Making Copper Products in Pune

A look at the traditional and contemporary processes of making copper products in Pune

Dastkari Haat Samiti

Dastkari Haat Samiti

Copper craft: Product development in the workshop (2017)Dastkari Haat Samiti

Tambat Ali's beaten copper craft

The art of beaten copper work in Pune, Maharashtra, is located in an old part of the city called Shitolewada. Tamba is the commonly used word for copper in North India and Tambat Ali is the famous alley where the community of coppersmiths or 'tambats' work on their craft. The group migrated to cities like Pune, Nasik, Mumbai and Mumbai from the Konkan coast of Maharashtra to get better value for their articles of manufacture.

Copper craft: Water Heater (2017)Dastkari Haat Samiti

The tambats were patronized by the Mughals, Chhatrapati Shivaji Maharaj, the Peshwa kingdom as well as by local chieftains or administrative authorities like tax collectors, for whom they made idols of their particular deities, protective casings for stone idols, weapons, and most importantly, coins.

Copper Craft: The workshop area (2017)Dastkari Haat Samiti

The effort, the shine, the patterns and the buzzing, active community demonstrate how traditional and contemporary customers and support keep this important craft alive and in demand.

Copper craft: Sheet cutting (2017)Dastkari Haat Samiti

Cutting the copper sheets

The process  of copper crafting starts with the craftsperson manually marking the required shapes on the metal sheet and then cutting it out with a pair of heavy scissors.

Copper Craft: Sheet cutting (2017)Dastkari Haat Samiti

Here, a craftsman begins creating a new copper product by making circles with a compass on a metal sheet.

Copper craft: Sheet cutting (2017)Dastkari Haat Samiti

The craftsman marks out cirles on an entire copper sheet.

Copper craft: Sheet cutting (2017)Dastkari Haat Samiti

Compasses of various sizes are used to make circles on the metal sheet.

Copper Craft: Sheet cutting (2017)Dastkari Haat Samiti

Watch how the copper craftsman cleanly cuts the sheet into perfect circles.

Copper craft: Sheet cutting (2017)Dastkari Haat Samiti

The left over pieces are melted and re-used.

Copper craft: Collapsible die (2017)Dastkari Haat Samiti

Shaping the metal

The craftsperson can shape products either by hand or use a lathe machine with collapsible die. The collapsible dies are made of acacia wood and metal is wrapped over it.  The die is held in place with a metal key. The metal collapses into the die on the lathe machine. The metal shavings left behind are also melted for re-use.

Copper craft: Metal work for temple carvings and idols (2017)Dastkari Haat Samiti

The lathe machine is an important tool in the workshop. It helps in shaping metal into the desired shape.

Copper craft: Collapsible die (2017)Dastkari Haat Samiti

The die is arranged inside the copper shape which is to be formed on the lathe machine.

Copper craft: Collapsible die (2017)Dastkari Haat Samiti

The collapsible die is made of Acacia wood since acacia wood is easy to maintain.

Copper craft: Collapsible die (2017)Dastkari Haat Samiti

A metal key is inserted to hold the wooden die in place.

Copper craft: Collapsible die (2017)Dastkari Haat Samiti

The key is an essential tool to ensure that the shape of the product is maintained.

Copper craft: Collapsible die (2017)Dastkari Haat Samiti

The artisans use a linear collapsible die for taller objects.

Copper craft: Collapsible die (2017)Dastkari Haat Samiti

Wooden die is used instead of metallic ones because metal on metal creates fiction.

Copper craft: Collapsible die (2017)Dastkari Haat Samiti

The use of die ensures that the metal is shaped into the desire shape. Seen here are the before and after stages of turning the metal on the lathe machine.

Copper Craft: Collapsible die (2017)Dastkari Haat Samiti

The use of collapsible die and a lathe machine ensures that the copper vessels with two diamteres is made in a single piece instead of two pieces being welded together.

Copper craft: Collapsible die (2017)Dastkari Haat Samiti

The metallic scrap from the lathe machine is reused. No scrap of metal is wasted in the workshop.

Copper craft: Firing Process (2017)Dastkari Haat Samiti

Firing process

Once shaped, the metal object is fired and put in an acid wash. This process is said to strengthen the metal. The firing process is repeated after every step to strengthen the metal.

