1415 - Modular Construction Details and Foundation Work
December 15-21, 2003 | June 14-20, 2004
HI, I'M BOB VILA.
WELCOME "HOME AGAIN"
TO OUR NEW
CONSTRUCTION PROJECT
HERE IN THE BERKSHIRE HILLS
IN WESTERN MASSACHUSETTS.
THIS IS
AN EXCITING PROJECT.
WE'RE GONNA BE
SPENDING SOME TIME TODAY
SHOWING YOU A PRE-FABRICATED
FOUNDATION SYSTEM
THAT'S BEING INSTALLED
IN THE GROUND,
AND SPENDING SOME TIME OUT
IN WESTERN PENNSYLVANIA
WHERE THEY'RE MANUFACTURING
OUR MODULAR HOUSE
IN A FACTORY.
STICK AROUND. IT'S GOOD
TO HAVE YOU "HOME AGAIN."
CAPTIONING MADE POSSIBLE BY
SEARS
AND THOSE ARE
THE FLYING FOUNDATION WALLS
WHICH ARE COMING
INTO PLAY RIGHT NOW.
JIM COSTELLO IS WITH US
FROM SUPERIOR WALLS.
HEY, JIM.
HI, BOB.
HOW ARE YOU?
GOOD, THANKS.
THIS IS
QUITE A MOMENT.
YES, IT IS.
MOST PEOPLE ARE
USED TO WATCHING
A FOUNDATION
KIND OF GET STRIPPED
A FEW DAYS AFTER
IT GETS POURED,
CONCRETE TRUCKS
ALL OVER THE PLACE.
THIS IS
SUCH A CLEAN,
SIMPLE APPROACH.
HOW DO THEY COMPARE?
I MEAN, HOW DOES
THIS COMPARE
TO A TRADITIONAL
FOUNDATION?
WELL, THIS IS CAST
IN A FACTORY,
AND IT'S CAST IN
A HORIZONTAL POSITION,
AND USING
HIGH STRENGTH CONCRETE,
SO IT'S MUCH STRONGER
THAN A TRADITIONAL
FOUNDATION
AND IT'S MUCH MORE
DIMENSIONALLY STABLE.
BUT IT'S ONLY
A COUPLE OF
INCHES THICK.
WELL, THE SHELL
IS A COUPLE OF
INCHES THICK,
BUT THE WALL ITSELF,
THE STRUCTURAL MEMBER,
IS 10 AND A QUARTER
INCHES THICK.
ALL RIGHT. AND IT
INCORPORATES STEEL
OR REINFORCING RODS
OR...
REINFORCING STEEL,
REBAR, IN EACH STUD,
SO IT'S REALLY
A CONCRETE VERSION
OF A STUD WALL.
I SEE. AND THE
ACTUAL BLUE STUFF
THAT WE'RE SEEING
OBVIOUSLY IS RIGID
INSULATION, RIGHT?
THAT'S DOW STYROFOAM.
OK. SO IT COMES
WITH AN R FACTOR.
RIGHT. IT HAS R5
INCLUDED IN IT
AS IT'S SHIPPED.
MM-HMM. NOW, YOU
CAN'T JUST BUY THESE
OFF THE SHELF,
THOUGH, RIGHT?
IT HAS TO BE
ENGINEERED
AND DESIGNED
FOR A SPECIFIC
HOUSE LOCATION.
YES. IT'S MADE
INDIVIDUALLY
FOR EACH HOME,
AND SO IT'S PRE-ENGINEERED
FOR ONE AND TWO-FAMILY
RESIDENTIAL USE,
BUT IT'S DESIGNED THEN
FOR EACH PARTICULAR HOUSE,
ANY DIMENSION YOU NEED.
RIGHT. YOU CAN'T
JUST GO OUT
AND BUY PANELS
AND STRING THEM
ALL TOGETHER.
NO, THAT'S CORRECT.
IT'S MADE INDIVIDUALLY.
OK.
