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Bob Vila
0102 - Building a Reinforced Concrete House
September 19-25, 2005 | March 20-26
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HI. I'M BOB VILA.

WELCOME TO OUR PROJECT
IN PUNTA GORDA, FLORIDA.

WE ARE BUILDING
AN ALL-CONCRETE HOUSE,

AND TODAY WE'RE PUTTING
THE FINISHING TOUCHES ON
SOME OF THE FORMWORK,

AND WE'RE ALSO GETTING READY
TO POUR ABOUT

4 TRUCKLOADS OF CONCRETE.

WE'LL ALSO VISIT WITH
WAYNE SALLADE,

WHO'S THE CHARLOTTE COUNTY
EMERGENCY MANAGER,

TO LEARN A LITTLE BIT MORE ABOUT
HOW DEVASTATING CHARLEY WAS,

AND WE'LL MEET OUR HOMEOWNERS.

STICK AROUND.

CAPTIONING MADE POSSIBLE BY
SEARS

WE'RE LOOKING AT OUR
ALUMINUM FORMWORK
THAT'S ALMOST DONE.

CAMERON PARKER IS
THE PRODUCTION MANAGER

FOR SOLID WALL SYSTEMS.

CAMERON, TELL US
A LITTLE BIT ABOUT,
JUST TO RECAP,

HOW THIS HAS
COME TOGETHER.

WE SPENT--

TODAY WE'RE TAKING
AND ERECTING THIS.

IT TAKES ABOUT 5 HOURS
IN AN 8-HOUR TIME FRAME,

DEPENDING ON THE SIZE
OF THE HOUSE...

PUTTING IT ALL TOGETHER.

YES, SIR.

WITH ABOUT A 6-MAN CREW.

WITH ABOUT
A 6-MAN CREW.
OK.

WE'VE GOT--

THIS IS A TYPICAL
FORM THAT WE USE.

UH-HUH.

WE SPRAY IT DOWN

WITH A BIODEGRADABLE
FORM OIL BEFORE WE
INSTALL IT,

THAT'LL ALLOW THE CONCRETE
NOT TO ADHERE,

SO WE CAN RELEASE IT
ONCE WE TAKE
THE FORMS OFF.

RIGHT. AND THEN
THE FORMS ARE
CLIPPED TOGETHER,

AS WE SEE HERE?

YES, THE FORMS
ARE CLIPPED TOGETHER

WITH A WEDGE
AND A PIN...
YEP.

AND THERE'S A WALL TIE
THAT'S INSTALLED

TO HOLD THE TWO FORMS
OUTSIDE AND INSIDE
TOGETHER.

AND YOU'VE ALSO GOT
CLIPS DOWN--

YES, SIR.

ON THE SLAB.

ABSOLUTELY.

AND THEN WE'VE GOT--

WHAT'S THIS
GOING IN HERE?

THIS IS A WINDOW BUCK.

WHAT THIS IS IS,
ONCE THE CONCRETE

IS POURED AROUND
THIS BUCK,

WE REMOVE THE BUCK
AND THE WINDOW CAN BE

DIRECTLY INSTALLED
IN THIS OPENING

WITHOUT ANY EXTRA
ADDITIONAL WORK.

A SPECIALIZED PART OF
THE FORMWORK...

YES, IT IS.

THAT CONFORMS TO
THE ROUGH OPENING

FOR THE WINDOW
THAT'S GOING THERE.

IT ELIMINATES THE NEED
FOR ADDITIONAL LUMBER

OR MATERIAL TO KEEP
FROM LEAKING OR

HAVE PROBLEMS WITH WATER
INTRUSION.

...ANY LUMBER USED HERE
AT ALL, RIGHT?

ABSOLUTELY.

GREAT.

AND THEN
THIS CLIP GETS...

NO, THEY'RE INSTALLING
WALL TIES RIGHT NOW.

WHAT HOLDS UP
THE WINDOW BUCK

AS WELL AS HOLDS THE FORM,

INSIDE AND OUTSIDE
FORM TOGETHER,

SO WHEN WE POUR,
THEY DON'T COME APART.

...WHEN WE START POURING
LATER ON, FROM THE TOP,

IT'LL JUST BASICALLY
GO DOWN,

FILL INTO THE AREA
UNDERNEATH IT...

YES.

AND WHEN WE STRIP,
WE HAVE OUR WINDOW
OPENINGS IN PLACE.

CORRECT, CORRECT.

ALL RIGHT.

THANKS, CAMERON.

YOU'RE WELCOME.

WE'RE GOING TO BE POURING
A LITTLE BIT LATER
IN THE SHOW, BUT

RIGHT NOW I THOUGHT
IT WOULD BE WISE

TO RECAP HOW WE
GOT YOU THIS FAR.