Copper craft: Firing Process (2017)Dastkari Haat Samiti

Coal is the preferred fuel used for the firing process.

Copper craft: Firing Process (2017)Dastkari Haat Samiti

Once the furnace is ready, the shaped object is fired.

Copper craft: Firing Process (2017)Dastkari Haat Samiti

After the first firing, the vessel is cooled by dipping it in water.

Copper craft: Firing Process (2017)Dastkari Haat Samiti

The vessel is re-fired after the dip in the water.

Copper craft: Firing Process (2017)Dastkari Haat Samiti

The final dip in water helps in cooling down the vessel temperature.

Copper craft: Finishing (2017)Dastkari Haat Samiti

Polishing, embossing and buffing

Once the pieces are ready, they are polished with tamarind paste or lime and are then embossed and buffed. Embossing is the final process, by which it gets its full strength and identity. Special hammers called 'polat' are used for final embossing.

Copper craft: Finishing (2017)Dastkari Haat Samiti

Tamarind paste or lime is used for polishing the utensil.

Copper Craft: Finishing (2017)Dastkari Haat Samiti

Embossing is the final process, by which it gets its full strength and identity.

Copper Craft: Finishing (2017)Dastkari Haat Samiti

The buzzing, active community of coppersmiths in Pune, demonstrates how traditional and contemporary customers and support keep this important craft alive and in demand.

Copper craft: Finishing (2017)Dastkari Haat Samiti

The hammer used for embossing copper utensils is called 'polat'. It is this highly buffed and polished hammer that gives copper products their signature look.

It is also extremely strong and made of the same metal that is used to make railway tracks.

Copper craft: Final finishing hammer (2017)Dastkari Haat Samiti

To maintain the excellence of the final emboss, the craftsmen polish their hammer on their own old leather shoes.

Copper Craft: Collapsible die (2017)Dastkari Haat Samiti

The final step in the process is the buffing. It gives a ready polished look to the products.

Copper craft: Collapsible die (2017)Dastkari Haat Samiti

Final buffing of the product is done to give the metal finish a smooth shine.

Copper craft: Start to end process (2017)Dastkari Haat Samiti

Forming by hand

Copper craftsmen are adept at shaping objects completely by hand. The process involves paper cutouts, standard sizes and various tools. The craftsmen use all of the above to form the metal by hand.

Copper craft: Tools (2017)Dastkari Haat Samiti

Various tools like chisels, compass and hammers are used in every stage of making the vessels.

Copper craft: Start to end process (2017)Dastkari Haat Samiti

Cutting and shaping the metal begins with the help of a paper cutout.

Seen here is a craftsman with the paper cutout of a flower shaped candle holder.

Copper craft: Start to end process (2017)Dastkari Haat Samiti

Flower shaped candle holders are cut and shaped entirely by hand.

Copper Craft: Brass thalis (2017)Dastkari Haat Samiti

Only an experienced craftsman can undertake the task of shaping the platter by hand with precision.

Copper craft: Finishing (2017)Dastkari Haat Samiti

Blackodizing + Brass work

Locally called Blackening, or 'blackodizing', a maker gives a black base to the copper piece for the sake of variety, by using oxidizing salt. Copper craftsmen also use brass along with copper to add a dimension of design to the product.

Copper craft: Contemporary products (2017)Dastkari Haat Samiti

Two copper pieces before and after being treated with oxidising salt.

Copper craft: Finishing (2017)Dastkari Haat Samiti

Copper workers often join copper and brass together in the same piece, like in the piece on the right in the image.

Copper craft: Finishing (2017)Dastkari Haat Samiti

Both metals are joined together with a tongue and groove joint, which is a traditional hinge or fastener used by the copper workers.

These joints add a nice element of detailing in the design.

Copper craft: Metal work for temple carvings and idols (2017)Dastkari Haat Samiti

Aluminum Foil Mould Technique

Some traditional pieces still made and sold by copper workers are lotas and devotional items for temples and prayer rooms. These items are made using aluminum foil moulds. 

