TRANSCRIPT

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Doug Pat (DP)

Let's go inside the vault. The design vault.

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Mateusz Nowacki (MN)

They grew up in small villages in southern Poland, where a lot of the typical houses there are just built out of, like, clay brick. One could look at that and say, well, that's really utilitarian and where's the cladding? But to me, I find that really interesting. I'm like, oh, that is the cladding. And how do we kind of represent that in a new way?

Hence, where we landed with the materiality of this project, which is a kind of smoked, darker tone sort of clay brick that ages really well and has this kind of grace and it's timeless quality.

00;00;30;27 - 00;02;13;21

DP

In this special series, we're unlocking some of the most powerful conversations we've had so far. We're connecting the dots, revealing hidden gems and unearthing insights that might have slipped by, all to spark your next big idea with brick. Whether you're looking for fresh inspiration or innovative solutions, this series is designed to fuel your creativity. So let's dive in.

Hi, I'm Doug Pat and this is Design Vault. Today, we travel around the world to examine the architectural vision behind three remarkable projects with insights from William Smart, founder and Creative Director of Smart Design Studio in Sydney, Lorne Rose, principal architect of Lorne Rose Architect in Toronto, and Mateusz Nowacki, architect and designer of the H House in Ontario, Canada. We’ll highlight various aspects of each project, including the architectural design process, construction challenges, and the thoughtful use of brick to blend modern and traditional esthetics.

When working on these projects, each architect faced the challenge of integrating modern design elements while honoring the character and history of their respective contexts. William Smart's Smart Design Studio, located in Sydney's inner city, stands within a conservation area of brick warehouses. William designed the building to reference the industrial roots of the area, while incorporating bold, modern design gestures. The curving and peeling brick facade creates a sculptural and dynamic presence, showcasing an innovative use of brick in a contemporary setting.

00;02;13;27 - 00;03;29;05

William Smart (WS)

So there's an existing warehouse here, and the front strip of that building, which was where the office’s meetings had been adjusted so many times over the past 60 years that it had lost all its integrity. And we demolished that front seven meters and rebuilt that. And then we kept the rest of the warehouse, which was about 80% of the footprint, and restored that.

And that's where that big room is in our studio. And the front strip, which is seven meters wide, has a beautiful brick vaulted facade that almost looks as though it's peeling open. The brick kind of curves outwards and leans downwards, and we worked out a way to lay bricks facing in a downward direction, and peels up again the other way.

And at the top of that three storey structure, we have this apartment building, which is called the four walls that we spoke of before. And so what we tried to do with the project was to use everyday, ordinary materials like galvanized roof sheeting and galvanized steel windows and a very simple brick. But to take these materials and do something extraordinary with them.

So make kind of beautiful sculptural shapes, or to make beautiful load bearing brick folds. So that was one of the primary objectives. And it talks to the history of the area and really relates back in a very sympathetic way to the context.

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DP

For Lorne Rose, the Tudor home in Toronto was inspired by a traditional Tudor style house from the turn of the century, but with modernized materials and craftsmanship. Replacing the half timber board work with stone, Lorne created a more durable and refined facade, all the while maintaining the Tudor character through intricate brick patterns like diagonal herringbone and basket weave.

00;03;53;17 - 00;05;23;14

Lorne Rose (LR)

There were some Tudor, a lot of postwar architecture. Toronto was very much influenced by English architecture, especially at the time, but the home that was the inspiration for this one was a much smaller home near Forest Hill Village. You know, where my office is, it was a much smaller home that had beautiful brickwork. And the Mick band was a homage to that house in Forest Hill.

Way to describe it is an orange segment carving. It would have been done out of wood on the original house, and these beautiful brick patterns, which you would see on other homes in Forest Hill village that really caught my eye and nobody really replicates properly these days. In addition to the first floor, as it were, carved, details like that on the old Tudor homes from the turn of the century in the revival of these styles are always left out.

So we really wanted to do it correctly on this home, and the homeowner spent extra money to do it properly and more authentic. Subsequent to that, there were quasi replicas of this house that popped up. People are in Toronto and they see something they want to emulate, but I don't take it as an offense, I take it as a form of compliment.

I didn't invent anything here. I was borrowing from, I have selected borrowing details from architecture styles that I like, and I do it with any style of modern or Georgian or French provincial. I like to use the most authentic details that clients will allow us to afford.

