Craft Documentation: Mannar Metals

Traditional Metal Craft of Mannar

The Bell Metal Town

Traditional Metal Craft of Mannar Mannar

The Bell Metal Town

Traditional Metal Craft of Mannar

Documented by Akhil Anand Siddharth Mannar

Acknowledgement

I’d like to express my gratitude to KSID for providing me with this opportunity to work directly with a community on craft documentation on Mannar Metal. I’d like to express my gratitude to Mr. Aredath Siddharth, our mentor, for his great assistance with this documentation.

I can’t move on without thanking the crafts people from the Mannar for learning about their traditional metal crafts. Mr. Sivanandan Achary and Raghu, who helped to understand about craft in Mannar.

Special thanks to Mr. Jayakrishnan and Nikhil Anand who helped me towards to complete this documentation.

Preface

The goal of the course is to learn about our rich heritage of craft practices. For this, we focused on in-depth study, research, and documentation with an analysis of the craft community, traditional methods of production, marketing techniques, and so on.

Students are required to spend significant time on field research and direct communication with practitioners.

1. Alappuzha : The Venice of the East

Alappuzha is the one of the district of the kerala. Also known as “Venice of the East”. Alappuzha derived from the tamil world “Alam” means marshy land and “puzha” means river. Alleppey district was formed on 17th of August 1957. Alappuzha is lies between vembanad lake and arabian sea.In the british raj period alappuzha is known as Alleppey later its changed “alappuzha” in 1990 officially.

Alappuzha famous for backwaters, by which it is well connected to other parts of Kerala, including the tourist destination of Kumarakom. Alappuzha is also known for its coir factories, as most of Kerala’s coir industries are situated in and around Alappuzha town.

Alappuzha is surrounded by arabian sea and vembanad lake. Major rivers are the Manimala, the Pamba, and the Achankovil, their branches and tributaries flow through Alappuzha

History of Alappuzha

The Cheras period had their home in Kuttanad and they were called ‘Kuttuvans’ named after this place. Some of the archeological antiques like stone inscriptions, historical monuments etc. found in the temples, churches, rock-out caves etc., and literacy works like Several inscriptions and artifacts describing the past of Alappuzha are founded.

History says Alappuzha had trade relations with ancient Greece and Rome in BC and in the middle ages. The Cheras period had their home in Kuttanad and they were called ‘Kuttuvans’ named after this place. Some of the archeological antiques like stone inscriptions, historical monuments etc. found in the temples,

Fig 1.1

Fig 1.2

Alapuzha have also have buddhist connection,a statue that found in karumady,near alappuzha 3 feet tall black granite statue called Karumadykuttan(nickname of buddha statue) literally means that boy from karumady. They believed to be old as 9th to 14th century not only in karumady.

In Mavelikara,there is a Buddha statue near Krishnaswamy temple. The statue is placed near a junction so its known as “Buddha Junction”,statue was excavated from paddy field near kandiyoor temple in 1900 accidenly. Not only these place, in Bharanikavu and Karunagapally also founded some buddha statues and its exhibited at the Thiruvananthapuram museum. most of the buddha statues that found in central Travancore.

Fig

After the portuguese invasion then dutch came to alappuzha, as a result of several treaties signed with Dutch and the Rajas of Purakkad, Kayamkulam and Karappuram, the Dutch built factories and warehouses in various places of the district for storing pepper, ginger etc.

Marthandavarma Maharaja had a remarkable role in the internal progress of the district. He gave special attention to the development of the district as an administrative as well as a commercial centre. During the reign of Dharmaraja the district was improved into a commercial city. Raja Kesava Das, the then Diwan of Travancore who was known as the ‘Maker of modern Alappuzha’ made Alappuzha a premier port town of Travancore. He constructed several roads and canals to improve communications and built warehouses.

(Fig 1.4)

Raja Kesava Das, Diwan of Travancore

Mannar

is very famous for traditional metal handicrafts producing utensils, lamps, bells etc. made out of bell metal, brass, bronze. Alloys like bronze, brass etc were used in ancient times also. In India, Mannar is the second largest metal producing place after Moradabad in UP. Tradional metal crafts are still here around more than 300 years. Their descents are still following their tardional works in mannar.

