Nelson Mandela - 9m Bronze Sculpture at Union Buildings Pretoria

NELSON MANDELA - 9m BRONZE SCULPTURE at UNION BUILDINGS, PRETORIA

Mould

Lifesize Clay

Marquette

The Process

Bronze

I was first contacted by Dali Tambo CEO of Koketso Growth in December 2012 with an enquiry as to wether we can sculpt a nine meter figure of former President Nelson Mandela to be installed & unveilled by 16th December 2013 (Day of Reconsilliation). It was considered possible and that work should commence immediately. When I heard in April 2013 that the chosen site was the Union Buildings, I went and investigated various possible options as to exactly where best the sculpture should stand. It was suggested the JBM Hertzog statue be moved & not removed and that, because of the central position in relation to the Union Buildings, the Madiba Statue should take his place.

I got the go-ahead in mid June 2013. The scale of 2.25m fitted 4x into 9meters – an easy conversion to make on all our measurements and also a larger than life-size presentation to get the proportions, likeness and all other details right. This was not my first collaboration on a slightly larger than life-size and I felt comfortable with the sculpture. My research showed that Madiba was 1.83m tall with a lean and elegant built. I wanted him to be accessible to the general public and decided to depict him with his trademark Madiba-shirt. Our Client insisted on a smiling face. Initially we had lots of patterns and other symbolism eg. the number 46664 on his shirt.

Due to safety considerations and also to make the work more accessible for various teams to work on simultaneously, we decided to build & sculpt the figure in two main sections each just over 4 meters tall. The head and hands were fitted to check proportion etc, then removed and sculpted seperately. First SCS welded the armature and mounted that to a secured wooden platform. This was then clad with the foam blocks. We then sculpted the complete surface and when we were satisfied, we assembled the complete sculpture vertically to check the over-all visual balance and alignment of sections. Once again, due to the time constraint, we started with the mouldmaking process whilst busy sculpting other sections.

Marquette A Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Marquette A Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Marquette A Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Marquette A Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Marquette A Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Marquette B Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Marquette B
Marquette B

Lifesize Clay Sculpture Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Lifesize Clay Sculpture Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Lifesize Clay Sculpture Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Lifesize Clay Sculpture Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Lifesize Clay Sculpture Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Lifesize Clay Sculpture Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Lifesize Clay Sculpture Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Lifesize Clay Sculpture Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Lifesize Clay Sculpture Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria

Moulding Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Moulding Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Moulding Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Moulding Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Moulding Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Moulding Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Moulding Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Moulding Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Moulding Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Moulding Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Moulding Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Moulding Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria

Bronze Casting & Assembly Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Bronze Casting & Assembly Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Bronze Casting & Assembly Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Bronze Casting & Assembly Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Bronze Casting & Assembly Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Bronze Casting & Assembly Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Bronze Casting & Assembly Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Bronze Casting & Assembly Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Bronze Casting & Assembly Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Bronze Casting & Assembly Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Bronze Casting & Assembly Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Bronze Casting & Assembly Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Bronze Casting & Assembly Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Bronze Casting & Assembly Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Bronze Casting & Assembly Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Bronze Casting & Assembly Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Bronze Casting & Assembly Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Bronze Casting & Assembly Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Bronze Casting & Assembly Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Bronze Casting & Assembly Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Bronze Casting & Assembly Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria

Wax Casting Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Wax Casting Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Wax Casting Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Wax Casting Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Wax Casting Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Wax Casting Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Wax Casting Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Wax Casting Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Wax Casting Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Wax Casting Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Wax Casting Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Wax Casting Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Wax Casting Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria

Wax

As the mould pieces were stripped off the sculpture, it immediately went to the Wax Room were the wax was applied and each panel was again ID’ed and the gated with Runners, risers & pouring cups. This was done whilst the wax was still in the mould as to maintain the integrity of the shape of each piece. There were a total of 178 pieces – a massive puzzle to be assembled by the welders & fettlers!

The Department of Arts & Culture and Koketso Growth had an autonomous impact study done investigating this matter and it was approved. The sculptors considered various poses eg. Raised Fist Salute, but once again, in the Spirit of Reconsilliation, suggested the current open arm pose. Fortunately, after much deliberation, this was approved & accepted by the Client.

In April 2013 we were requested to present 600mm high marquettes depicting the two considered poses as well as a life-size bust. After carefull consideration the Client selected the open arm pose.

But due to the severe time constraint and also to not have him stand for any specific cause, it was decided to keep the basic “feel” of the sculpture one of simplicity.

Unveilling Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Unveilling Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Unveilling Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
Unveilling Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria

In the meantime the structural engineers and building contractor prepared a foundation with registering footprint as per footprint supplied by the foundry. On the arrival on site, the sculpture was re-assembled and patina was applied over the bronze joins. With the aid of two cranes the sculpture was lifted and carefully lowered onto it’s final resting place in one day - two days before it’s unveiling. The whole process from 2.25m scale model to installation took less than 6 months – excluding 6 months of paperwork and final approval by the various role players. That included it will be exactly 12 months as of date of first discussion with the Client.