00;05;23;16 - 00;05;48;21

DP

Mateusz Nowacki’s H House located in a suburban area embraced minimalism and functionality. The home's clean, modern lines are contrasted with the strong material palette, where brick serves as a key element in grounding the design. The use of brick in simple linear forms respects the suburban context, while emphasizing craftsmanship and architectural simplicity.

00;05;48;23 - 00;07;00;10

MN

From a style perspective, the house is certainly a deviation from them, like they used to kind of live in a house that was quite ornamented and detailed and things like that was a beautiful house, right? But I think them seeing me continue to work on projects and the kind of projects I was working on, it really started to kind of have an effect on them.

And me coming on home at Christmas and talking about how important natural light is and that kind of stuff. It really had an impact. So they saw that as something that they could kind of work with themselves in terms of how to approach the house. And then on top of that, we looked at references of Eastern European architecture that felt familiar to them in terms of their context, right.

So they grew up in small villages in southern Poland, where a lot of the typical houses there are just built out of like clay, brick and the clay brick is exposed, all the mortar’s exposed, so it's all load bearing. One could look at that and say, well, that's really utilitarian and reflective of the structure of the house and you know, where's the cladding?

But to me, I find that really interesting. I'm like, oh, that is the cladding. And how do we kind of represent that in a new way? Hence where we landed with the materiality of this project, which is a kind of smoked darker toned sort of clay brick that ages really well and it has this kind of grace and it's a timeless quality.

So we looked at those precedents as a reference in terms of where the style of the house itself went.

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DP

Each project seamlessly blends modern elements with traditional craftsmanship. A strong emphasis on materiality and detail was evident in all three projects. William's use of brick in the Catenary Vaults of the caretaker's apartment is a striking example of blending contemporary design with age-old techniques.

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WS

I've had quite a lot of experience in working with brick, so over the years I've started to understand how to do more joints really well, how to make it kind of work gymnastic so it can do more expressive forms, and it felt like the right material. And then for us, it came down to the point of choosing exactly the right brick and we have two types of brick in our building.

One is called a dry press brick, and that's made about 60km from Sydney to very local and they're beautiful. They're white to they're in the space that I'm in now. They're chalky. They chip easily. They have incredible material quality to them. And because they're on the inside, we can afford to use these more softer bricks and look after them well.

And then on the outside of the building, we used a very durable brick called La Paloma, which is made in Spain, actually, and we wanted to use a black brick on the outside of the building for a bunch of different reasons. But in Australia we don't have the really good clays and my good black bricks. So we had to use the Spanish brick and they made a special profile for us so they were able to customize it, and they're just incredibly strong and durable and look beautiful with the trees in the landscaping that's in this area.

And marry perfectly with the building opposite that I mentioned.

00;08;36;10 - 00;08;55;10

DP

So let's get back to these unique vaults in the apartment. How did you build these? So there's a series of them. I saw some photos. They looked like they were built in one location or perhaps moved, or were they built at the spot they ended up in? And they're also a really unique shape, right? They're elliptical.

00;08;55;13 - 00;11;18;16

WS

Yes. They're all built in situ and how we built them was pretty close to what we imagined at the start. So we made a catenary shaped false curve. So like a hull of a boat sitting upside down, we made a timber plywood form. And then we literally put the brakes on top of that form so that the mortar didn't leak out in between.

We didn't use regular mortar. We used a terracotta tile glue, and we glued the bricks together so that there's no mortar joints. And if you're laying them upside down, that's a good way to do it, because you don't have that problem with the mortar leaking out in an uncontrolled way towards the inside face. We made the timber false work that was all CNC cut and was put together without using any nails.

We worked out that you could make the CNC machine work very hard for you and the CNC cutting is incredible false work because you can make it a perfect shape and it's really fast. They were all cut overnight, delivered in one day, all assembled it within one week. So a very fast process. We laid the bricks across the top and then we put a thin layer of reinforcing mesh over the top of that.

And we sprayed it with 60 mil stick of concrete. Now in that process where all the bricks are glued together and you have this concrete on the outside, the brick itself in this catenary shape doesn't need any support. It will hold itself up. It is the perfect structural shape, and that shape can also be described by or represented by taking a chain and hold it at the two ends that slumps to a catenary shape in tension.