Mannar is situated on the banks of the Pamba river, Manimala River and Achan kovil river. Mannar is 9 km from Chengannur, Thiruvalla, Haripad and 8 km from Mavelikara. The Mannar Grama Panchayat has 17 wards and it is situated on the western end of the Chengannur block. It is connected with some part of upper Kuttanadu, the rice bowl of Kerala.

Mannar is a place of numerous temples.Shiva and Bhagavathi are most. The most important Shiva temple being the Thrikkuratti Temple. The place name Kurattikadu where the temple is located is derived from the name of the temple itself. Kurattikadu Pattambalam Devi temple is another temple in Mannar.

(Fig 2.2)

Mannar Thrikkuratti Shiva Temple

The famous Church Parumala,the pilgrim centre of Orthodox Syrian Church known as Parumala Palli is sitiuvated near Mannar. There are various colleges, schools and other educational institutes in the town Nair Samajam higher Secondary school, DB Pamba College and Jawahar Navodaya Vidyalaya are the main educational institutes in Mannar.

Historical Importance

Mannar occupied importance in Travancore history. Northern side of the Shiva temple in padanilam ,there is war between king Marthanda Varma and the Kayamkulam Raja, later Kayamkulam Raja lost in the war. After that they made a Treaty was held in Mannar Thrikkuratti Temple. Later its known as “Treaty of Mannar”.

(Fig 2.3)

A depiction of Marthanda Varma

Fig 2.2

Fig 2.3

2. Metal Crafts of Mannar

History

Metalcraft was established in Mannar around 300 years ago, by the people who migrated from Thanjavur in Tamil Nadu. All craftsmen are surrounded by the great temples in their kingdoms. These craftsman construct great temples and buildings during this cholapallava periods in south india.

In their period every craftsman got great honor from their kings. The famous Brahadisvara temple of Raja Raja Chola I (Tenth century) has the name of the architect engraved on it by the master craftsman himself as “Kunjaramallan Raja Raja Perunthachan”.

Vishwakarma community came here around more than 300 years. Vishwakarma community invited from Shankarankovil and Tanjavoor of Tamil Nadu to built temples. It temple building was a time consuming process so those people settled in Kerala. Then they started to build temples in other places also.

Fig 2.4

(Fig 2.4)

Sangam Age Map (Chola, Pandya, Chera Kingdoms)

(Fig 2.5)

Brihadisvara temple, Tanjore

Fig 2.5

Vishwakarma Community

According to Hindu mythology, Vishwakarma or Vishvakarman is the divine architect of god and craftsman’s god. Vishwakarma crafts chariots, weapons and builds gods’ palaces. Cities like Lanka, Dwaraka and Indraprastha are built by the Vishwakarma. Lately, the Vishwakarma community formed and they claimed there are descended from Vishvakarma(God). This community has an important role in building great temples in South India.

Vishwakarma community has 5 subgroups. Carpenters, Metal Workers, Stone Masons, Blacksmiths and Goldsmith. In Kerala, they are known as Achary, Mooshary,Thattan, Kallashary and (Fig 2.6) Gold Smith (Fig 2.5) Vishwakarma Bronze Sculpture (Fig 2.8)

Black Smith (Fig 2.7) Carpenter (Fig 2.9) Stone Mason

Fig 2.7Fig 2.6

Fig 2.8

Fig 2.5

Fig 2.9

Metal Workers

When we entered into mannar we can see that every shop is filled with bronze and some brass metals products like Nilavilakku, Bells for chruch and temples and other metal utensils.

Metal workers uses Bronze and Brass are the main components.In kerala there are two major locations for metal crafts, one is in Mannar and other one is Kunhimangalam, Kannur.

In Mannar there are 40 units before now its only 4 units only making crafts on bronze and brass.

Fig 2.11

Fig 2.12

Fig 2.10

(Fig 2.10)

Metal Workers of Mannar (Fig 2.11) Nilavilakku (Bronze Lamp) (Fig 2.12) Uruli (Cooking Utensils)

3.People Behind Mannar Craft

Sivanandan Achary

He has more than 60+ years experience in metal crafting product. All metal work is done under him. There are 3 employees working under him. Now he only supervises every work and helps them. He supplies all crafts to metal shops in Mannar and other parts of Kerala. Some orders come from other parts of India and foreign countries like Denmark, UAE, USA ..Etc are also coming in orders for him.