NOW, JIM,
THIS NEXT PANEL
THAT'S COMING IN IS
A MITERED CORNER.
WHAT'S THE MATERIAL
THAT HE'S
PUTTING IN?
IS IT A TYPE
OF ADHESIVE?
IT'S A POLYURETHANE
SEALANT, BOB.
IT'S SPECIALLY FORMULATED
FOR APPLICATION TO
OUR TYPE OF CONCRETE.
AND IT'S, UH...
HE USES A BEAD
ON THE EXTERIOR
AS YOU JUST SAW HIM
JUST PUT ON,
AND THEN AFTER
THE PANEL IS SET
THERE'LL BE
AN ADDITIONAL BEAD
TO THE VERY OUTSIDE
AND ONE TO THE INSIDE.
WHAT IS ABOUT THIS
CONCRETE THAT NEEDS
THIS SPECIAL TYPE
OF PRODUCT?
WELL, WE USE A 5,000
PSI CONCRETE MIX,
AND IT HAS
A WATER CEMENT RATIO
OF .4, SO IT'S
A HIGH STRENGTH MIX,
AND IT HAS
SOME CHARACTERISTICS
THAT WE SPECIALIZED
THIS CAULK TO MEET.
IT'S A HIGH STRENGTH
MIX.
IT'S RICHER
IN PORTLAND CEMENT,
RIGHT?
THAT'S CORRECT.
WHAT ABOUT NORMAL
CONCRETE THAT
COMES TO A JOB
AND GETS POURED
INTO WOODEN FORMS?
WELL, TYPICALLY
THAT WOULD BE
IN THE ORDER OF 2,500
TO 3,000 PSI.
SO, JIM, THIS IS
KIND OF ONE OF
THE KEY PANELS.
THIS WILL ACTUALLY
HAVE PATIO DOORS
INSTALLED
IN THE CENTER
OF IT, RIGHT?
YES, THAT'S CORRECT.
GOOD. AND NOW WE'VE
SEEN THE ADHESIVE
GO DOWN
ON THE BOTTOM
AND IN THE CORNER,
BUT...
WHAT'S THE ACTUAL
FASTENING PROCESS?
I MEAN, HOW DO THESE
THINGS--DO THEY GET
BOLTED TOGETHER?
YES, THEY DO.
WHEN THE PANEL IS
CAST IN THE FACTORY
THERE'S AN EMBEDDED
SADDLE BOLT ASSEMBLY
THAT'S EMBEDDED
IN THE LOWER BOND BEAM
AND THE UPPER BOND BEAM,
AND THERE'S THE HALF INCH
DIAMETER BOLT
THAT BOLTS THEM
BOTH TOGETHER.
TERRIFIC.
NOW THIS ONE
HAS BEEN LAID
ON ITS SIDE,
AND IT LOOKS
FOR ALL THE WORLD
LIKE JUST
A BIG WIDE SIDEWALK
IN LOS ANGELES
OR SOMEPLACE.
YES.
FIRST OF ALL, WHY IS
IT ON THE GROUND?
IT'S BEEN SET ASIDE
BECAUSE IT'S OUT OF
SEQUENCE ON THE TRUCK.
OH, SO IT WASN'T
LOADED IN THE RIGHT
SEQUENCE.
THAT'S CORRECT.
OK. AND I'M AMAZED
AT THE STRENGTH
OF IT,
BECAUSE IT'S ONLY
THAT THICK, RIGHT?
THE SHELL IS AN INCH
AND 3 QUARTERS
ON THE SHELL,
BUT THE OVERALL STRUCTURE
IS 10 AND A QUARTER.
OK. LET'S LOOK AT IT
WHERE IT'S STANDING
UP OVER HERE
SO WE CAN
GET A BETTER IDEA
OF THAT.
THE OVERALL SHELL
BECAUSE OF THESE STUDS
GETS TO BE
THAT DIMENSION, RIGHT?
THAT'S CORRECT. RIGHT.
