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Concrete challenges hit home for American expatriate

By: The Associated Press//March 21, 2023//

Concrete challenges hit home for American expatriate

The Associated Press//March 21, 2023//

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Cain Burdeau covers a wall of a barn near Castelbuono, in Sicily, Italy, with a coat of concrete plaster. Masonry has long been a popular construction method in Italy. (Audrey Rodeman via AP)

By Cain Burdeau

The Associated Press

CONTRADA PETRARO, Sicily 鈥 Everywhere you look in Italy, it鈥檚 there. It can be hulking and gray but also colorful and fun. Ominous but also beautiful.

Masonry using concrete and its old ingredient, cement, are inescapable here. It鈥檚 a crucial difference between construction in North America and in Europe: the carpenter versus the stone worker.

That was the difficult reality I faced when I moved with my family from the U.S. into a long-abandoned farm property a couple of miles outside a town called Castelbuono in the Madonie mountain range of north-central Sicily.

I had a whole bunch of ugly and crumbling concrete to deal with. Or that鈥檚 how I saw it at first.

Coming from a background in American carpentry, the art of masonry was entirely new to me. But here, in a land where laborers have long excelled with trowels, chisels, mortar mixes, stones and bricks, I realized I鈥檇 have to become familiar with them too.

Masonry is especially legendary in Italy, home to many of the world鈥檚 most spectacular examples of stone and mortar work. The country also boasts the largest unreinforced concrete dome still in existence: the Pantheon of ancient Rome.

As I began experimenting with concrete work and got a little better at it, I also gained greater appreciation for all those concrete buildings around me in Sicily 鈥 from the ancient beauties to the clunkier, Brutalist-style versions that went up in a post-World War II building boom.

The farm鈥檚 main part consists of two barns: an old stone structure, and a newer, tower-like one made of concrete blocks. Nearly five years went by before I finally attempted to turn the barns into a house.

During those years, my family had been living comfortably in a tiny, modern home, also built in concrete blocks, a few yards from the barns where the farmer who built this place kept animals and tools, and made wine and olive oil. The 430-square-foot home 鈥 with a flushing toilet, lights, shower, windows, veranda and tiled floors 鈥 was the reason we鈥檇 bought the property.

The hulking barns, though, remained always at the back of my mind, holding the potential to be transformed into a bigger, more beautiful house.

Finally, one day I picked up a borrowed, handheld jackhammer and started busting into the work.

Property owner Cain Burdeau pours water into a batch of concrete outside of a concrete barn being renovated into a home. (Audrey Rodeman via AP)

My first objective was to remove a concrete-and-stone bench sitting against a sagging wall of the old barn. After a few weeks of work, I鈥檇 burnt through my friend鈥檚 jackhammer and a cheap new one.

It was hard going. Hand chisels were more apt to bounce off than accomplish any demolition. Normal drills were useless. The hours accumulated, along with a pile of busted concrete bits, stones of many sizes, lots of sand and cement, steel rods, broken bricks, pebbles.

My back was sore. I was exasperated. I looked up and sighed at the thought of what still awaited:

One side of the two-story barn was bereft of even a coat of plaster, and bats flew in and out of its gaping cracks. A big concrete trough was pulling away from the wall of the main barn. Inside the barns, the walls had no electrical outlets. Water lines and windows were scarce. The floors needed to be layered in new concrete.

And maybe worst of all, concrete beams throughout the structure were showing cracks.

Overwhelmed, I went back to jackhammering, chiseling, cutting steel rebar, piling up rubble, cutting electrical lines into the concrete walls and, eventually, even beginning to plaster.

鈥淩ome wasn鈥檛 built in a day, I suppose,鈥 I bolstered myself.

In town, a friend and marble worker tried to teach me the mysteries of Italian construction, running his hand over a massive stone and mortar edifice.

鈥淟ook at this ancient place鈥檚 walls; look at how thick these walls are,鈥 said Antonio Capuana, admiration in his voice. 鈥淭hese are load-bearing walls that keep up the entire house. This wall was part of a barn for an old monastery.鈥

Back then, he said, cement didn鈥檛 exist. The builders used stone and cocciopesto 鈥 a clay mixed with lime 鈥 to make huge structures.

Widespread use of modern concrete and cement arrived in Sicily in the early 1900s and boomed after World War II, as it did in much of the world.

鈥淐ement changed the world,鈥 Nicolo Pierlucio Raimondo, an architect in Castelbuono, told me.

The art of mortar-making goes back to the ancient Romans and Arabs, he said. They experimented with the binding qualities of pozzolans, naturally occurring cements such as volcanic ash and gypsum. The invention of Portland cement in the 1820s, and its mass adoption in the early 1900s, was another game changer.

鈥淭hink about how much bigger cities have gotten in these last 100 years. Cement had a big part in this,鈥 the architect said. 鈥淚t helped speed up construction.鈥

But he added a cautionary note: 鈥淗ow long will these concrete structures last? No one knows.鈥

Capuana pointed across the street to a row of concrete homes built in the 1960s and 鈥70s.

鈥淟ook at the overhangs on all those buildings,鈥 he said. 鈥淭hey were made with steel and concrete. Over time, we鈥檝e had to rebuild them all.鈥

By contrast, experts are still trying to understand the secret to the longevity of the ancient Romans鈥 concrete.

Modern concrete鈥檚 biggest weakness is water seeping through its tiny pores, a major factor in hairline cracks. Once water penetrates and rusts the steel used to reinforce concrete, a cracking process known as spalling worsens.

Gioacchino Allegra, a master builder overseeing the remodel of a concrete home on the outskirts of Castelbuono, said today鈥檚 concrete is more compact (reducing spalling) than that of the building boom of the 1960s.

I also reached out to the International Masonry Institute for guidance. Amy Lamb Woods, a concrete expert and preservationist there, said the post-World War II boom in concrete construction 鈥 the Brutalist stuff 鈥 was made possible by the advent of better kilns in the early 1900s.

On the downside, concrete became associated with urban decay. On the upside, its use helped create substantial modern infrastructure, from highways to hospitals.

鈥淭here鈥檚 this onslaught of: 鈥極h, it鈥檚 concrete; it鈥檚 ugly,鈥 and they want to tear them down,鈥 Woods said. 鈥淎ll of us preservation people are advocating for their preservation because we believe these buildings are iconic, breathtaking, especially when they鈥檙e maintained well.鈥

In the U.S., that debate has intensified because concrete structures age 50 or older are now eligible for landmark status.

Also, it鈥檚 because concrete is now recognized as causing some 8 percent of all carbon dioxide emissions, mostly from cooking that cement in those kilns.

Yet 鈥渢he most green building you can build is the one that you restore and preserve,鈥 Woods said. 鈥淵ou鈥檙e in essence keeping the building. And so, you鈥檙e not putting it into a landfill, and you鈥檙e continuing its use.鈥

Listening to her made me feel so much better about the potential in my towering and downright ugly concrete barn, and about all the concrete work waiting to be done.



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