SUMMERTIME WEATHER
IN SOUTHWEST FLORIDA

OFTEN MEANS
AFTERNOON SHOWERS,

BUT THIS TIME AROUND
HERE IN PUNTA GORDA,

WE'VE HAD 7 DAYS OF
UNINTERRUPTED DOWNPOURS,

WHICH HAVE FINALLY JUST ABATED,

AND TODAY WE ARE POURING
OUR CONCRETE SLAB.

NOW, MUCH OF
THE PRELIMINARY WORK

THAT'S HAD TO TAKE PLACE HERE

INVOLVED BRINGING IN
TRUCKLOADS OF FILL

SO THAT WE COULD
GET UP TO AN ELEVATION

THAT MEETS CURRENT REQUIREMENTS.

AND PUTTING IN
A NEW SLAB FOR THE HOUSE

IS NOT AS EASY AS IT ONCE WAS,

CAUSE REQUIREMENTS NOW DICTATE
THAT YOU BUILD A STEM WALL

AROUND THE WHOLE PERIMETER
OF THE HOUSE.

THIS MEANS THAT
YOU'RE GOING DOWN

ABOUT 3 COURSES OF
CONCRETE BLOCKS,

SO THAT YOU CREATE A BARRIER TO
STORM SURGE WATERS,

PREVENTING THEM FROM GETTING IN
UNDERNEATH A SLAB

AND CREATING
THE HYDROSTATIC PRESSURE

WHICH COULD MOVE THE SLAB
AND, IN FACT, DESTROY THE HOUSE.

NOW, ALL THE CONCRETE
THAT WAS POURED IN HERE

WHICH TOOK ABOUT 3 TO 4 HOURS
TO GET IN PLACE

WAS DELIVERED VIA
A BIG PUMPING RIG,

THE BIG JOHNSON OVER HERE,

AND THIS MAKES IT VERY EASY
TO MOVE THE CONCRETE

AROUND THE WHOLE FOOTPRINT
OF THE HOUSE

TO MINIMIZE THE AMOUNT OF
LABOR INVOLVED.

NOW, THE IMPORTANT THING
TO KEEP IN MIND

IS THAT THE REINFORCING IS
VERY, VERY, VERY IMPORTANT

TO THE STRENGTH OF THE SLAB,

AND SO WE HAVE TO MAKE SURE
THAT THEY'RE LIFTING IT

SO THAT IT FLOATS
IN THE MIDDLE OF THE SLAB,

AND ONCE ALL OF THIS POURING
HAS BEEN DONE,

THE FINISHING BEGINS.

WE USE, OBVIOUSLY,
BOW FLOATS AND MOTORIZED FLOATS,

AND WE GO THROUGH STAGES OF
FINISHING AND POLISHING
THE CONCRETE.

THE SOLID WALL SYSTEM ITSELF

REQUIRES THE CONSTRUCTION OF
AN ELABORATE WEB OF

STEEL REINFORCING RODS,

VERTICAL REBAR,
USUALLY NUMBER 5s,

HORIZONTAL PIECES FOR
HEADING OFF WINDOW OPENINGS,

AND THEN ALL OF IT IS COVERED IN
A STEEL MESH,

WHAT LOOKS LIKE
A STEEL MESH REINFORCING.

AH, ALL OF THIS TOOK BASICALLY
ABOUT 4 OR 5 HOURS

TO GET ACCOMPLISHED.

[NO AUDIO]



WE'RE GOING TO CHAT NOW
WITH WAYNE SALLADE,

A CHARLOTTE COUNTY
EMERGENCY MANAGER.

WE'LL TALK
A LITTLE BIT ABOUT

SOME OF THE EFFECTS
OF THIS STORM

ON NOT JUST FLORIDA
IN GENERAL

BUT ON
THE COMMUNITY HERE.

WE'RE STANDING
RIGHT IN FRONT OF

SOMETHING THAT,
9 MONTHS LATER,

IS STILL
LARGELY DESTROYED,

AND NOW I LEARN
IT'S CONDEMNED.

TELL US A LITTLE BIT
ABOUT THE IMPACT OF
THIS STORM.

ONE OF OUR
BIG PROBLEMS, BOB,

AS WE GO INTO ANOTHER
HURRICANE SEASON IS

WE'VE GOT
HUNDREDS AND HUNDREDS
OF PROPERTIES

LOOK JUST LIKE THIS ONE.
YEAH.

WE'VE GOT HOMES THAT
LOOK THE DAY THEY DID
AFTER HURRICANE CHARLEY,

AND THAT'S A REAL--
REAL CONCERN,

BECAUSE RECOVERY IS NOT
SOMETHING THAT HAPPENS
INSTANTANEOUSLY.