Raghu

Raghu, Most active crafts man in Mannar. This bald headed guy talks friendly to everyone. He is most active in making every craft. He speaks English very well. He always says, about the hard work behind making every craft. He has a son who works in Nigeria. He is not interested in craft making; beacause of lot of time and hard work is needed.

Rajan

Another craft man who works for long hours at a stretch. He only wake up to use washroom. Drink half a glass of water and work for 2-3 hours. He is from Pandalam (Pathanamthitta district). In his home he has his own metal craft unit in his home. Now he is currently making molds for the crafts.

Sunil

He is most helpful craftsman for other people. He calculates the amount of items needed and works on all in all.

4.Tools & Raw Materials

(Fig 4.1) Hammer (Fig 4.2)

Roller Stone

(Fig 4.3) Blower

Hammer : Iron hammers are used in chiseling for engraving and finishing purposes, breaking big chunks of raw materials including metals and clay. Wooden hammer is used to beat and smoothen the wax before it is applied to the mold.

Files : Used for smoothening the irregular surface.

Blower : Used to blow enough air in the furnace while melting the wax or metals in the crucible.

Roller Stone: It is a hand grinder used for grinding the baked broken mold clay pieces into powder.

Pincers : It is a gripping tool used for holding crucibles.

Kada Irumbu : tool used for smoothening the wax on the mold.

Crucible: Crucibles are mud pots, used to melt metals.

Fig 4.1 Fig 4.2

Fig 4.3

Fig 4.6

Wax : It is used for making the model and can be collected and its reused.

Chenchalyam : Its mix with wax and make hard mold and used for determine the thickness of product.

Clay : It is used to make molds.Mineral less clay is used for making mold, otherwise it will break while heating.

Bell Metal : It is a heavy metal having the density of 8.7 gm/ cm3 and a very high melting point of 1500˙C. It is the mixture of copper and tin in the ratio of 78% and 22% respectively.

Brass : It is the alloy of copper and zinc in ratio of 60% and 40% respectively. Its melting point is 900˙C and the density is 8.4 g/ cm3.

Bronze : It is the mixture of copper, zinc and tin in ratio of 85%, 5% and 5% respectively. It is reddish in color having higher melting point of 950˙C than brass because of the presence of tin.

Copper : It is a metal with reddish orange color and melting point of 1084˙C. It’s highly malleable, soft and ductile. It’s a good conductor of electricity. Its density is 8.9 gm/cm3.

Zinc : It is lustrous metal silvery grey in color and have a melting point of 919˙C. Its density is 7.14gm/cm3.

Tin : It is a very hard in nature, silvery white metal and have melting point of 231˙C. Its density is 7.36gm/cm3.

Fig 4.9

Fig 4.10

Fig 4.11

(Fig 4.9) (Fig 4.12) (Fig 4.10) (Fig 4.13) (Fig 4.11)

Fig 4.12

Fig 4.13

(Fig 5.1) Clay Mixture

5. Process : Lost Wax Method

Step 1

The first step is making the mixture of clay taken from the paddy field and mixed with jute (fine powdered), burned husk of paddy (Umikari) and broken pieces of burned clay are used. Mix this material with clay to get the mold to be stronger.

Rolling stone is used grind and mix the mixture.

(Fig 5.2) Grinding & Mixing with rolling stone

Fig 5.1

Fig 5.2

Step 2

The second step is as follows make the mold of the product. Here making the bell. Start the clay mixture is attaching to a stronger wooden piece. Wooden piece should have length more than the bell’s actual size. This wooden piece is known as Achukol. Over this Achukol the dough formed clay is applied around it.

