Amber Denim Loom Shed - Amazon S3

by Danny Wicaksono

2019 On Site Review Report

Amber Denim Loom Shed

Architect Jubair Hasan / Archeground

ClientShowkat Aziz Russell

Design2013

Completed2015

Gazipur, Bangladesh

5036.BAN

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Amber Denim Loom ShedGazipur, Bangladesh

I. Introduction

The Amber Denim Loom Shed is a project that was initiated by Amber Denim Ltd. The structure is located inside the Amber Denim factory compound, in the Gazipur area of Bangladesh.

What started as a project to welcome guests and buyers, evolved into an activity space for workers and visitors of the factory, improving their welfare.

The design, by Jubair Hasan of Archeground, takes its inspiration from a traditional Bengali pavilion – a simple post-and-beam structure with pitched roof that can be found in villages all around Bangladesh.

Working with the factory workers, the architect led the process of building the shed/pavilion using three main materials: unused gas pipes that were already owned by the client as the main structure of the building; local bamboo for walls; and custom-made concrete roof tiles.

II. Contextual information Bangladesh is a riverine country, located on the warmer side of the continent. The temperature is around

12–40°C, with humidity around 60–80% throughout the year. These natural conditions makes it an ideal region for textile production.

Textiles have always been a part of Bangladeshi culture. The area has been very well known for producing high-quality textiles since long before Industrial Revolution.

After the Bangladesh War of Independence in 1971, the textile industry rose to another level, and is now one of the biggest in the world. Many Bangladeshis work in textile and garment factories, and the issue of workers’ safety and welfare has been one of the major concerns to come out of this situation, due to the poor conditions they have been enduring.

The owner of Amber Denim (est. 1996), one of the biggest textile factories in Bangladesh, initially felt the need to build a space where they could present their products and operations to their buyers. They asked Jubair Hasan to design it for them. The location is an empty piece of land inside their factory. Located next to the workers’ compound and several other factory facilities, it is a relatively flat site, with a small canal to one side.

Jubair Hasan wanted to create a building that reflects the design of a traditional Bangladeshi pavilion – a semi-open, simple post-and-beam structure with pitched roof, that can be found in many villages in the country. He felt compelled to do this because nowadays there are fewer and fewer people living in the villages, and the construction techniques to make these pavilions are slowly disappearing.

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III. Programme

After working with the architect on another project, the owner of Amber Denim Ltd asked Jubair Hasan to design them a facility inside the factory compound, in the Gazipur area, that would be used as a space to welcome their buyers, to communicate how they operate, and to showcase the quality of their products.

In this space the client wanted to have a lounge area, with kitchenette and seating, where they can relax while doing business; an area to showcase their loom machines and the process of looming in their company; and prayer space for anyone to use.

Jubair Hasan then came up with a design that employs previously unused steel gas pipes as the main structure of the building. Realising that the construction workers of the factory had experience in working with steel structures, he decided that they should be the ones to execute the construction of this building.

After the building had been completed and been running for a while, the company felt there was a growing need to provide a dedicated space for workers – a space where they can attend workshops about safety, efficiency and other aspects of work. The company then decided to alter the function of the building. It now became more of an activity space for the workers and an alternative place of work that is more open than the regular working space. In addition to the workshops and classes held here for the factory employees, visitors who wanted to know more about the factory are brought here to be given explanations about the company. Educational events are also held here, in the form of courses on topics that relate to the company’s field of expertise. There is also quite a large area that showcases different traditional looming machines of Bangladesh, and an area which displays a modern looming machine.

IV. Description

A. Building data: volumetry, massing, number of units, surface in square metres, etc.

The building is a single mass, a rectangular structure covering an area of 1,068 square metres. The whole footprint of the building (including the body of water) measures 80 metres long and 30 metres wide.

B. Evolution of design concepts

The site that was initially presented to the architect for this building was actually around 10,000 square metres. It is an empty plot located in the middle of the factory compound, next to another facility and the workers’ compound.

The architect decided to make a setback from the nearest logistical circulation route, creating an open space that can be used for outdoor activities.

Reacting to the initially stated requirements, the architect placed the two main areas of this building in its two ends: the visitors’ lounge closer to the end where most visitors will enter the building, and the more noisy looming machines area in the farther part, closer to the workers’ compound, where fewer visitors would enter first.