I MEAN, IT TAKES
A LOT OF EFFORT

TO GET THESE
BUILDINGS DOWN

AND TO BEGIN THE PROCESS
OF REBUILDING
OUR COMMUNITY,

AND SHOULD
ANOTHER STORM THREATEN,

WE'VE GOT SOME VERY
SERIOUS ISSUES

TO--TO DEAL WITH
IN TERMS OF
FLYING DEBRIS.

NOW, IS THE PROBLEM
MOSTLY JUST THAT

THE NUMBERS ARE SO HUGE?

THERE HAVE BEEN
SO MANY DAMAGED BUILDINGS

THERE AREN'T ENOUGH
CONTRACTORS TO GO AROUND?

THERE JUST AREN'T ENOUGH
DEMOLITION COMPANIES
TO DO IT.

I MEAN, DEMOLITION IS
A TEDIOUS PROCESS.

IT HAS TO BE DONE RIGHT.
YOU DON'T JUST COME IN
AND CLEAR A SITE.

IT'S GOT TO BE DONE.
IT'S GOT TO BE
DONE SAFELY.

THERE'S OSHA
RULES AND REGULATIONS,

AND GETTING CONTRACTORS
THAT ARE SKILLED

AND DO THAT
FOR A LIVING,

AND AGAIN, THERE JUST
AREN'T THAT MANY
TO GO AROUND,

AND THEY'RE SPREAD
PRETTY THIN ACROSS
THE STATE OF FLORIDA.

YOU GOT 'EM
IN PENSACOLA,
YOU GOT 'EM HERE,

AND--SO IT'S--
IT'S A BIG PROBLEM.

NOW, WERE THERE
SOME HOMES

THAT WERE MORE SUSCEPTIBLE
TO DESTRUCTION

IN THIS HURRICANE
THAN OTHERS?

ABSOLUTELY.

YEAH, I MEAN, ANYTHING,
PRETTY MUCH,

YOU COULD WRITE OFF
THOSE THAT WENT THROUGH
THE EYEWALL OF CHARLEY

THAT WERE BUILT IN
SIXTIES, SEVENTIES,
EARLY EIGHTIES.

WERE GOING TO
HAVE DAMAGE,

PARTICULARLY
ROOF FAILURE.

THIS EXAMPLE IS
PROBABLY FROM
THAT PERIOD.

THIS IS
A VERY GOOD EXAMPLE

OF PRE-FLORIDA
UNIFIED BUILDING CODE,

AND A PLACE
THAT WAS BUILT WITH

MATERIALS AND--AND WOOD
FRAME CONSTRUCTION

WITH LAP SIDING,
AND JUST REALLY DIDN'T
STAND A CHANCE.

AND YOU CAN SEE WHERE
THE DAMAGE IS ON THIS
PARTICULAR BUILDING,

THAT THE WINDS DID COME
AROUND FROM THE EAST
AND SOUTHEAST

AS CHARLEY PASSED OVER,

AND DID ITS DAMAGE
ON THIS SIDE OF
THE BUILDING.

AND SO IT'S UNFORTUNATE

THAT YOU SEE PROPERTIES
LIKE THIS,

AND PEOPLE
HAVE TO UNDERSTAND

THE 50-50 RULE
THAT'S OUT THERE.

THAT IF A PROPERTY
IS DAMAGED BEYOND
THE 50% LEVEL,

IT HAS TO BE REPLACED,
IT'S A TEAR-DOWN,
AND THAT'S--

...SOME CASES,
ZONING CHANGES

AFFECT WHAT CAN
BE REBUILT.

ABSOLUTELY.
I MEAN, AND THAT GETS

INTO THE WHOLE
INSURANCE ISSUE

AND HAVING
LAW AND ORDINANCE

COVERAGE ON
YOUR PROPERTY

THAT PROTECTS YOU
WHEN THE RULES
AND REGULATIONS CHANGE

SO THAT YOU CAN
BUILD A SIMILAR
TYPE OF STRUCTURE

FOR THE AMOUNT OF MONEY
THAT YOU MIGHT
HAVE AVAILABLE.

SO, YEAH, YOU GET PEOPLE
THAT ARE CAUGHT IN THE--

YOU KNOW, YOU HAVE
A REAL CATCH-22

WHEN YOU HAVE
A SITUATION LIKE--LIKE
THIS ONE IN PARTICULAR.

NOW, OTHER HOMES,
LIKE THIS LOVELY

LAVENDER HOUSE OVER HERE,

SEEM TO HAVE GOTTEN
THROUGH THE STORM
PRETTY MUCH UNSCATHED.

WELL, IMAGINE,
NOW, THESE PEOPLE--
A COUPLE REASONS.

ONE, OBVIOUSLY,
POINT NUMBER ONE,

THIS HOUSE A HIP ROOF.