The unveilling of the statue took place on The Day of Reconcilliation 16th Dec 2013 by the then President of South Africa Mr Jacob Zuma. In his speech he explained the embracing pose and that the open arms was an embracing gesture of reconcilliation.

Unveilling

3D Scan Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
3D Scan Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
3D Scan Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
3D Scan Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
3D Scan Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
3D Scan Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
3D Scan Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
3D Scan Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
3D Scan Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
3D Scan Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
3D Scan Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria

3D Scan

The above 3D scanned image was then digitally enhanced & upscaled to 9 meters tall. The maximum size that the CNC machine could handle was 2.4m long by 1.2m wide x 400mm thick. All panels were cut within these dimensions using high density polyurethane foam. During this process SCS also then digitally designed a steel frame / armature around which these blocks were to be built.

CNC Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
CNC Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
CNC Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
CNC Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
CNC Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
CNC Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
CNC Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
CNC Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
CNC Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria
CNC Nelson Mandela - 9m Bronze Sculpture at Union Buildings, Pretoria

CNC

Due to the time constraint and looming installation date, we decided that the only viable option was to make use of modern technology in the up-scaling of the 9 meter sculpture. The foundry (Sculpture casting Services) also have the fascility to 3D scan the 2.25m sculpture and then digitally upscaling it to 9m. The process of scanning took about 2.5 hours and special attention was given to the detailed areas like hands & face.

In order to get rid of the sandstone texture of the polyurethane foam, we re-worked the complete surface with plaster-of-paris (gypsum). This created a sculpted feel (to get away from the machined surface of th CNC) and also aligned all the joins between the blocks. SCS simultaneously started with making the silicone rubber mould in a fibre-glass jacket whilst we were busy with other sections. The mould was mostly constructed in one piece only to be cut later with a diamond cutting blade into the desired workable mould pieces. This was done with the size of a wax panel in mind considering each piece’s weight and dimensions. Each piece was also ID coded, photographed in it’s place for future assembly.

The panels in wax were prepared so that it could be suspended in a drying chamber. They went through the ceramic shell dipping process (about 14 layers depending on size and shape) including reinforcing of the panels with thin stainless steel wire. This was done to withstand the tremendous pressure in a panel when the hot bronze is poured. And again, their was no margin for error due the the time constraint. The ceramic shell moulds were then sent to be de-waxed prior to the bronze pouring.

Ceramic Shell 9m Mandela Sculpture, Union Buildings, Pretoria, 2013
Ceramic Shell 9m Mandela Sculpture, Union Buildings, Pretoria, 2013
Ceramic Shell 9m Mandela Sculpture, Union Buildings, Pretoria, 2013
Ceramic Shell 9m Mandela Sculpture, Union Buildings, Pretoria, 2013
Ceramic Shell 9m Mandela Sculpture, Union Buildings, Pretoria, 2013
Ceramic Shell 9m Mandela Sculpture, Union Buildings, Pretoria, 2013
Ceramic Shell 9m Mandela Sculpture, Union Buildings, Pretoria, 2013
Ceramic Shell 9m Mandela Sculpture, Union Buildings, Pretoria, 2013
Ceramic Shell 9m Mandela Sculpture, Union Buildings, Pretoria, 2013

Ceramic Shell

This assembly is the stage that can make or break a bronze sculpture – utmost care must be taken to re-assemble the individual panels to firstly fit well together and to maintain the shape of the original sculpture. Secondly the fettling and finishing must be done in such a was as not to destroy the original sculpted surface of the sculptor(s). The 9m sculpture came with it’s own set of challenges due to it’s size. The foundry worked with a structural engineer to reinforce the bronze with a stainless steel inner armature. The weight of the bronze is about 3500kg & the stainless an additional 800kg. Thus making the total weight close to 4400kg.

The Client wanted a multi-coloured patina so as to create more interest. This was achieved using cold patina application from the top down. The hair has a slight white over the bronze to achieve Madiba’s greying hair. The hands and face was treated a light brown with bronze high lights. The top of the torso (shoulders and arms) is verdigris green fading to brown in the mid section. This in turn gradually changed to dark brown lower trousers and ended in black shoes. This was then sealed with a layer of wax.

The bronze pouring was next. This operation took careful planning in order to pour the correct panels for the correct pieces simultaneously eg. the left arm and hand together etc. Each panel was de-waxed, the ceramic shell was then checked for leaks and patched if necessary. Then they were pre-heated to the correct temperature to fascilitate the bronze pouring. After a succesful pour, the ceramic shell mould was then removed from the bronze and then the runners & risers are cut off to be re-melted for the next pour.

Prior to the loading for transport, the Client once again had to approve and for this the sculpture was completely assembled in a vertical position. After a succesful sign-off by the client, the arms and head were removed in preparation for the transport. At 4400kg the weight was not a problem. However the road restrictions (height & width) had to be considered. The figure was supported in a custom made steel & wood cradle with arms and head seperately packed and strapped. The 1670 kilometers from Cape Town to Pretoria was covered in a modest and safe time of about 22 hours.

The Client

Department of Arts and Culture

Koketso Growth - National Heritage Project

Location of the sculpture

Click on th inter active map to see the location of the sculpture

Reference

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