All the active areas are positioned in the middle of the building, leaving two wings for circulation.

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Most of the interior has no walls. Only toilets and storage areas have solid walls. Partitions for other areas are made of bamboo, similar to the building’s exterior walls.

There is no ornamentation in the building, but shadows created by the sun penetrating the bamboo walls, and also water reflections in the ceiling, give a natural ornamental sense that creates different atmospheres in the building.

The water body around the building was added as a way to create boundaries and also to maintain humidity inside the building at a certain level, so that the yarns in the looming machines maintain flexibility.

C. Structure, materials, technology

The main structure of the building is post-and-beam, with pitched roof, employing 10-inch gas pipes that the company had previously bought but had not used. Since the length of a single pipe is 40 feet (12 metres), the architect thought there was enough length and strength for this pipe to serve as the building’s main structure.

The roof covering is of custom-made concrete roof tiles, produced on site. Fewer and fewer buildings in Bangladesh use roof tiles, and the technique of making them is slowly disappearing. Jubair Hasan saw it as part of his obligation to maintain the presence of this material, which is why he used roof tiles for this building.

Walls are made of local bamboo that is dipped in a chemical solution and then treated with oil (chorsh polish) and bobhakali (a type of local sand) to give a dark and coarse finish.

The floor is in concrete with a cement finish.

Even though the inspiration of the structure comes from traditional Bengali pavilions, the construction technology used in this building is a relatively modern welded steel structure, concrete/cement-based materials, and bamboo with chemical treatment.

D. Origin of:

1. Technology

The origin of the technology is modern. Steel and concrete structures have been widely used in the past 100 years. Bamboo has been widely used in Bangladesh as a material for traditional buildings, but its use is waning.

2. Materials

The unused steel pipes, for the main structure of the building, were said to have been bought from China and delivered to the site using shipping containers.

The cement to make the concrete roof tiles, floors, foundations and other related parts was bought locally.

Bamboo was bought in a local bamboo market. Amber Denim Ltd is now planting bamboo in the factory facility, so they can source it easily, should any of the bamboo used in the building need to be replaced.

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3. Labour force

The labour force were the factory workers.

4. Professionals

The architect, Jubair Hasan, is a Bangladeshi architect who had worked on several projects for this client prior to working on this building.

The contractor is another employee of the factory.

All the consultants who worked on this building – structural engineer, MEP consultants and others – were employees of the factory.

V. Construction schedule and costs

A. History of project design and implementation, with dates

After working on another project for the client, Jubair Hasan was appointed as the architect of this building in 2013. Took him five months to design the building, and so later that year, in September 2013, the construction process began. In January 2015 the construction was completed, and in February 2015 the building was in operation.

B. Total costs and main sources of financing

The total cost of the building is 90,000 USD. This is half of the initial budget. The source of the financing is from the client’s private funding or the Amber Denim Ltd company.

C. Comparative costs (if relevant)

Not applicable.

D. Qualitative analysis of costs (per square metre, per unit, etc.)

Not applicable.

E. Maintenance costs (heating, cooling etc.)

The maintenance costs for the building are almost zero, especially for heating or cooling, because of its semi-open design. The materials used are highly durable, so there is very little need to replace them.

F. Ongoing costs and “life performance” of building, in terms of materials, maintenance, etc.

In terms of electricity, the building uses around 20 kWh for its operations, compared to 50 kWh that were allocated for it. The whole compound has a capacity of 3,600 kWh, generated using the company’s natural gas electric generator.

There are no ongoing costs for the building.

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VI. Technical assessment

A. Functional assessment (use)

The shed has been operating for over three years now. After three years there was an alteration in the function of the space. What was once projected as a buyers’ lounge, or a buyer-oriented space, has now become a more workers-oriented space – a sort of activity area for the factory employees.

The space now hosts workshops, safety awareness classes and orientation classes for factory workers, and also hosts students or other visitors who want to know more about the factory. Due to the open-plan nature of the space, it can easily house different activities that the owners want to hold.

The original plan that was designed with the client has now gone through some changes. The prayer room has become a loom machine gallery, showcasing loom machines from different eras and areas.

The toilets do not seem to be used very often, and also does not seem to be well maintained. Waste from the toilets goes to a septic tank, and the excess goes straight into the ground.