YEAH.
GABLE ROOFS JUST DON'T
MAKE IT,

ESPECIALLY WHEN THEY'RE
FACING THE WIND.

NOW, THAT GABLE
IS GOING TO FAIL
WITHOUT BRACING.

THE GABLE END
IS LIKE A SAIL.

BUT THE HIP ROOF
PROVIDES DEFLECTION OF
THE WIND,

AND THEN THAT'S
KEY POINT NUMBER ONE.

NUMBER TWO, THEY HAD
WINDOW PROTECTION
ON THIS HOUSE.

PARAMOUNT TO PROTECTING
A FLORIDA HOME.

KEEP THE WIND OUT OF
THE DOORS AND WINDOWS

AND YOU'RE NOT
GOING TO GET THOSE
UPLIFT PRESSURES

AND YOUR HOUSE STANDS
A SIGNIFICANT CHANCE
OF SURVIVAL.

AND SURPRISINGLY,
MANY HOUSES LIKE

THE COTTAGES
ACROSS THE WAY,

WHICH COME, YOU KNOW,
GO BACK TO THE TWENTIES
OR THE THIRTIES,

ARE STILL INTACT.

ISN'T IT AMAZING
TO TAKE A LOOK AT
OLD FLORIDA CONSTRUCTION

AND--AND REALIZE THAT
WE HAVE HUNDREDS

AND HUNDREDS AND HUNDREDS
OF HOMES JUST LIKE THESE

THROUGHOUT THE PUNTA
GORDA COMMUNITY
THAT DID JUST AS WELL.

IT--IT'S A--
WHEN I FIRST GOT OUT
INTO THE COMMUNITY,

IN FACT, THE DAY AFTER
THE STORM,

WHEN WE FLEW OVER
THE CITY,

AND I WAS ABLE
TO LOOK DOWN,

AND, I MEAN,
THESE STREETS HAVE BEEN

MY HOME FOR 40 YEARS,

AND I LOOKED AT
SOME OF THESE HOUSES

AND I SAID, "YOU GOT
TO BE KIDDING ME.

I CAN'T BELIEVE THAT
THAT'S STILL THERE,"

WHEN I SAW BUILDINGS
ALL AROUND

THAT HAD
FAILED MISERABLY

UNDER THE--
THE WIND FORCES.

I THINK OF THEM
AS BASKETS.

THEY--THEY'RE FLEXIBLE,
THEY GIVE IN THE WIND,

BUT THEY--
THEY STAY THERE.

WAYNE, THANKS FOR
COMING ON THE SHOW.

THANKS, BOB.
PLEASURE.

Vila: CLOSED CAPTIONING
PROVIDED BY...



Vila: HI. I'M BOB VILA.

THIS WEEK WE'RE BACK AT
OUR STORM-READY HOUSE

IN THE HURRICANE HOT SPOT OF
PUNTA GORDA, FLORIDA,

WHERE WE'LL CATCH UP ON
HOW WE BUILT

THIS CAST-IN-PLACE
STATE-OF-THE-ART STRUCTURE.

WE'LL SET THE ALUMINUM FORMS,

ADD SPECIAL BUCKS
FOR THE WINDOWS,

GET OUR INSPECTION, AND START
POURING THE WALLS

OF WHAT'S GOING TO BE
A VERY STURDY HOUSE.

AND WE'LL MEET CHARLOTTE COUNTY
EMERGENCY MANAGER WAYNE SALLADE,

WHO'S GOT HIS WORK
CUT OUT FOR HIM

AS FLORIDA ENTERS ANOTHER
HURRICANE SEASON.

THAT'S NEXT TIME ON "BOB VILA"
DON'T MISS IT.



Vila: HI. I'M BOB VILA.

THIS WEEK, WE'RE BACK AT
OUR STORM-READY HOUSE

IN THE HURRICANE HOT SPOT OF
PUNTA GORDA, FLORIDA.

WE'LL SET THE ALUMINUM FORMS,

ADD SPECIAL BUCKS
FOR THE WINDOWS,

AND START POURING THE WALLS

OF WHAT'S GOING TO BE
A VERY STURDY HOUSE.

THAT'S NEXT TIME ON "BOB VILA."
DON'T MISS IT.



Vila: NEXT TIME ON "BOB VILA,"
WE'LL POUR THE WALLS

OF OUR CAST-IN-PLACE,
STORM-READY HOUSE

IN PUNTA GORDA, FLORIDA.

WHEN THE FORMS COME OFF,
THE WALLS ARE DONE.

DON'T MISS IT.



THE CONCRETE TRUCKS
SHOULD ROLL IN JUST ANY MINUTE,

BUT BEFORE THEY DO AND BEFORE
WE START POURING,

LET'S SAY HI TO
JIM CRAIN,

WHO'S WITH
PRECISE FORMS,

A COMPANY THAT DEVELOPED
THIS SYSTEM.