After that it should be kept for 1 or 2 days for sun dried (In rainy seasons they use burn firewoods and coconut husks to dry fast)

Fig

(Fig 5.3)

Sun Dried Bell Mold’s

(Fig 5.4)

Sun Dried Cheenachatti

(Fig 5.5)

Sun Dried Uruli’s

Fig

Fig

(Fig 5.5)

Melting wax

(Fig 5.6)

Beating Wax

(Fig 5.7)

Polishing the mold using files

Step 3

After the mold has dried, they polish the mold using files and hand to avoid grains texture inside the product. After 1 hour, then they apply the wax on top of the mold. Wax is not directly applied to the mold.

Here are calculation used to make wax mold, for making 100 Kg bell 10 Kg of wax be used. first wax melted by boiled water. After boiling, the take each chunk of wax, then smooth the wax using a hammer by beating it.

Fig 5.5

Fig 5.6

Fig 5.7

Now it will apply wax to the mold, before that a certain thickness of wax has to be maintained while applying it to the mold.

A fine strip of wax (made with Chanchalyam and wax) with desired thickness of the product is placed across the mold, and its match up this strip over the mold. The wax is appiled on mold is using lathe mechanism rotate by hand.

Fig 5.10

Then the base is waxed and for fast setting a hot kada irumbu is used otherwise, it is difficult to mold.

(Fig 5.8) Making Fine Strip

(Fig 5.9) Applying wax on mold

(Fig 5.10) Wax shaping using Kada irumbu

Fig 5.8

Fig 5.9

(Fig 5.11)

Second layer of wax (Fig 5.12)

Third layer of wax

Fig 5.11

Fig 5.12

after the first layer completed, again the wax is appiled over the mold for shaping the mold.

Step 4

After wax is applied, then mixture of clay is applied on top of the wax mold after cooled. Make an inlet of the molten alloy at last.

After the clay is appiled, then place broken peice of the baked-broken molds appiled on the clay to fix the mold stronger otherwise when the molten metal pouring the internal should be broken. So to avoid this issue, use this method.After thar it should dried for 7-10 days

Fig 5.15

(Fig 5.13)

1 Ton Kg Bell Mould 5.14)

Baked-Broken clay pieces bell mould 5.15) Bell Mould

Fig 5.13

Fig 5.14

(Fig 2.11)

Molten

After mold is dried well, now its ready to place in furnace to make the product. Crucibles are used to melt metals. Crucibles are made of special mud, from UP. It holds more than 10-15 times at higher temperatures. Then the raw metal or alloys are weighed, according to the size wanted for the final product that’s filled in crucibles.

For bell metal, ratio of copper and tin is 4:1. Bell metal is used in bells because we need sound from bells, so adding tin produces the sound for the bell. For Bronze, mixture of copper, zinc and tin in a ratio of 85%, 5% and 5% respectively Copper and zinc in ratio of 60% and 40% respectively for Brass.

Mouths of crucibles are covered with clay to avoid spilling while heating and transferring. These crucibles are placed in a fire vent (choola) for melting the raw metals to form an alloy. These crucible are takes to melt 5-6 hours. Then they takes and pour molten metal into the mold and its coverd with sand to avoid the heat transfer from the mould.

After 3-4 hours molten metal covers entire area in the mould, then 50% of wax is lost due to form of fumes and smoke due to the high temperature.

(Fig 2.11)

(Fig 2.11)

Pouring

Fig

Fig

Fig

Step 6

After 6 hours of cooled, then the mold digged from the sand and cleaned with the brush to remove the baked parts of the mold (it can be reusable). While taking the mold then craftsman should careful because some othe them are not set so it may be molten part should fall on the feet its to dangerous. after the all unwanted parts removed then it will go the grinding and polish on the products. Now the product is ready to supplied to the suppliers and shops

Fig

(Fig 5.18) 5.19)

(Fig 5.20)

Fig

6. Products of Mannar

Mannar is famous for making traditional lamps, vessels and bells.

Uruli : Used in home for cooking and in Ayurvedha to make medicines, also its used for decoration and festivals

Chembu : Mainly used for boiling paddy to make rice.

Kindi : A vessel for taking water for washing, also used in temples for pooja’s

(Fig 6.1) Bronze Bell (Fig 6.2) Nilavilakku (Bronze Lamp) (Fig 6.3) Uruli (Cooking Utensils) (Fig 6.4)

Kindi

Bell : Percussion instrument used in temples and churches.Ancient times bell is used in to share information in public.

