the order of technologies. Also, as many of the alternate technologies in question required building materials that were either precast or produced on site, a parallel production system of manufacturing them was set up. As the structure was built from foundation to roof, all the technologies were employed one at the time, allowing for the masons to focus on the correct methods of construction of each.

 Day 1: Introduction to the Training The first day of the training programme was spent as an introductory meeting of the entire workshop group, including the artisans to be trained, the master masons and the supervising architects from DA, Amol Mangrulkar and Rita John. A total of 25 artisans were appointed to work together during the training and build an extension to an existing storage area using various LC-CR technologies.

Orissa-Artisan Training Report

The site of construction was finalized and measured and list of technologies to be used were finalized. While preparation of the site began, detailing of the design of the structure to be built was worked out in collaboration with the participants.

 Day 2: Design Development & Site Excavation Excavation of the site for laying of the foundation was carried out. Precast materials, like planks for the plank and joist roofing technology, to be used in the structure were manufactured on site. Some preliminary hands-on design exercises were carried out on site to work out various options of how the different types of technologies were to be showcased. The design of the structure to be built was finalized and shared with the team by Amol Mangrulkar and Rita John.

Figure 2 : On-site production of planks, preparation of hollow concrete blocks for masonry, Fly-ash brick placement experiments

Mason interactions: While experimenting with the different types of masonry, it was evident that the masons had a keen interest to use the building materials in ways other than the conventional walling technique. As a result, they were an integral part of the hands-on design process of deciding what combination of technologies to use in which building element. For example, it was agreed upon that the hollow concrete block would be used not only the walls, but also as load bearing elements in the columns and as containers for planters in an outer seating area. Based on all these decisions and experiments, the drawings of what was to be built were finalized and shared with the masons.

 Day 3: Laying the Foundation The dug out foundation was leveled and compacted with Compressed Earth Blocks and sieved sand. The layers of the plinth were laid in solid concrete blocks masonry while ensuring the wall centre-lines and levels of each layer by repeatedly checking the plumb.

Orissa-Artisan Training Report

Figure 3 : : Laying of foundation

Mason interactions: The masons were initially not careful about maintaining accuracy of levels and right angles while compacting the earth or laying the first courses. After a great deal of constant supervision of checking these points at every stage of work, they developed a routine of doing so. The right mortar mixes and methods of aligning masonry layers were other areas of concern that also had to be standardized.

 Day 4: Laying the Plinth and Column Footings The foundation was raised to plinth level in solid concrete block masonry. The plinth beam was cast between fly-ash bricks placed on edge.

Figure 4 : Laying of column foundation, Casting of plinth beam

The column footings were raised. These columns were to be load bearing with some steel reinforcement running through it.

Orissa-Artisan Training Report

Figure 5 : Column footing and layers of load bearing CEB masonry

Mason interactions: Innovative techniques of using the interlocking CEB block were put to use in the columns by placing them on edge. This technique was demonstrated by one mason, Khadim, and soon all the others employed the same in the remaining columns.

 Day 5: Wall Masonry – Interlocking CEB Masonry The CEB masonry layer above the plinth level is begun. Variations in this masonry were done for window openings. Jaali patterns worked out in interlocking CEBs because the veranda space is semi-open.

Figure 6 : CEB interlocking wall masonry

Mason interactions: The masons needed to be told the importance of using CEB blocks that did not have cracks or were weathered. The interlocking block, which does not use mortar in its construction is a walling material that can be put in place quite quickly and the masons were able to raise the walls to sill height in a matter of hours. An issue faced repeatedly, though, was the fact that not all the blocks were of the exact same length, varying by around an inch. The joints formed due to this difference in length had to be dealt with using a trial and error method of using different blocks to see what fit. Another issue faced was the lack of half-length blocks or a proper mechanism to cut a full block. This, too, had to be dealt with using basic masonry tools.

 Day 6: Wall Masonry – Interlocking CEB jaali Various semi-open masonry techniques using interlocking CEBS were demonstrated. Jaali design using the interlocking blocks without mortar was executed. The load bearing coulmns showcasing various types of masonry options was completed to the beam level.