HOW OLD IS THIS?

WE STARTED
MANUFACTURING THIS IN
MARCH OF 1967.

INTERESTING.
SO THEY'VE BEEN AROUND
FOR A WHILE.

A LONG WHILE.

HAVE THEY ALSO BEEN USED

FOR UNDERGROUND
PURPOSES,
FOR FOUNDATIONS?

YEAH, THAT WAS
THE INITIAL USE.

IN THE BEGINNING WAS
SUBTERRANEAN BASEMENTS,

FOUNDATIONS,
THAT SORT OF APPLICATION.

I SEE.
AND WHEN DID THEY START
GOING ABOVE GROUND?

ABOUT 5 YEARS AGO,
WE HOOKED UP WITH

MERCEDES HOMES HERE
IN CENTRAL FLORIDA

AND STARTED POURING
A LOT OF THEIR HOMES
ABOVE GRADE.

WE HAD DONE SOME
PREVIOUS TO THAT,

BUT IT WAS
MORE SCATTERED.

ONCE WE GOT INVOLVED
WITH MERCEDES,

IT BECAME A REAL
PRODUCTION ISSUE
AT THAT POINT.

AND IS IT PRIMARILY
SOMETHING THAT'S

BECOMING POPULAR
IN THE SUN BELT?

RIGHT. IT'S
TAKING OFF MORE

IN THE STATE OF FLORIDA
THAN ANYWHERE.

THERE'S MORE MOTIVATION
LOCALLY, IF YOU WILL,

BECAUSE OF
THE INCLEMENT WEATHER

THAT THEY EXPERIENCE
DOWN HERE,

FOR A MORE SECURE HOME.

YEAH. IT'S PERCEIVED
AS BEING

A MUCH MORE STURDY
WAY OF BUILDING A HOUSE.

ABSOLUTELY.

WHAT'S THE GROWTH BEEN
LIKE FOR YOUR COMPANY?

WE'VE EXPERIENCED,
OVER THE LAST 5 YEARS,
FOR EXAMPLE,

ABOUT 30% A YEAR.

30% A YEAR.

YES.
SO THAT GOES ON TO IMPLY

THE NUMBER OF NEW HOUSES
BEING BUILT

WITH THIS KIND OF
SYSTEM--ENORMOUS.

RIGHT.
I HEARD THAT
THE AVERAGE--

WELL, THE AVERAGE HOME
LIKE THIS,

THE SET OF FORMS ITSELF,

IS WORTH ABOUT $150,000.

DOES THAT MAKE SENSE?

ACTUALLY, THIS SET HERE
IS PROBABLY

CLOSER TO $125,000.

125. OK.

THAT WOULD INCLUDE
THE FORM BASKETS
AND EVERYTHING.

YEAH. AND YOU'RE
GOING TO GET A LOT OF
USE OUT OF THEM.

OK, SO WE'RE JUST
A FEW MINUTES AWAY
FROM POURING,

AND I GOT TO ADMIT,
THIS REALLY LOOKS LIKE
A CONTAINER,

LIKE SOMETHING SHOULD BE
ON ONE OF THOSE

CONTAINER SHIPS
RIGHT NOW.

YES, SIR,
IT DOES.

YEAH.

BUT LET'S GO THROUGH
THE LAYOUT,

AND JUST COME IN
THE ENTRANCE HERE.

WHAT'S ON THE RIGHT?

WHAT WE GOT IS
THE MASTER OVER HERE, SIR.

WHEN WE WALK IN
THROUGH HERE,

WE'VE GOT THE DINING
AND LIVING ROOM AREA.

NO WINDOWS AT ALL?

THERE IS SOME WINDOWS.
THEY'RE ENCAPSULATED.

THE WINDOW BUCKS
ARE BEING PUT INTO
THE SIDE [INDISTINCT].

WHEN WE STRIP 'EM,
YOU'LL BE ABLE TO SEE
THE WINDOWS.

OK. SO THIS IS MASTER
BEDROOM AND BATHROOM,

AND YOU'LL HAVE A BIG
WINDOW OVER THERE

AND A BIG SLIDER
OVER THERE.

CORRECT.

AND THEN THIS AREA?

THIS IS THE DINING/
LIVING AREA.

OVER TO THE LEFT
OVER HERE IS
THE KITCHEN.

WE'VE GOT THE BREAKFAST
NOOK AREA.

OH, THAT'S NICE, YEAH.

ALONG THE CORNER
OVER HERE.

WE HAVE THE NICE, BIG
FAMILY AREA,

WHERE WE HAVE TWO BIG
WINDOWS INSIDE OF
THAT WALL

THAT LOOK OUT
ONTO THE CANAL.

SO WE DO HAVE
A VIEW WINDOW THERE.