IT'S A CONCRETE STUD,
AND IT HAS A WOOD NAILER
HERE ON THE FACE.
THE WOOD HAS
NOTHING TO DO
WITH THE STRUCTURAL
INTEGRITY.
THAT'S JUST
FURRING OR NAILING.
THAT'S RIGHT.
FOR THE NEXT
APPLICATIONS
IN HERE,
WHETHER IT'S DRYWALL
OR WHATEVER.
EXACTLY.
AND THIS IS THAT
500 POUND...
5,000 PSI STEEL
REINFORCED CONCRETE.
OK. AMAZING.
NOW DO YOU EVER
HAVE TO WORRY
ABOUT SETTLEMENT?
WELL, SETTLEMENT IS NOT
ANYMORE AN ISSUE
WITH THIS SYSTEM
THAN WITH ANY
CONCRETE WALL SYSTEM,
SO YOU DO HAVE TO
BE CONCERNED ABOUT
WHAT YOUR SOILS ARE,
BUT IT'S NOT A PROBLEM
DIFFERENT THAN ANY
OTHER CONCRETE WALL.
AND HOW MUCH
CRUSHED STONE DO WE
HAVE BELOW THIS?
THIS HAS ABOUT 8 INCHES
OF CRUSHED STONE
BENEATH IT,
AND TYPICALLY YOU HAVE
6 INCHES OR SO.
SO IT'S A PRETTY
GOOD FIRM BASE.
THAT'S CORRECT.
IT ACCENTS THE FOOTING.
WHAT ABOUT WORRYING
ABOUT THEM TRYING
TO GO LATERAL,
YOU KNOW.
THAT'S A GOOD
QUESTION, BOB,
BECAUSE THERE'S
SOIL PRESSURE
ON THE OUTSIDE
IN A BASEMENT,
AND THIS IS
A VERY RIGID WALL,
AND YOU NEED TO
CONNECT IT CORRECTLY
TO THE TOP OF THE WALL,
TO THE FLOOR SYSTEM
IN ORDER THAT THE SOIL
DOESN'T PUSH THE WALL IN.
SURE.
BUT SO THERE ARE
VERY SPECIFIC DIRECTIONS
FOR THE CONTRACTOR
TO CONNECT
THAT FLOOR SYSTEM
TO THE TOP OF
THE WALL PLATE.
THE KEY IS
MAKING SURE YOU'VE
CREATED A BOX.
THAT'S CORRECT.
LET'S LOOK OVER HERE
AT THE CORNER
WHERE THEY'RE
PUTTING DOWN
ANOTHER PANEL.
Bob: OK, THIS IS THE NEXT
TO LAST SECTION
FOR THIS MAIN PART
OF THE HOUSE, JIM,
AND IT'S THE ONE WALL
THAT'S GONNA BE
RETAINING SOIL
BECAUSE OF THE GRADE
SLOPING OFF,
THE OTHER SIDES ARE
KIND OF OPEN.
YES, BOB,
THAT'S RIGHT.
SO THIS IS THE CHALLENGING
CONDITION, RIGHT?
THAT'S CORRECT.
THE WALL IS
FULLY ENGINEERED
TO WITHSTAND
THE BACKFILL
PRESSURE,
BUT IT'S
IMPORTANT THEN
TO POUR THE FLOOR
AND PROPERLY FASTEN
THE FLOOR SYSTEM
OF THE HOUSE ABOVE
IN ORDER TO MAKE
A RIGID BOX.
ALL RIGHT. SO WE WON'T
BE BACKFILLING
UNTIL THAT POINT.
THAT'S RIGHT.
YEAH. AND THEN
THIS GUY HERE
THAT WE WERE
JUST WALKING ON
WILL BE THE LAST ONE.
WILL BE THE LAST ONE
OF THIS SECTION.
AND I HAVEN'T SEEN
ANYBODY PUT A LEVEL
UP TO ANY OF THESE
TO MAKE SURE
THAT THEY'RE PLUM.