When you invert that and put that up the other way, it stays true to its shape. But it's all in compression, and brick is a great material for compression. It's strong when the forces are loaded on top of it, and the person that made that famous is the Sagrada Familia Building in Barcelona uses catenary vaults everywhere, and Antoni Gaudí is the master of how those elements come together.

We laid bricks on top. We sprayed it with a thin layer of concrete, what we call shock created in Australia. It's a similar way to how you build swimming pools. They dried that off and they left it to dry for a month. And then after that we took it away. So the concrete in that system provides stability, because you could imagine if you make this brick fold, then it's a bit vulnerable when you have kind of a strong sideways force, like a very large wind or a branch or a tree falling on it, it could all fall sideways and topple over.

And then you take it away and it stands up beautifully in this space. It's kind of fun to do all that.

00;11;18;18 - 00;11;32;21

DP

In Lawrence Tudor Home, the thoughtful arrangement of brick patterns and carved stone details brought a level of authenticity and timelessness to the project, enhancing the traditional Tudor aesthetic in a modern urban context.

00;11;32;23 - 00;11;58;16

LR

There were examples that I looked at as well, where the second floor, rather than brick, you could do some of these patterns in stone, but red brick was dear to the owner's liking, and I don't think there was really another option in the sides and the rear of the house there's a stone skirt that wraps around the house, but the rest of the house is broken while many people do a front end of all stone sites and red brick, it allowed us to tie the brick in all the way around the house.

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DP

What I think is really pretty when you look at the exterior gables, the half timbered construction has become stone. Talk a little bit about that. And where have you seen that in the past?

00;12;08;04 - 00;12;39;26

LR

There were some examples I've seen in the city, but for the most part, you know, even on a lot of the house since we do that are Tudor, but we'll have a cornice detail. Our winters are harsh, or whether it's harsh or summers or hot, sticky. And we have extremes. The thought of sort of painting wood timbers, have timbers every now and then was not something the homeowner wanted to do.

So we suggested doing them out of stone. There's no maintenance. So we've done that a couple of times just to cut down on maintenance. There are some parts that are wood, but not a lot of this house.

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DP

Matisse's minimalist approach to the brick design provided an understated elegance that complemented the home's modern design.

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MN

Specifically, I remember for my mother when I said, you know, we're thinking about this kind of clay colored brick and something that looks really natural. She loved that idea. She really never understood why more houses in a kind of contemporary context didn't do that, at least in the context where they live, and to some degree, because the house, you know, in its design, in its formal and massing quality, it can appear really stark compared to its neighbors.

The materiality choices of it are meant to sensitize that approach. So this notion of really conventional brick is meant to appear familiar to kind of the onlooker or to the person that, you know, lives in that home. It has this really timeless quality to it. It's like, I can understand that house because it's made of brick. It's made of a conventional thing that I know that's been around for ages and has its conventional color.

That's the color that brick usually looks like. When you ask a child to draw a brick, they're going to draw you a red brick. Maybe with three quarters if the child is advanced enough. Right. There's this familiarity which helps make the architecture more digestible.

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DP

So set up the building materials in general for us because the palette isn't just brick.

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MN

Yeah. So the kind of two wings that ground the house at the base are a smoked Tudor velour modular brick. So it has this kind of rusty sort of clay color.

00;13;57;09 - 00;14;02;24

DP

And those colors I would use the word variegated right so we see a series of different colors, that red clay.

00;14;02;24 - 00;14;28;02

MN

Yeah. The specification of the brick itself has a variation in it. It's up to a good bricklayer to make sure they patronize it quite well. But a lot of that is just coming from like the brick. Looks like it's been smoked at its edges and some are more smoked than others, which is where you start to get that kind of differentiation.

And we like that a lot because the house has these really monolithic, large brick volumes. And so the kind of variation, the slight variation in the tone really helped to kind of break that monotony apart a little bit.

00;14;28;06 - 00;14;31;21

DP

Was it hard to find a mason, a good mason?

00;14;31;21 - 00;14;32;26

MN

Yes. It's always hard.

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DP

It's crazy.

00;14;33;26 - 00;15;06;21

MN

Yeah. And so this is why, you know, as a studio, we think it's important to kind of collaborate with trades early on because they can help kind of understand or they can help kind of propose ideas about how to get the masonry right at these angles or at the cantilevers that we're proposing, things like that. And then the other materials, we're using a black standing seam metal above.