Copper craft: Metal work for temple carvings and idols (2017)Dastkari Haat Samiti

Called the ‘lost wax’ process, it is a method where wax is poured into aluminium foil moulds.

Copper craft: Metal work for temple carvings and idols (2017)Dastkari Haat Samiti

Copper craft: Metal work for temple carvings and idols (2017)Dastkari Haat Samiti

The metal is shaped either with wax or tar.

Copper craft: Metal work for temple carvings and idols (2017)Dastkari Haat Samiti

The shaped object when heated, causes the wax to melt and pour out.

Copper craft: Water Heater (2017)Dastkari Haat Samiti

Making the water heater

A group of copper workers exclusively make around fifty water heaters a week. Their work has to be collective and collaborative to meet with the high demand, which is interesting considering the days of electric geysers to heat water arrived long ago. The workspace suited to collective activity established by the Peshwas with much forethought, is called a bakhal.

Copper craft: Working seat (2017)Dastkari Haat Samiti

Copper workers use a saddle-like seat like this one for sitting while working. Its design is a unique combination of wood and metal, that helps turn metal pieces on the central iron rod.

Copper craft: Water Heater (2017)Dastkari Haat Samiti

The water heater is built in parts. Seen here is a copper worker shaping the central shoot of the water heater.

Copper Craft: Water heater (2017)Dastkari Haat Samiti

A craftsman hammers the body of the water heater into shape.

Copper craft: Water Heater (2017)Dastkari Haat Samiti

The base for the water heater is formed separately. A metallic mould is used to help form the base frame.

Copper craft: Water Heater (2017)Dastkari Haat Samiti

The base frames are kept ready in the workshop and attached to the main body once it is ready.

Copper craft: Water Heater (2017)Dastkari Haat Samiti

For the copper lid, the craftsmen fashion tongue and groove joints to attach it to the body of the water heater.

Copper craft: Water Heater (2017)Dastkari Haat Samiti

The lids for the water heater have space for the center pipe through which steam escapes and one for pouring water in.

Copper craft: Water Heater (2017)Dastkari Haat Samiti

The workshop is equipped with all the materials that are needed for welding.

Copper craft: Water Heater (2017)Dastkari Haat Samiti

Various parts of the water heater undergo the firing process individually after being shaped.

Copper craft: Water Heater (2017)Dastkari Haat Samiti

Once the entire water heater is constructed it undergoes the firing process one more time.

The water heaters require the most number of processes to be made.

Copper craft: Acid Wash (2017)Dastkari Haat Samiti

The impurities are washed away before the final finishing of the water heater can be undertaken.

Copper Craft: Water storage container (2017)Dastkari Haat Samiti

All parts of the water heaters and containers undergo the final buffing process.

The process of making water heater is long and the work has to be collective and collaborative to meet with the high demand.

Copper craft: From old to new (2017)Dastkari Haat Samiti

The crafts persons also repair old utensils in addition to making new ones.

Copper craft: Moulds (2017)Dastkari Haat Samiti

The copper workers keep the old shaping moulds made of iron or stone in their workshops.

These moulds were made in iron or stone since the dimensions of traditional items were always standard.

Copper Craft: The workshop area (2017)Dastkari Haat Samiti

Coppersmiths work on various items in groups and the multiple sounds of beaten copper can be heard far before entering their homes and workplaces.

Copper craft: Contemporary products (2017)Dastkari Haat Samiti

Credits: Story

Text: Jaya Jaitly
Photography: Suleiman Merchant
Artisans: Balachandra Kadu, Ishwar Karade, Sharad Kharavlikar, Manoj Photfode, Ganesh Wadke, Arun Patil, Mahesh Nizampurkar,Ganesh Photfode, Uday Kavale, Sunil Kharavlikar, Satish Nizampurkar, Chandrashekar Salvi, Ganesh Karade, Ajit Pimple, Bharat Nizampurkar, Sunil Wadke, Pravin Kharavilkar and Sandeep Kharavilkar and fellow craftsmen.
Ground Facilitator: Jui Tawade
Documentary Video: Suleiman Merchant
Curation: Ruchira Verma

Credits: All media
The story featured may in some cases have been created by an independent third party and may not always represent the views of the institutions, listed below, who have supplied the content.
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