YOU GOT A LOT OF
FAITH IN THE SYSTEM
HERE, RIGHT?
IT--THEY ACTUALLY
HAVE BEEN CHECKING FOR--
FOR THE PANEL
BEING LEVEL LEFT
TO RIGHT AS THEY GO...
OK.
BUT IT'S
A SELF CLOSING BOX.
IT IS.
COMPUTER DESIGNED
AND MADE IN STEEL FORMS.
SO WHAT ABOUT MAKING
SURE IT'S SQUARE
AFTER YOU'VE SET
THEM ALL DOWN?
AFTER THEY SET THEM,
THEY DO SQUARE THE CORNERS
SO THEY WILL CONTINUE
TO CHECK THE CORNERS
ARE SQUARE.
AND THEY TAKE
THE TAPE FROM
CORNER TO CORNER?
YES, THAT'S RIGHT.
OK.
2 MORE BOLTS
AND THEY'RE DONE
WITH THIS SECTION.
2 MORE BOLTS
AND WE'VE GOT A BOX.
YES, SIR.
THANKS, JIM.
THANK YOU, BOB.
OK.
Bob: WHEN WE COME BACK,
WE'LL BE
AT THE SIMPLEX PLANT
IN SCRANTON,
PENNSYLVANIA,
FRAMING THE ROOF
FOR OUR MODULAR HOME.
Bob: WE'RE BACK
IN SCRANTON, PENNSYLVANIA,
AT THE SIMPLEX FACTORY,
WHERE OUR MODULAR HOME
IS BEING MANUFACTURED.
WE'RE CHECKING IN AT VARIOUS
STAGES OF THE PROCESS
OVER A NUMBER OF WEEKS.
TODAY WE'LL FOCUS
ON THE ROOF STRUCTURE
AND SOME OF
THE PRECAUTIONS TAKEN
BEFORE TRANSPORTING
THE MODULES
TO THE HOME SITE.
NOW LET'S GET TOGETHER
WITH DAVE BONIELLO
INSIDE THE PLANT.
DAVE BONIELLO'S
WITH ME.
HE'S THE VICE PRESIDENT
OF MARKETING HERE
AT SIMPLEX HOMES,
AND RIGHT NOW,
IT LOOKS LIKE IT'S
COFFEE BREAK TIME
SO IT'S A LITTLE
BIT QUIET
BUT NORMALLY
THIS IS VERY
NOISY OPERATION.
NOW, WHAT BOX ARE WE
LOOKING AT HERE?
WE'RE LOOKING AT
THE SECOND FLOOR
UPPER ROOF SECTION
THAT'S GOING TO GO
ON TOP OF OUR
BERKSHIRES PROJECT.
THIS IS OVER
THE FRONT DOOR
OF THE HOUSE.
THIS IS WILL BE
OVER THE FRONT DOOR
WITH THE VAULTED CEILING
IN THE FOYER AREA.
I THINK
A LOT OF PEOPLE
PROBABLY THINK
THAT A HOUSE
MANUFACTURED
IN A FACTORY
WOULD NOT HAVE
THE SAME KIND
OF WOOD FRAMING
THAT A STICK BUILT
HOUSE ON THE FIELD
WOULD HAVE.
A LOT OF PEOPLE
WOULD THINK THAT,
BUT THAT'S REALLY NOT
A TRUE ASPECT.
WHAT WE'RE DOING HERE
IS WE'RE USING
FRAMING MATERIALS
THAT ARE VERY SIMILAR
TO ANY TYPE
OF FRAMING MATERIALS
THAT YOU WOULD SEE
IN THE STICK BUILT INDUSTRY.
MM-HMM.
YOU SEE THAT WE'RE USING
SOME FIR RAFTERS HERE.
2 BY 12 FIR RAFTERS.
IT'S A TRUSS
RAFTER SYSTEM
THAT'S DESIGNED
FOR OUR INDUSTRY.