Vaarpu : Large bowl made from bronze. It is used for making Ayurveda medicines and meals during festivals in homes and temples.

Nilavilakku : The traditional lamps which are lit during every traditional occasions used in homes and temples.

Fig 6.1

Fig 6.2

Fig 6.3

Fig 6.4

Some of the products in mannar are very famous. In front of legislative assembly of Kerala there is a big Kerala emblem is engraved on a big plate is made from Mannar.

In Chettikulangara Devi Temple, a big lamp is made from mannar. The world’s biggest cauldron placed in an antique shop in Jew Town in Kochi are also made from Mannar.

Fig 6.5

(Fig 6.5) Lamp at Chettikulangara Devi Temple (Fig 6.6) Biggest Cauldron at Jew town, Kochi (Fig 6.7) Kerala Legislative Assembly

Fig 6.7

Fig 6.6

(Fig 7.1) Bronze Lamp

7. Marketing

Mannar Metal marketing started around 300 years ago. Most of the products are traditional products like Neelavilakku (Bronze Lamp). Bells, Utencils like Uruli, Chempu and some God Idols made from bronze for temples, churches and for memorials.

They are currently struggling which cheaper products that’s came from madurai by machine cutting products. In Mannar, everything that is made by the handmade. They are currently struggling with cheaper products that come from madurai for machine cutting products in market. In Mannar,everything that is made by the handmade. When the entrance of the aluminum metal demand of bronze and brass metal is decreased because of cheaper.

Fig 7.1

8. Problems

1. Working Environment

Working environment is full of dust and smoke in uncomfortable positions. Everywhere we can see that black color is surrounded. No one used gloves or other safety precautions while working. They say this has been habitual for years, that they don’t care about it now.

Most of the workers age is more than 40 years some of them are less eyesight. while working they uses only one bulb for 4 people.

2. Government Support

The government says Mannar is a heritage village, but government financial support is not happening there. day by day cost of the raw material is increased and employees daily wages these are the main problems reduced 40 units to 4 units now.

Fig 8.1

(Fig 8.1)

Waxing the Mold

3. Cost of Raw Materials

Major reason for the cost hike availability of the raw materials. Before they used honeywax its is best wax and get good results, but, now they are using wax that gets from pine trees collected by the tribes. For 1 kg honey wax more than 500 rupees.

While increasing the cost of raw materials, product costs, and day wages also increase. This will affect huge impact on the manufacturer.

4. Mindset of Descendants

Now craftsman think about the future of mannar metals. They are worried about their descendants because they don’t follow their tradition. They are not looking up to forge space. They don’t care about what their father is doing? How is it made? What made mannar metal popular in society? They are busy with their time.

9. Current Scenario and Future Propositions

In Malayali culture, religious ceremonies and traditional customs were immensely important. Every custom shows the impact of bronze metal. The most common bronze metal used in traditional customs is Nilavilakku (Bronze Lamp).

Due to the duplication of things imported from other states, traditional craftsmen efforts are reduced to none. People seek out low-cost goods because they are concerned with the price rather than the quality.

Following the pandemic, the financial crisis impacted negatively on metal craft. Nevertheless, unemployment causes return to the craft sector. The younger generations are busy with their time and they are not ready to hard work and continues their predecessor works. The government make Mannar metal crafts are the traditional icon of the Kerala. The government announced that the Mannar as the craft village ,but these are just announcement. Currently craftsmen’s are suffering the finacial support to build these metal crafts.

Fig

(Fig 9.1)

Bronze Lamps in Shop

References

• https://www.dsource.in/resource/brass-metal-casting-mannar-kerala

• Divine Images in Stone and Bronze: South India, Chola Dynasty (c. 850-1280) Author(s): Aschwin Lippe

• Globalisation Traumas and New Social Imaginary: Visvakarma Community of Kerala, Author(s): George Varghese K. Source: Economic and Political Weekly, Vol. 38, No. 45 (Nov. 8-14, 2003), pp. 4794-4802 Published by: Economic and Political Weekly.