Orissa-Artisan Training Report

Figure 7 : CEB interlocking wall masonry jaali

Figure 8 : CEB interlocking wall masonry jaali

Figure 9 : Load bearing column and CEB interlocking wall masonry jaali

Orissa-Artisan Training Report

Mason interactions: One of the masons, Khadim, had experimented with the CEB blocks and created a layer of tilted interlocking jaali masonry which not only looked very aesthetically pleasing but also was very stable. To provide encouragement to the other masons to make similar innovations in their work, it was decided that this tilted block jaali would be incorporated into the front elevation wall somehow. While executing the other full height jaali in interlocking CEBs, the same issue of varying block lengths had to be dealt with. The masons were made to measure each block used and group similarly sized blocks so that they could be used together without disturbing the jaali design and stability.  Day 7: Fly-ash Masonry & Ferro-cement Channel Roofing Jaalis using fly-ash brick were executed in the veranda front and for making ventilator screens in a toilet wall. These jaalis were constructed with stress on accuracy of masonry levels and angles and were finished by pointing immediately after. Precast ferrocement channels were placed over a back room to complete its roof.

Figure 10 : Fly-ash brick jaali, Ferro Cement channel being placed.

Mason interactions: The spiraling fly-ash masonry jaali was of great interest to all the masons alike. A special template was made with which 15 degree markings were made on each brick used allowing for the spiraling masonry to maintain its centre of gravity. Great care was given to the pointing and finishing of this particular jaali.

 Day 8: Casting Roof and Lintel Beams

Orissa-Artisan Training Report

Figure 11 : Beam reinforcement being placed, wall masonry up to the lintel level.

The beam that was to support the roofing over the columns was cast. The wall masonry was completed up to the lintel level. Mason interactions: Maintaining the level of the 45 beam being cast was a task and requirement the entire team of masons to work together. Instead of using wooden shuttering on the sides to cast the concrete, the masons suggested the use of old CEBs which could be later removed. This method saved a great deal of time in casting the beam.

 Day 9: Rat-trap Masonry, Bamboo Structure, Plank and Joist Roofing The internal walls were completed in rat trap masonry. A front overhang to the veranda was designed to be constructing using bamboo framing and MCR tiles. Treated bamboo was cut to size and joined used the various joint details and wiring. Bamboo columns were cast into the ground for vertical support and split bamboo sections were used as rafters spanning the width of the frame. Precast Planks were installed on the beam. Mason interactions: The rat-trap masonry technique, already prevalent in the area, was known by most of the masons and the ones who did not know were supervised by those who did. Special artisans who work with bamboo were called in and made to work with the masons to be trained demonstrating the techniques of construction with bamboo. The bamboo structure to be built was worked out in collaboration with both groups. Initially they were skeptical whether such a structure would indeed be able to support the MCR tiles in a uniform fashion. After working out a rafter detail of split bamboo with them, and supporting a few MCR tiles on it, confidence was established in the system and the rest of the bamboo structure was completed.

Orissa-Artisan Training Report

Figure 12 : Rat trap masonry in the internal walls

Figure 13 : Completed bamboo frame structure, Planks installed over the beam covering the veranda space below

Orissa-Artisan Training Report

 Day 10: Roof Finishing & MCR Tile Roofing Cement concrete was laid over planks to finish it. This was done with a slope to allow water run-off. Painted MCR tiles were placed overlapping each other over the bamboo frame.

Figure 14 : MCR tiles beign installed on the bamboo structure, Completed structure after the tiles have been laid.

 Concluding session: On the last day of the training there were sessions for mutual interaction among trainees, master masons and master trainer. They were asked to share their views on training conducted, learning, their expectation and improvement. To reinforce the gained knowledge a recap of 10 day’s learning were presented. Thereafter, an oral test as well as a practical examination was conducted to evaluate learning of trainee masons. Masons were awarded grade and remaining instruments of their tool kit.