IT HAS SPECIAL
GANGED NAILERS
THAT HAVE HINGES
BUILT INTO THEM
THAT ALLOW US TO BE
ABLE TO FOLD BACK EAVES
AND FOLD BACK
UPPER ROOF SECTIONS.
YEAH, THIS IS
MY NEXT QUESTION,
BECAUSE WHAT WE'RE
LOOKING AT HERE
IS REALLY SOMETHING
THAT'LL FLIP OUT
IN THE FIELD TO
CREATE THE OVERHANG,
THE ROOF OVERHANG,
AND THERE
YOU SEE IT,
AND THEN IT JUST
GETS FASTENED DOWN.
LET'S PUT IT
BACK UP.
WHAT ARE
ALL THESE STRAPS
THAT I WAS LOOKING
AT DOWN HERE?
WELL, BOB,
IN OUR INDUSTRY,
WHAT WE'RE DOING IS
WE'RE SHIPPING PRODUCTS
THAT CAN GO ANYWHERE
FROM 6 MILES
TO 600 MILES,
AND THE WAY WE FASTEN
THINGS IS WE NAIL IT
AND THEN WE
FOLLOW IT UP
WITH A STRAP
THAT TAKES IT
FROM THE TOP OF
THE RAFTER CORE
DOWN ONTO THE WALL
OR FLOOR BAND,
WHATEVER IT MAY BE
IN THAT CASE,
AND WE'RE TYING IT
WITH STAPLES AND METAL
GALVANIZED STRAPS.
WHAT KIND OF PLYWOOD
DO YOU USE
FOR YOUR SHEATHING?
Dave: WE'RE USING
GP PLYTANIUM.
IT'S A VERY FLEXIBLE
STABLE PRODUCT
THAT IS USED
IN OUR INDUSTRY.
IT ALLOWS US
THE ABILITY
TO NOT HAVE
ANY PROBLEMS
RESTRICTING US TO
ANY FLOOR USES
THAT WE MAY
WANT TO USE.
YEAH, YOU CAN USE
ANY KIND OF FLOOR
PRODUCT IN THIS,
AND WHEN YOU'VE GOT
A STABLE PLYWOOD
LIKE THAT
YOU DON'T HAVE TO
WORRY ABOUT
FLOORS SQUEAKING.
WELL, ESPECIALLY
THE FACT
THAT WE'RE SHIPPING
IT DOWN THE ROAD,
AND THERE IS
SOME FLEXIBILITY
THAT'S NECESSARY.
RIGHT. SO IT'S GOTTA BE
TIED DOWN TIGHT.
IS THIS JUST
PART OF THE...
THIS IS A PART OF
THE GABLE END OVERHANG
THAT'LL BE COMPLETED
AS WE START MOVING
THIS PRODUCT
DOWN THE PRODUCTION
LINE.
OK. SO WHAT WE'RE
LOOKING AT HERE
IS A GABLE END
WALL, RIGHT?
YES. THIS IS
A GABLE END WALL
THAT WAS BUILT
ON A TABLE
AND BROUGHT OVER
AND PLACED IN.
WE THEN FASTEN ALL OF
OUR GABLE END WALLS DOWN
WITH 2 NAILS AND A SCREW
IN EVERY BAY.
2 NAILS AND A SCREW
IN EVERY BAY
DOWN ONTO
THE SHEATHING.
TIED RIGHT DOWN
INTO THE SHEATHING.
THEN WHAT'S
THE BLOCKING
THAT WE'RE
LOOKING AT HERE?
THIS IS A RECEIVER
FOR AN INSIDE PARTITION.
AN INSIDE
CORNER. OK.
AND THEN
THE BLOCKING
AT THE BOTTOM?
WELL, THIS PARTICULAR
PRODUCT, BOB,
HAS 1 BY 10
BASE MOLDINGS,
SO WE'VE ADDED
BLOCKING IN HERE
TO HELP GIVE US
SOME GOOD NAILING
WHEN WE'RE PUTTING THAT BASE
MOLDING ON LATER ON.