The loom machines area seems to work well. There is a flexibility of plan, in terms of how the looms are placed.

The dining area / lounge area, which initially was planned to be located in one side of the building, was not built. Instead, the space is now a multi-purpose area for classes or workshops for factory workers.

B. Climatic performance, lighting, natural and/or mechanical ventilation, sun control, insect control, acoustics, orientation, etc.; description of systems developed and utilised

In terms of climatic performance, the building performs admirably. The bamboo walls soften sunlight that hits the west-facing façade. Inside the shed never lacks light. It is very well lit.

Air also circulates very well. It feels significantly nicer inside the shed than in the neighbouring open field. It is cooler inside the shed, in the shade.

The water body placed to both sides of the building was intended as a way to help maintain a certain level of humidity, so that the yarn has enough flexibility when it is woven. It seems to fulfil this function effectively, as the loom machines were working non-stop during the review visit, and the weaving process was running smoothly.

C. Response to treatment of water and rainfall; discharge of water, and retention and release systems (if any)

There is nothing special about the response to treatment of water and rainfall in this structure. Rain that falls on the roof is contained inside the pond that is located around the structure.

The water that was used to fill the water body / pond came from a bore well that is also used by the whole factory compound.

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D. Environmental response; adaptation to the natural environment; adaptation to native flora and fauna

The most significance effort regarding environmental response in this structure is the use of local bamboo for its façade.

Since the building was completed, Amber Denim Ltd has been planting bamboo trees around the shed. This seems to help lower the temperature, and also provides a greener view for people who are using the shed.

E. Choice of materials, level of technology

The bamboo used for the façades of the building is in good condition. It is protected well from the rain by the roof’s overhang.

The main structure of the shed, made of surplus steel pipes, is in good condition as well. The flooring, made of concrete with cement plaster, is also in good condition. Both construction techniques are simple, but need to be done by professionals who have sufficient experience in working with these types of construction.

The building uses concrete roof tiles that were custom-made on site. The construction technology is simple and can be replicated by many people. It is a more durable and versatile alternative for roof covering than the zinc roofing that is now widely used in Bangladesh.

F. Response to, and planning for, emergency situations, i.e. natural disasters, floods, winds, fires, earthquakes, etc.

The building benefits from good safety measures. Fire extinguishers are located in places that are very easy to access and find. The building also has large openings in both ends that connect directly to an open field.

The structure also seems to be sturdy enough to withstand earthquake, with no materials that can drop easily from the ceiling or the roof, should there be tremors from earthquake or any other cause.

Exposed electricity cables in several parts of the building might be prone to be damaged by animals or other factors that could cause a short circuit.

G. Ageing and maintenance problems

The design of the building makes it very easy to maintain.

There should not be any significant problem in maintaining the bamboo façades, if any parts of them should need to be replaced.

All other elements of the building are made with relatively strong and durable materials. The building ought to last for a long time with little maintenance.

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H. Design features: massing and volume, articulation of spaces, integration into the site (topography and neighbouring buildings)

The design of this structure is very simple. It is a rectangular single-storey building, spanning north to south, with the longer façades facing east and west. This positioning concept creates an attractive shadow feature during the afternoon, when the sun hits the west façade. Also when the sun hits the water, it creates a nice reflection in the ceiling of the overhangs.

All active spaces are located in the centre of the building. Linear circulations are located in the east and west of the space, spanning from north to south. This creates uninterrupted activity spaces, allowing multiple and various types of activities to be held in the building.

I. Impact of the project on the site, in terms of increased circulation or vehicular movement, changes required for infrastructure (particularly for projects in high-density areas), etc.

The project was built on a vacant plot at the back of the factory’s compound. It is located near factory facilities and the workers’ housing compound. There is no direct connection between the building and any of the factory’s facilities or the workers’ compound.

Its location does not impact the factory’s logistical circulation, but the positioning of the building has created an open field that is often used by factory workers for recreational activities or other factory gathering events.

J. Durability and long-term viability of the project

Looking at the materials used, the location of the site, the activities held and the background of the owner, it is highly possible that this project will be where it is, for as long as the company exists.

K. Ease and appropriateness of furnishings; interior design and furnishing

Several items of furniture were custom-made for the building by the architect. Some tables and chairs, for workshop purposes, were designed by the client/factory.