YES, WE DO.
WE HAVE TWO
3-6 WINDOWS OVER THERE,

THEN WE'VE GOT ONE,
TWO, 3 BEDROOMS
OVER HERE,

AND A LAUNDRY ROOM.

EXCELLENT.

SO WE'VE GOT 3 BEDROOMS
AND A BATH.

AND A LAUNDRY ROOM.

A LAUNDRY ROOM
AND THEN A TWO-CAR GARAGE.

AND WE GOT MARK
OVER HERE.

HEY, MARK, THIS IS
AN EXCITING MINUTE.

YES, IT IS.

NOW, THE CONCRETE

THAT GETS POURED,
WHAT'S THE PSI?

WHAT'S--IS THERE
ANYTHING SPECIAL
ABOUT THE CONCRETE?

Mark: SMALL AGGREGATES
AT 3,000 POUND.

UH-HUH, AND--AND YOU
DON'T HAVE TO PUT

ANY KIND OF EXTRA
INGREDIENTS IN IT?

JUST ADD WATER.

JUST ADD WATER. OK.

ALL RIGHT, SO DO YOU
HAVE TO WORRY ABOUT

ALL THIS CONCRETE
STICKING OR, YOU KNOW...

SETTING UP OR...?

ACTUALLY THE FORMS
HAVE BEEN

OILED WHERE THE CONCRETE
WON'T STICK TO IT.

[INDISTINCT]
AND IT NORMALLY
TAKES [INDISTINCT]--

ONCE WE GET DONE PUMPING,

IT TAKES 4 TO 6 HOURS,

DEPENDS ON THE WEATHER,

AS TO WHETHER THE CONCRETE
SET UP OR NOT.

THAT'S JUST A TEST.

WE WILL ALSO VIBRATE
AROUND WINDOWS
AND DOOR OPENINGS

TO MAKE SURE THAT
THEY GET FULL COVERAGE
AROUND THE DOOR.

SO THAT YOU DON'T
END UP WITH

ANY KIND OF
HONEYCOMBING EFFECT.

HONEYCOMBING OR
BLOWOUT OR
ANYTHING LIKE THAT.

NOW, A BLOWOUT,
I WOULD THINK,

WOULD BE AN EXTREMELY

HORRIBLE THING
TO HAPPEN IN HERE,

IF--IF ONE OF THESE
FASTENERS LETS GO.

RIGHT. RIGHT.

THAT--WHAT I WAS
JUST REFERRING TO
AS A BLOWOUT,

WHEN YOU TAKE THE FORMS
AWAY FROM THE WALL,

THE CONCRETE BLOWS OUT
WITH IT,

WHICH MEANS IT EITHER
STUCK TO THE FORM

OR YOU DIDN'T GET
GOOD CONFORMITY.

YES, I UNDERSTAND.

NOW, I NOTICE THEY'VE
SET UP A WHOLE ROW OF

2 x 4s ALONG
THE PERIMETER
UP AT THE TOP.

WHAT'S THAT DO?

RIGHT. THAT--

2 x 4s ARE
THE [INDISTINCT] BRACKETS,

THOSE LITTLE BRACKETS
ARE CALLED.

THEY HELP HOLD
THE WALL SQUARE.

YOU'VE, GOT, LIKE,
36-INCH PANELS,
24-INCH PANELS.

THE 2 x 4s ARE USUALLY
16 TO 20 FEET LONG,

ADD STRAIGHT TO
THE WALL

SO AS YOUR
STATIC LOAD

COMES IN FROM
THE CONCRETE.

YOU DON'T HAVE ANY
SQUEAKING OF THE PANELS.

SO THERE'S NO--
EVEN A MINOR VARIATION
LIKE THAT

CAN MAKE FOR
A MESSY--MESSY LOOK.

YES.

YEAH. GREAT.



ALL RIGHT.
IT'S DAY TWO NOW.

WORK CONTINUED UNTIL
AFTER 8:00 LAST NIGHT,

AND, YOU KNOW, OVERNIGHT IS
ALL IT TAKES.

WE'RE NOW IN THE PROCESS OF
STRIPPING AWAY THE FORMWORK,

AND WE CAN SEE WHAT'S HAPPENING
RIGHT OVER HERE.

HI, GUYS.

Both: GOOD MORNING.

JESSE, IT'S ONLY BEEN

APPROXIMATELY 12 HOURS
SINCE WE POURED IT,

AND SO IT'S
STILL RELATIVELY--

GREEN.
GREEN, YEAH,

BUT IT'S OK TO TAKE
ALL THESE FORMS OFF.

SET TIME IS NORMALLY

[INDISTINCT]
ANYWHERE FROM
6 TO 8 HOURS.

THAT'S ALL YOU NEED.