So conceptually, the volume that hovers above these two things floats. So metal felt more appropriate. And then we're using a composite wood system in between the windows. So that's meant to kind of be a homage to sort of old wooden shutters that kind of peel away from the window itself.

00;15;06;24 - 00;15;08;04

DP

Where did you find that?

00;15;08;07 - 00;15;23;08

MN

It's a product. I think it's based in the States, I can't recall. It's meant to be a veneer, but it's made out of wood fibers that are infused with like fiberglass and resin. Okay, so from a durability perspective, there's no means. So, and it retains its color over time really well.

00;15;23;13 - 00;15;29;04

DP

And you're using steel lintels over these large openings that you're then using this wood infill between the windows.

00;15;29;08 - 00;15;33;12

MN

Correct wood, the main one being the cantilever at the front entry of the home.

00;15;33;14 - 00;15;35;05

DP

So how did you pull that off?

00;15;35;08 - 00;15;54;06

MN

So you know we're looking at brick as a simple material. And it's execution that appears very traditional in the way that we're applying it. But we found moments where we could start to kind of give it a more contemporary execution. And the main one being that cantilever at the front entry, which is just upheld by steel beams that are cantilevered out and transforming their way back to kind of point lower.

00;15;54;06 - 00;15;55;24

DP

So they're tied back into the walls?

00;15;56;00 - 00;16;08;22

MN

Yeah. Correct. And that cantilever holds a terrace on the upper floor. So that dormer above the entry that opens out onto a south facing terrace that you can use. And even in the kind of cooler spring months, because the sun gauges that terrace quite nicely.

00;16;08;28 - 00;16;11;27

DP

Right. And that's a clear glass guardrail up there.

00;16;11;27 - 00;16;13;10

LR

Just a butt joint, no frames.

00;16;13;10 - 00;16;51;17

MN

No frames. Yeah. So that it just it kind of appears really minimal and visually to kind of carry on the notion of this house being an antithesis that's exemplified in this entry. Now, you know, just talking about it. So many of the houses in the context, you know, the entries are these large columnar conditions, you know, with very ornamented roofs and things like that meant to kind of evoke this kind of grandiosity.

And here I think we're trying to evoke a grand door, but we're doing so in a more nuanced way, layered elements, a kind of a structural acrobatic of this cantilever, the brick kind of enveloping you, your eye moving vertically towards that dormer. It's creating that grandeur, but doing so and using kind of tectonic architectural elements.

00;16;51;20 - 00;17;03;27

DP

Each project faced unique construction challenges. William discussed how his team worked closely with bricklayers and engineers to achieve the complex peeling facade and vaulted brick ceilings.

00;17;04;00 - 00;18;38;25

WS

All of the work is in sections, in cross-section, not in plan. So when you look at the building as a floor plan, they're all rectangular rooms on the inside, but in section we have a part of the facade that peels outwards at the top and sort of leans outwards. And we worked out a way to lay the bricks on top of each other almost at 45 degrees.

And we're able to do that with creating a small jig to lay them on. And then we laid up to three courses at once, and then we'd have to leave it for overnight and then lay another three courses the next day so it dried. And then on the bottom part, we lay them over a steel frame. And on that steel frame we had a curved sheet of metal.

So they were laid on to that curved sheet of metal and then tied back using brick ties to that other element that the projected outwards. That's sort of what was done in construction. How we came up with that was to work collaboratively with our bricklayers and our engineers and just sit down on the table, and we knew who we wanted to build the project before we'd finished all the documentation.

And so we're able to sit down with them at a meeting table. And I've kind of said, here's the vision, this is what we want to do. And this is how I thought you might make it, but I don't really know how to lay a brick. Can you help us with this process? And the builders we chose are experts in heritage construction, and they also know a lot about engineering.

So they were able to sit down with their bricklayers and myself and our structure engineer, and we workshopped it together. And in a few hours we worked out how to do that. And then they went away and did it on their own lawn.

00;18;38;25 - 00;18;50;17

DP

Lorne and his team also had to work closely with skilled masons to ensure the intricate brick and stonework met the high standards required to replicate traditional Tudor craftsmanship.

00;18;50;20 - 00;19;36;26

LR

At the time, I was dealing with a gentleman named Isaac Raposo from King Masonry. Now he had an idea. We worked with Isaac for years at King Masonry and other companies he worked at. He's passionate about brick and stone. So he said to me, Lorne, I got this special brick that's being used in university in the States, and it's Glen-Gery brick and it's 85% Shenandoah and 50% called 53DD that's being used at a university.