OK. AND YOU'VE GOT
THE ROUGH WIRING
GOING ON.
THIS HAPPENS
AT THIS STAGE.
I MEAN,
AT THIS POINT,
YOU'VE GOTTA DO
ALL THE ROUGH
AN THEN INSULATE
AND STUFF?
ALL RIGHT, LET ME
SHOW YOU WHAT WE DO
OVER HERE IN OUR
ELECTRICAL DEPARTMENT.
WE DADO OUT OUR STUDS
IN ADVANCE,
AND THEN WE RUN
THE WIRES THROUGH
AND WE TIE IT INTO A BOX
THAT WE'LL BE PLACING
OVER INTO THIS
PRE-ROUTED HOLE.
THE HOLE IS ROUTED OUT
IN ADVANCE,
THEN THE BOXES ARE
PLACED IN.
Bob: ALL RIGHT,
SO THE WIRING
COMES THROUGH
THESE TROUGHS HERE.
AND YOU'VE ALREADY
CUT THE HOLE
OUT FOR THE BOX.
SO ONCE THE BOX
IS PLACED IN
AND THE WIRES ARE
ALL FASTENED IN PLACE,
WE THEN WILL TAKE
THESE METAL PROTECTORS,
THESE DADO PROTECTORS,
AND WE'LL PUT THOSE
OVER THE DADOED AREAS
TO PROTECT FROM ANY NAILS
THAT MIGHT HAPPEN
IN THE SHEATHING PROCESS
OR IN THE SIDING PROCESS.
OK. WELL, CAN WE GET
UP ON THIS CATWALK
AND TAKE A LOOK AT
IT FROM UP ABOVE.
Dave: SURE.
ALL RIGHT.
SO FROM THE CATWALK,
WE CAN GET A GOOD VIEW
OF OUR 3 LARGE WINDOWS,
AND I GUESS YOU'VE GOT
THE INSULATION PROCESS
ALREADY STARTED.
YES. AFTER
THE WIRING PROCESS,
WE THEN START TO
INSTALL INSULATION.
WE'RE USING
OWENS CORNING.
IT'S A FAST BAT
INSULATION.
IT'S GREAT
FOR OUR INDUSTRY
BECAUSE OF THE FACT
THAT THE DRYWALL
IS INSTALLED ON
THE TABLE IN ADVANCE.
THIS ALLOWS US
TO FRICTION FIT
THIS INSULATION
WITHOUT ANY
MECHANICAL FASTENERS.
IT'S TERRIFIC
FOR OUR INDUSTRY.
IT REALLY
SPEEDS THINGS UP.
WHAT'S THE R FACTOR HERE?
YOU GOT 6-INCH WALLS.
6-INCH WALLS. BUT THIS
IS R21, NOT R19.
OH, IT IS?
YES, IT IS.
GREAT. AND THEN WHAT IS
THIS OTHER PRODUCT
THAT WE'RE
LOOKING AT UP HERE?
WELL, THIS SYSTEM,
IT'S A FOAM SEAL SYSTEM.
IT'S MADE AGAIN
FOR THE MODULAR
HOUSING INDUSTRY.
IT COMES OUT
IN A LIQUID FORM.
AS YOU SEE THE FOAM
BUILD UP,
IT TURNS INTO FOAM
IN A MATTER OF SECONDS.
IT BONDS THE DRYWALL
TO THE BOTTOM CORD
OF THE TRUSS.
WHEN THIS FASTENS
AND SETS UP,
YOU CAN'T REMOVE
THIS DRYWALL.
IT REPLACES ALL
MECHANICAL FASTENERS.
YOU DON'T HAVE TO
USE SCREWS?
NO SCREWS, NO NOTHING.
SO NOTHING
TO POP THROUGH.
IT'S GREAT.
I LIKE THAT.
IT'S PHENOMENAL
FOR OUR INDUSTRY.