The designs are attractive and suited to the characteristics of the place and the activities inside it.

The toilet furnishings are not as good as they might be. The toilet bowls and washbasins are good products, but the wall finishings and floor are not very neatly done.

VII. Users

A. Description of those who use or benefit from the project (e.g. income level, socio-cultural profile, etc.)

The people who benefit from this project include the factory workers, most of whom are Muslims and come from underprivileged backgrounds. The building also benefits people who are interested in knowing more about how the factory works. But ultimately it is the company that benefits the most from this project, because this facility is designed to increase productivity, communication, work efficiency and workers’ safety.

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B. Response to project by clients, users, community, etc.

There are mixed reactions regarding this project. Architecturally, it has gained praise and respect among Bangladeshi architects for its design. Several awards have been given to the project.

There are also some in the country who are of the opinion that this project is essentially a “greenwashing” move by the company, to raise its image amidst the current attention on garment industries in Bangladesh due to poor working environments.

However, it should be noted that after looking around the facility, one has the impression that this company treats its workers properly, providing them with an excellent working environment as well as decent living quarters located inside the compound.

VIII. Persons involved Client: Showkat Aziz Russel Principal designer: Jubair Hasan Structural consultant: A.K.M. Saiful Bari Master craftsman, steel structure: Mojibur Rahman Mostafa Chief engineer, utility & maintenance: Thowai Mogh Mong Civil contractor (outsourcing): Abdul Manan Landscaping: Jafar Ali Khan Jafar

IX. Bibliography

• Genesis & Response, 2016 Published by ARCHEGROUND LTD, 44/1, Lake Circus, Kalabagan, Dhaka 1205 +88 02 9138516

[email protected] • Journal of the Indian Institute of Architects Refereed journal of IIA, ISSN-0019-4913. Vol.82, issue 2, March 2017 • DOT Art & architecture magazine Bangladesh Vol.2, issue 1, September 2016. Published by DELVISTAA Foundation Bangladesh • 2A Architecture & art magazine ISSN: 1735-519-2. Autumn 2015 / Winter 2016 quarterly, issues 33 & 34 • Bengal Stream: The Vibrant Architecture Scene of Bangladesh ISBN 978-3-85616-843-8 www.merianverlag.ch • IAB newsletter Issue 4/21, January 2016 (period: October–December 2015). Published by Institute of Architects Bangladesh

Danny WicaksonoMay 2019

Site plan

Ground floor plan

Section

The loom shed was built on a vacant land in the back end of the factory’s compound.

The position of the building has created an open-field that is often being used by factory workers for recreational activities or other factory gathering events.

It is a rectangular single story building, spanning north to south, with the longer facade of the building facing to east and west, inspired from the traditional Bangali pavilion.

Three main materials are unused pipe gas that was pre-owned by the client as the main structure of the building; local bamboos for wall materials and, custom made concrete roof tiles.

Waterbody around the building was added as a way to create boundaries and also to maintain humidity inside the building at a certain level.

Only toilets and storage areas have solid walls. Partitions for other areas, are using bamboo walls.

An area showcases traditional looming machines of Bangladesh.

The Loom shed became more of an activity space for the workers and an alternative place of work that is more open than the regular working space.

Buyers are driven in the loom shed where they can see the quality of the products and how the factory is operated.

Workshops about safety, efficiency and other aspects of work are organised in the shed.

The main structure of this building is post-beam structure, with pitched roof.

10” unused gas pipe that the company had previously bought, but did not used, have been reused as main building structure.

The roof covering is using custom concrete roof tiles made on-site.

Bamboos used for the facades are in good condition, protected well from the rain and water, by the roof’s overhang.

Architect Jubair Hasan / Archeground

Client Showkat Aziz Russell

Design 2013

Completed 2015

The “Loom Shed” is a new design that employs a traditional Bangladeshi residential architecture with contemporary elements that give it a modern twist. The building has a simple layout comprising a large open space to accommodate the loom machines, a buyers’ lounge, a dining space for workers, a prayer area and washrooms. The factory workers took an active part in the building process and put their knowledge of vernacular building techniques to use. The whole structure is erected on an artificial waterbody and supported by upcycled gas pipes that act as steel columns. The high ceiling, bamboo screen-walls and open space design allow natural light and ventilation, thereby eliminating the need for artificial air-conditioning or lighting.