AND HERE'S ONE OF
OUR WINDOW BLOCKS,
RIGHT, THE WINDOW BLOCKS.

[INDISTINCT]
A LITTLE BIT SCARED
THAT THE THING IS

GOING TO BREAK
AT THE CORNERS.

NO, IT'S--

[INDISTINCT]
SHOULD BE PERFECT.

PERFECT.
LOOK AT THAT BLUE
FLORIDA SKY.

THE--THE LOCATION HERE
IS THE MASTER BEDROOM.

CORRECT.

AND LOOK AT HOW
THOSE CLIPS

JUST BREAK RIGHT OFF.

THEY'RE ACTUALLY
MADE TO DO THAT.

NOW, THE--
THE VERTICAL CLIPS

THAT WE SEE AT
THE TOP OF THE WALL,

TELL ME ABOUT
THOSE, JESSE.

THOSE ARE
THE TRUSS STRAPS.

THEY'RE THE SIMPSON
STRONG-TIE
TRUSS STRAPS.

AND THEY WERE INSTALLED
AT THE END OF THE POUR
LAST NIGHT.

CORRECT.

WHAT'S THE SPACING?

DEPENDING ON
THE TRUSS LAYOUT.

OK. BUT THEY BASICALLY
TIE AROUND THE--THE--

CORRECT.

THE BOTTOM MEMBER OF
THE TRUSS.

NOW, IS THAT SOMETHING
THAT IS NEW

IN TERMS OF HURRICANE
ROOF CODE REQUIREMENTS?

NO, THEY'VE JUST UPPED--
UPPED THEIR
CODES, THOUGH,

BUT THEY'VE ALWAYS
BEEN IN PLACE.

THEY'VE ALWAYS
BEEN REQUIRED.
GOOD.

HOW LONG IS IT GOING TO TAKE
TO STRIP THE WHOLE...

NORMALLY 6 TO 8 HOURS.

ALL RIGHT. GOOD.
WE'LL BE WATCHING.

YEAH.

BOY, THAT ONE REALLY
CAME OUT REAL CLEAN,
DIDN'T IT?

YES, IT DID.

OK.

NOW WE'VE GOT TWO, 3
SECTIONS OF THE WALL

THAT ARE EXPOSED HERE.

LET'S LOOK AT
THIS SECTION OVER HERE

AND TALK A LITTLE BIT
ABOUT THE CONDITION.

IT'S SO WET
TO THE TOUCH

AND THERE ARE JUST
LITTLE, TINY AREAS
WHERE YOU GOT,

YOU KNOW,
LITTLE IMPERFECTIONS
LIKE THAT.

WHAT--WHAT DO YOU
HAVE TO DO NEXT?

WHAT WE'LL DO IS
WE'LL COME THROUGH

AND PUT A SKIM COAT
OF CONCRETE,

FILL ALL THE VOIDS
SUCH AS THIS,

WHERE THE WALL TIE WAS.

BUT THE SKIM COAT
JUST IN LITTLE AREAS,

WHERE TIES WERE
AND THE LIKE,

BUT THIS RIGHT HERE,
WHAT DO YOU DO?
ANYTHING ELSE?

NO, THE OTHER THING
WE DO

IS PUT ELASTOMERIC
WATER INTRUSION
SUBSTANCE.

THE OUTSIDE WILL BE
PAINTED ON.

THE INSIDE IS
NIGHT GRADE.

PRETTY MUCH WHERE
THE WALL TIES WERE,

WE'LL HAVE NO
WATER INTRUSION.

OK. AND THEN FROM
THE POINT OF VIEW
OF FINISHES,

COME ON UP HERE
AND LOOK AT THIS.

I MEAN, WE'RE NOT
GOING TO JUST

TROWEL PLASTER RIGHT
AROUND THERE, ARE WE?

Gonzalez: NO, SIR.
WHAT WE DO HERE IS,

THIS IS A--WE'LL HAVE
A 3-STEP PROCESS HERE.

ACTUALLY, WHAT WE DO IS
WE COME IN
AND WE PRESSURE-WASH

TO GET SOME OF
THE OIL RESIDUE

OFF FROM
THE FORM BOARDS,

AND THEN WE COME IN--

BUT THERE'S HARDLY ANY,
JESSE.

I MEAN, IT DOESN'T
FEEL AT ALL OILY.

WE DO IT FOR
A SAFETY PRECAUTION
AND FOR BONDING,

AND WHAT WE DO HERE IS
WE COME IN
AND PRESSURE-WASH

AND THEN WE ACROBOND
IN FRONT OF OUR
SCRATCH COAT.

ACROBOND.

ACROBOND. IT'S
A BONDING AGENT.

OK. A CATALYST.