AND THEN I NOTICED
IN EVERY BAY
YOU'VE GOT ONE OF
THESE METAL STRAPS.
WHAT ARE THESE
DOING FOR US?
THESE METAL STRAPS
WILL BE PLACED ON,
THEY'LL NAILED
TO THE SIDE
OF THAT TRUSS
AND BRINGING THAT
FASTENING DOWN INTO
THE WALL SYSTEM.
AGAIN, WE DON'T
WANT ANYTHING
TO VIBRATE LOOSE
OR PULL LOOSE
DURING THE SET.
SO THERE'S ANOTHER ONE OF
THESE HINGES HERE,
AND WHAT WE'RE LOOKING
AT HERE IS THE REST OF
THE ROOF RAFTER.
RIGHT. THAT'S
THE TOP CORD
OF THE ROOF.
THAT HINGE SYSTEM
WILL BE LIFTED UP
IN PLACE
AND THEN THERE'S
A KNEE WALL
THAT DROPS DOWN.
WHEN THIS ARRIVES
AT THE SITE, THAT GOES UP.
OK. AND THEN OVER HERE
THEY'RE PUTTING IN
THE REST OF THE OVERHANG.
RIGHT. THE GUYS ARE
GETTING READY TO TIE
THIS OVERHANG IN.
IT'S A GABLE END
OVERHANG.
WE PRE-BUILD IT,
AND IT'LL BE
FASTENED
INTO THE SIDE
OF THAT LAST TRUSS.
AND THAT CAN TRAVEL
DOWN THE HIGHWAY?
ABSOLUTELY.
AND THEN WHAT I'VE GOT
IN FRONT OF THEM RIGHT HERE,
WHAT DOES THAT DO?
WELL, WHAT THAT
PIECE DOES IS THAT'S
THE UPPER FLIP
THAT'S BUILT
INTO THE TRUSS.
THAT WILL FLIP OVER
DURING THE SET
ON JOB SITE,
AND WHEN IT FLIPS
OVER, THAT'LL
EXTEND THE ROOF RUN
ALL THE WAY UP
JUST PRIOR TO
THE RIDGE LINE.
OK, SO THIS IS
THE LAST SECTION
OF THE SAME
OVERHANG, RIGHT?
YES. LIKE I TOLD YOU
ON THE LOWER SECTION,
WE HAVE ANOTHER
GABLE END OVERHANG
THAT'S GOING
ONTO THE UPPER ROOF
SECTION NOW.
THAT'S THAT
SECTION OF ROOF
THAT LOOKS LIKE
A DORMER
SITTING HERE,
BUT THAT'S
GONNA FOLD OVER,
AGAIN LIKE I
MENTIONED EARLIER,
AT JOB SITE.
I TELL YOU, THOSE HINGES
REALLY MAKE IT POSSIBLE
TO GET A LOT OF WORK
DONE HERE IN THE FACTORY.
PHENOMENAL LOCATION.
AND THEY KEEP US DOWN
LOW FOR TRANSPORTATION.
EXACTLY. SO WE ARE
LOOKING AT ONE
OF HOW MANY BOXES,
DAVE?
THERE'S 5 LARGER BOXES
AND 2 SMALLER BOXES.
AND THEY WILL ALL BE
COMPLETED DURING
THE COURSE OF...
ROUGHLY 5 DAYS.
ROUGHLY
A WEEK'S WORK
HERE IN THE PLANT.
YES.
AND THEN HOW LONG
WILL IT TAKE YOU
TO GET IT
TO OUR SITE?
ONE DAY.
HALF A DAY
OR THEREABOUTS.
AND WE'LL,
OF COURSE,
LOOK AT THE PROCESS
OVER THE COURSE
OF SEVERAL WEEKS.
YES.
THANKS, DAVE.
THANKS, BOB.
Bob: WE'LL BE BACK
WITH CHRIS VILA
AND MORE ON THE SUPERIOR
WALLS FOUNDATION
AT OUR BUILDING SITE.