5036.BAN

2019 Award Cycle

Gazipur, Bangladesh



Gazipur, Bangladesh

Architects Archeground / Jubair HasanDhaka, Bangladesh

Client Showkat Aziz Russell

Commission 2013Design 2013 – 2013Construction 2013 – 2015Occupancy 2015

Site 283,280 m2

Ground Floor 1,068 m2

Total Floor 1,068 m2

Costs USD 90,000

Programme On the grounds of an existing factory outside Dhaka, the new shed contains fifty looms and a buyers’ area, as well as dining and toilet facilities and a prayer area for the workers. Based on traditional residential architecture, the main structure employs unused gas pipes as steel columns that measure 25 cm in diameter, and the roof is supported on steel girders; concrete tiles cover the roof that is raised in six places to evacuate hot air.Bamboo screens are used for infill walls and provide natural ventilation and lighting. Water is an essential component of the design, and the building seems to float within lily ponds located along both sides of the long, horizontal plan.

Building Type Industrial Facilities2019 Award Cycle 5036.BAN

5036.BAN

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Gazipur, Bangladesh

Client

Amber Denim Ltd, Dhaka, Bangladesh

Showkat Aziz Russell, chairman and managing director

Architects

Archeground, Dhaka, Bangladesh:

Jubair Hasan, principal

Nabi Newaz Khan, Lutfullahil Majid, Tahmida Afroze, Ahmed Faisal, architects

Project Manager

Shahidul Hasan, Director, Amber Denim Ltd

Structural Consultant

Saiful Bari, Dhaka, Bangladesh

Steel Structure

Mojibur Rahman Mostafa, Gazipur, Bangladesh, master craftsman, Amber Denim Ltd

Engineering, Utility and Maintenance

Amber Denim Ltd, Gazipur, Bangladesh:

Thowai Mogh Mong, chief engineer

Contractor

Abdul Manan, Gazipur, Bangladesh

Landscape

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Jubair Hasan, Jafar Ali Khan Jafar, Gazipur, Bangladesh

Project Data

Site area: 10,000 m2

Ground floor area: 1,068 m2

Cost: 90,000 USD

Commission: February 2013

Design: March 2013 – August 2013

Construction: September 2013 – January 2015

Occupancy: February 2015

Jubair Hasan/Archeground

Jubair Hasan is a practising architect who graduated from Bangladesh University of Engineering and Technology in 2008, then worked as a project architect for Vitti Sthapati Brinda Ltd until 2010. Thereafter, together with Nabi Newaz Khan and Lutfullahil Majid, he founded along a design-studio-based platform, Archeground Ltd. He is continuously in search of a language, through his work, which can complement the context, climate and culture of his country.

Every project is a pursuit of his vision to develop an architectural vocabulary that truly represents the specific socio-cultural attributes and contextual demands of the situation. He was shortlisted for several awards and competitions while working with Ehsan Khan Architects and later with ‘Team Archeground’ (TAG). He is a founder member of Mongolbarer Shabha Lecture Forum, a platform that promotes dialogue between architecture students, professionals and individuals from different disciplines and different generations. The ideology of master architect Muzharul Islam is an inspiration for him.

5036.BAN Amber Denim Loom Shed

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P05036_BAN_DRAWINGS_Detail_Section_01.jpg© Md Jubair Hasan

P05036_BAN_DRAWINGS_GF_plan.jpg© Md Jubair Hasan

P05036_BAN_DRAWINGS_Section_AA.jpg© Md Jubair Hasan

P05036_BAN_DRAWINGS_Site_plan.jpg© Md Jubair Hasan

P05036_BAN_DRAWINGS_West_elevation.jpg© Md Jubair Hasan

P05036_BAN_Ground Floor Plan.tif© Md Jubair Hasan

P05036_BAN_Section AA.tif© Md Jubair Hasan

P05036_BAN_Site Plan.tif© Md Jubair Hasan


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P05036_BAN_SANDRO-001-DJI_0494.jpgPhotographer: Sandro di Carlo Darsa© Aga Khan Trust for Culture / Sandro di Carlo Darsa







P05036_BAN_SANDRO-008-_DSC1341.jpgPhotographer: Sandro di Carlo Darsa© Aga Khan Trust for Culture / Sandro di Carlo Darsa




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