It had a nice tonal range. Some fired bricks in there. So it wasn't all flat coloring, a great deal of variation on the brick. And I said, great, let's do it. Isaac was instrumental in suggesting that brick and had other clients that have used a similar mix.

00;19;37;04 - 00;19;46;22

DP

So were there any unique construction details using masonry or brick on the home? Anything that you had never done before? Anything that you do a lot?

00;19;46;25 - 00;21;11;14

LR

This was the first time that I used the stone boards and so to speak, I have to bring and it was the first time, I believe, that I had these different brick patterns on a house, so it was challenging for the Masons. I remember calls about, how do you want to deal with this? Even on the stonework, we had some smoother blocks, but I wanted them chiseled with different patterns on them.

Really authentic stuff. Didn't want perfectly aligned joints. I wanted it a little bit, I call it messy, but when it's done perfectly linear, you can spend the money on a real stone. It does look real because it's so perfectly laid up. Bellies were put on a lot of the stones chipping the edges off. It's a little bit of a messier joint, you know?

I like to call it a rock joint. I was particular about the laying of the stone brick and quite happy with the way it turned out. The chimneys are quite detailed with different patterns as well, and limestone caps. One of the things I like to do is put superior clay chimney pots on jumbo ones. One of the details I loved and traveling in England is they would have many chimneys, and different clay pots on top of each.

Normally on our homes we put two of the same. I wanted to do something a little more British and mix them up. So each chimney has two different pots on it just for fun.

00;21;11;17 - 00;21;15;24

DP

For Mateusz, the design approach was driven by constructability.

00;21;16;02 - 00;22;29;25

MN

From a challenge perspective, I think the biggest one is one that surrounds the way in which I approach all my projects, which is buildability. With that, I mean, I try to find a way to create really interesting and engaging architecture using really conventional methodologies. So this is a stick frame house that limits its use of steel. And yet we see cantilevers and floor protrusions and things like that.

It's like, how do we get there if you're not building a full house out of steel and largely like my kind of interest in that was trying to make engaging and good architecture available to both clients and contractors at a better price in a way that feels more approachable from a building standpoint. And because with this house, my father being the contractor working on it, I knew inherently how he likes to build things and what his limitations are as a builder, I use that as a framework within which to start thinking about the design, thinking about the tectonics, thinking about really strategically where we're using more costly steel, where we were using larger expanses of glass, but also where we were tightening them up.

And so though the house looks like it's tectonically a lot more maybe complex than it looks, if you peel all of it back to the bones, it's no different than all the neighbors’, which are just typical conventional stick build houses with wood trusses.

00;22;30;03 - 00;22;34;19

DP

So a lot of thought went into, I would imagine how much this thing was going to cost?

00;22;34;21 - 00;23;21;28

MN

Certainly how much it was going to cost, and just the approach to how it was going to be built. So I remember, you know, when we were working through the construction documents on the project, having weekly conversations with the contractor and with trades that were involved from the early onset of how do we want to actually make this thing materialize?

How do we want to build this thing? Like, you know, how is this beam going to sit, what kind of post this is going to sit on and almost working through it with a really solid understanding of structural engineering, without going right to the consultant and asking him what to do. Like we had this really intimate relationship with how this thing was going to be built and in a way that sort of harkened back to the agrarian structures that it's influenced by.

Was the individual who owns that property is going to come in and look at the timber he has and build it himself. And we're sort of creating a modern interpretation of that approach in some degree.

00;23;22;00 - 00;24;20;15

DP

Reflecting on the design and construction of these three projects Smart Design Studio, the Tudor Home in Toronto, and the H House, several key themes emerge. Each project masterfully integrates traditional craftsmanship with modern design innovation. The architects William Smart, Lorne Rose, and Mateusz Nowacki emphasize the importance of collaboration throughout the process, working closely with craftsmen and construction teams to overcome challenges and bring their vision to life.

The use of brick as a versatile material is central to all three projects, whether it was to honor the history of a site, recreate the intricate patterns of a Tudor Revival, or enhance the minimalist esthetics of a suburban home, brickwork was reimagined to meet contemporary needs without losing its timeless appeal.