• Vishwakarma Craftsmen in Early Medieval Peninsular India Author(s): Vijaya RamaswamySource: Journal of the Economic and Social History of the Orient, Vol. 47, No. 4 (2004), pp.548-582

Image References

• Fig 1.1 - [https://m5.paperblog.com/i/86/869103/karumadikuttan-temple-thebest-example-of-bud-L-CEBe2Q.jpeg](https://m5.paperblog.com/i/86/869103/ karumadikuttan-temple-the-best-example-of-bud-L-CEBe2Q.jpeg)

• Fig 1.2 - [https://alappuzhaonline.com/images/buddhastatue.jpg](https:// alappuzhaonline.com/images/buddhastatue.jpg)

• Fig 1.4 - [https://upload.wikimedia.org/wikipedia/commons/6/6c/Raja_Kesava_Das_ Statue_in_Alleppey_-_Changanassery_Road_%40_Changananassery_Junction.jpg] (https://upload.wikimedia.org/wikipedia/commons/6/6c/Raja_Kesava_Das_Statue_in_ Alleppey_-_Changanassery_Road_%40_Changananassery_Junction.jpg)

• Fig 2.2 - [https://pbs.twimg.com/media/Etqv7AbVEAIXMM0.jpg](https://pbs.twimg.com/ media/Etqv7AbVEAIXMM0.jpg)

Image References

• Fig 2.3 - [https://upload.wikimedia.org/wikipedia/commons/6/63/Anizham_Thirunal_Marthanda_Varma. jpg](https://upload.wikimedia.org/wikipedia/commons/6/63/Anizham_Thirunal_Marthanda_Varma.jpg)

• Fig 2.4 - [https://upload.wikimedia.org/wikipedia/commons/thumb/4/46/South_India_in_Sangam_Period. jpg/1200px-South_India_in_Sangam_Period.jpg](https://upload.wikimedia.org/wikipedia/commons/ thumb/4/46/South_India_in_Sangam_Period.jpg/1200px-South_India_in_Sangam_Period.jpg)

• Fig 5.15 - [https://www.dsource.in/resource/brass-metal-casting-mannar-kerala/making-process](https:// www.dsource.in/resource/brass-metal-casting-mannar-kerala/making-process)

• Fig 5.17 - [https://www.dsource.in/resource/brass-metal-casting-mannar-kerala/making-process](https:// www.dsource.in/resource/brass-metal-casting-mannar-kerala/making-process)

•

• Fig 6.1 - [https://www.dsource.in/sites/default/files/resource/brass-metal-casting-mannar-kerala/ products](https://www.dsource.in/sites/default/files/resource/brass-metal-casting-mannar-kerala/ products)

•

• Fig 6.4 - [https://www.dsource.in/sites/default/files/resource/brass-metal-casting-mannar-kerala/ products](https://www.dsource.in/sites/default/files/resource/brass-metal-casting-mannar-kerala/ products)

Image References

• Fig 6.5 - [https://4.bp.blogspot.com/-Bh3dgr-PHU4/WgxzVmdfZiI/AAAAAAAAWoA/TkKi_RkWSoQp48WAxbKs3vLrmg-DdhSgCLcBGAs/s400/47_big.jpg](https://4.bp.blogspot.com/-Bh3dgrPHU4/WgxzVmdfZiI/AAAAAAAAWoA/TkKi_Rk-WSoQp48WAxbKs3vLrmg-DdhSgCLcBGAs/s400/47_big. jpg)

• Fig 6.6 - [https://pbs.twimg.com/media/BpqWhuaCEAAf2sG.jpg](https://pbs.twimg.com/media/ BpqWhuaCEAAf2sG.jpg)

• Fig 6.7 [https://upload.wikimedia.org/wikipedia/commons/thumb/e/eb/Kerala_Legislative_ Assembly%2C_Thiruvananthapuram.jpg/250px-Kerala_Legislative_Assembly%2C_ Thiruvananthapuram.jpg](https://upload.wikimedia.org/wikipedia/commons/thumb/e/eb/ Kerala_Legislative_Assembly%2C_Thiruvananthapuram.jpg/250px-Kerala_Legislative_Assembly%2C_ Thiruvananthapuram.jpg)