Orissa-Artisan Training Report

5. Observations and Lessons learnt

 The local masons are keen to experiment in various aesthetics of different materials that haven’t really been explored so far at the BMSB. The masons have already developed these in their day to day work and these must be further employed.

 Full potential of different materials by experimenting with various masonry techniques, roofing techniques, etc needs to be understood. There is still much scope for innovation in the design and use of these technologies.

 Standardization of block sizes, especially in walling materials is a must. Production of half blocks and standardizing cutting techniques are needed.

 To maintain quality of construction, more such masons need to be trained more strictly in basic good construction practice.

Orissa-Artisan Training Report

6. Annexure 1 : List of Participants

01 Paramananda Tarai At:-Sankar Pur, Po:-Sankar Pur P.S:-Chaudwar, Dist:-Cuttack 02 Kartik Chandra Sahoo At:- O.T.M Bazzar 2no. Word, Po:-Chaudwar P.S.:-Chaudwar, Dist :- Cuttack 03 Sasmita Sahoo At:-Paikar Pur, Po:-Daulatabada, P.S:-Chaudwar,Dist:-Cuttack 04 Rina Nayak At:-Charigharia, Po:-Daulatabada P.S.:Chaudwar, Dist:-Cuttack 05 Prakash Behera At:-Naupatana, Po:-Kayalpada, P.S.:-Chaudwar, Dist:-Cuttack 06 Manas Nayak At:-Gopal Pur, Po:-Chasapada, P.S.:-Chaudwar, Dist:-Cuttack 07 Rabi Pradhan At:-Gopal Pur, Po:-Chasapada, P.S.:-Chaudwar, Dist:-Cuttack 08 Suzit Behera At:-Rangal, Po:-Godiputmatiapada, P.S.:-Dalanga, Dist:-Puri 09 Prasanta Bisoei At:-Charbatia, Po:-Charbatia , Dist:-Cuttack 10 Sudhira Swain At:-Similihand, Po:-Kayalpada, P.S.:-Chaudwar, Dist:-Cuttack 11 Narendra Swain At:-Samilihand, Po:-Kayalpada, P.S.:-Chaudwar, Dist:-Cuttack 12 Laxmidhara Pradhan At:- Samilihand, Po:-Kayalpada, P.S.:-Chaudwar, Dist:-Cuttack 13 Tapas Behera At:-Kumar Pur Po:-Kumarpur , P.S.:-Grudighatia, Dist:-Cuttack 14 Narendra Swain At:- Samilihand, Po:-Kayalpada, P.S.:-Chaudwar, Dist:-Cuttack 15 Samir Sahoo At:-Sasanga, Po:-Kumar Pur, P.S.:-Grudighatia, Dist:-Cuttack 16 Prakash Parida At:- Sasanga, Po:-Kumar Pur, P.S.:-Grudighatia, Dist:-Cuttack 17 Khadim Sek A/P:-O.T.M. Labour Coloni , P.S.:-Chaudwar, Dist:-Cuttack 18 Ratnakar Mallik A/P:-O.T.M. Labour Coloni ,P.S.:-Chaudwar, Dist:-Cuttack 19 Sasadava Mallik A/P:-O.T.M. Labour Coloni ,P.S.:-Chaudwar, Dist:-Cuttack 20 Daitari Pradhan At:-Badapada Po:-Dianipatana, P.S.:-Chaudwar, Dist:-Cuttack 21 Kalandi Khatua At:-Mundumala, Po:-Chaudwar, P.S.:-Chaudwar, Dist:-Cuttack 22 Mrutunjaya Swain A/P:-Bhatimunda, P.S.:-Tangi, Dist:-Cuttack 23 Kalandi Swain A/P:-Daptari, P.S.:-Chaudwar, Dist:-Cuttack 24 Naresh Lenka At:-Biratbazar.,Po:-Charibatia, Dist:-Cuttack 25 Dusmanta Swain At:-Banipada,Po:-Banipada,Dist:-Cuttack

Orissa-Artisan Training Report

7. Annexure 2 : Drawings

Orissa-Artisan Training Report

Funded by :

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