AND THEN WE PUT IN
OUR FIRST COAT,

WHICH IS OUR
SCRATCH COAT,

AND THEN WE COME BACK
OVER THAT

ONCE IT GREENS UP
A LITTLE BIT

AND WE PUT
A SECOND COAT,

WHICH IS CALLED
A BROWN COAT,

AND THEN ONCE THAT
HARDENS UP,

THEN WE COME BACK AND WE
PUT OUR FINAL COAT ON.

OK. AND SO IT'S--
IT'S BASICALLY

GOING TO HAVE THE LOOK OF
A TRADITIONAL FLORIDA
PLASTER [INDISTINCT], RIGHT,

AND WHAT ABOUT
THE FORMS THERE, MARK?

I MEAN, WHEN USE THEM
ON THE NEXT JOB
TOMORROW OR WHATEVER,

DO THEY HAVE TO BE
SCRAPED OR SANDED
OR CLEANED UP?

WHAT HAPPENS
WHEN THEY COME OFF

IS THEY WILL SCRAPE IT
AND RE-OIL IT

BEFORE IT GOES INTO
THE BASKET.

WINDOW BUCK,
ALL ALUMINUM PIECES
WILL BE RE-OILED.

THEY GET OILED
WHEN THEY COME OFF

AND THEY GET OILED
RIGHT BEFORE THEY GO ON,

SO WE'LL HAVE
VERY LITTLE STICKING OF
THE CONCRETE.

IT'S NOT PETROLEUM
OR DIESEL OR ANYTHING
LIKE THAT.

SOMEBODY SAID IT WAS
A BIODEGRADABLE...

YES, IT IS.

OK, SO ANYTHING THAT

SPILLS OVER AND STUFF
IS NOT HARMFUL
TO YOUR WORK SITE.

CORRECT.

THAT'S GREAT.

ALL RIGHT.
LET'S TALK
A LITTLE BIT ABOUT

THE TIMING INVOLVED HERE.

BEFORE YOU GO TO
THIS FINISH STAGE,

DO YOU HAVE TO WAIT
AND LET IT CURE

FOR A WEEK OR TWO WEEKS
OR WHAT?

THIS HOUSE WILL PROBABLY
SIT A COUPLE WEEKS

BEFORE WE ACTUALLY
GO INTO OUR PROCESS.

OK. ALL RIGHT, GUYS.

WELL, BEFORE WE
WRAP THINGS UP HERE,

I WANT TO SAY HI
TO THE HOMEOWNER.

COME OVER HERE, BOB.

HEY, JIM.
WELL, WHAT DO YOU THINK?

I MEAN, THIS IS PRETTY

LIGHTNING-FAST STUFF
THAT'S GOING ON HERE.

ISN'T IT INCREDIBLE?
INCREDIBLE WE HAD, LIKE,

TWO DAYS AGO,
NOTHING BUT SAND,

AND NOW IT SEEMS LIKE
I JUST WOKE UP

AND HERE'S A--
A HOUSE THAT'S
PRACTICALLY BUILT.

YEAH, I KNOW,
IT IS AS--AS CLOSE TO

DREAM HOUSE BUILDING
AS IT GETS, I SUPPOSE.

NOW, HAVE YOU--HAVE YOU
FIGURED OUT THE LAYOUT?
WHERE ARE YOU?

WE'RE--WE'RE IN
THE MASTER BATHROOM,

AND THIS IS WHERE
OUR TUB IS GOING TO BE.

SO YOU GOT A WINDOW
RIGHT OVER THE TUB.

WINDOW RIGHT OVER
A BIG TUB.

BUT, OF COURSE,
A LOT OF THESE
NEW WINDOWS

HAVE TINTING IN THEM
AND STUFF,

SO THAT PRIVACY'S
NOT MUCH OF AN ISSUE.

NOW, TELL ME ABOUT,
YOU KNOW,

YOU KIND OF--
YOU AND YOUR WIFE

WORKED ON DESIGNING
THIS HOUSE

WITH MERCEDES HOMES
AND STUFF,

AND NOW YOU'VE GOT
AN ACTUAL OPPORTUNITY
TO WALK THROUGH IT.

DOES IT FEEL RIGHT?

OH, IT SEEMS
SO MUCH BETTER.

ALL WE SAW WAS PRINTS

AND ON--ON PAPER
FOR JUST WEEKS,

BUT NOW IT'S MANIFESTED
AS A HOUSE,

AND IT'S INCREDIBLE
TO EVEN--MORE INCREDIBLE

THAN I THOUGHT
IT WOULD BE.

CONCRETE, TO USE
THE RIGHT TERM.

CONGRATULATIONS. OK.
WE'RE RUNNING OUT OF TIME.

NEXT TIME, WE'RE GOING TO BE
SHEATHING, HOT-MOPPING,

AND TILING THE ROOF.

TILL THEN, I'M BOB VILA.

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