Bob: NEXT TIME ON...
WE'RE AT OUR
NEW CONSTRUCTION PROJECT
IN THE BERKSHIRE HILLS OF
WESTERN MASSACHUSETTS.
WE'LL BE PUTTING IN
A PREFABRICATED
FOUNDATION SYSTEM
THAT IS POURED UNDER
FACTORY-CONTROLLED
CONDITIONS
TO THE EXACT SPECIFICATIONS
FOR OUR PROJECT.
FOUNDATION SECTIONS ARE
DELIVERED TO THE SITE
AND INSTALLED IN ONE DAY.
WE'LL ALSO SPEND SOME TIME
IN SCRANTON, PENNSYLVANIA,
WHERE THEY'RE MANUFACTURING
OUR MODULAR HOUSE
IN A FACTORY,
SO DON'T MISS IT.
THAT'S NEXT TIME ON...
Bob: NEXT TIME ON...
WE'RE ASSEMBLING
THE FOUNDATION
AT THE BUILDING SITE
AND CONSTRUCTING THE ROOF
IN A FACTORY. DON'T MISS IT.
Bob: WE'RE BACK
AT OUR BUILDING SITE
IN THE BERKSHIRE HILLS
OF WESTERN MASSACHUSETTS,
AND WORK IS PROGRESSING
ON THE INSTALLATION
OF OUR
PRE-FABRICATED FOUNDATION
FROM SUPERIOR WALLS.
MY SON CHRIS VILA
IS JOINING US HERE.
HE GOT TOGETHER
WITH MEL ZIMMERMAN,
THE INVENTOR
OF THIS SYSTEM,
TO FIND OUT MORE ABOUT
THE UNIQUE FEATURES
OF OUR FOUNDATION.
SO, MEL, TELL ME
A LITTLE BIT MORE
ABOUT YOUR
BACKGROUND
AND WHAT EXACTLY
PROMPTED YOU
TO COME UP
WITH THIS PROCESS.
WELL, I WAS A BUILDER,
AND I USED TO BUILD
HOUSES, MEDIUM RANGE HOUSES
THAT--WE WERE USING
CONCRETE BLOCK FOUNDATIONS,
AND THERE WAS
SOME PROBLEMS WITH--
WHAT KIND
OF PROBLEMS
WERE YOU HAVING?
WELL, WE HAD WATER
PENETRATIONS
THROUGH THE WALLS.
WE ALSO HAD STRENGTH
PROBLEMS, AND...
SO YOU WERE GETTING
SOME CALLBACKS
FROM CUSTOMERS
WHO WERE WONDERING
WHY THESE THINGS
WERE HAPPENING.
YEAH, WATER LEAKING
THROUGH THERE
IS ONE OF THE REASON
WE HAD CALLBACKS.
AND ALSO,
THEY WERE QUITE DAMP
AND COLD,
AND I JUST THOUGHT
THAT THE CUSTOMER DESERVED
A BETTER PRODUCT,
SO THIS REALLY TURNED OUT
GOOD FOR US.
SO SPEED'S
AN ISSUE HERE, MEL.
I MEAN, IN A TYPICAL
FOUNDATION,
WE'RE LOOKING AT
PUTTING ON THE FOOTING,
THEN THE FORMS,
THEN WE ACTUALLY
GOTTA DO
THE POURING,
WAIT A FEW DAYS,
THEN WE HAVE TO
TAKE, YOU KNOW,
DO THE STRIPPING.
WE COULD BE LOOKING
AT ANYWHERE
FROM A WEEK
AND A HALF
TO 2 WEEKS, RIGHT?
SURE.
WHAT ABOUT THIS?
HOW ABOUT
SUPERIOR WALLS?
THIS'LL GO IN IN A DAY.
SO YOU'RE GONNA BANG
IT OUT IN A DAY.
YEAH.
YEAH.
AND THAT'S A BIG
BENEFIT TO A BUILDER,
TO KEEP
A PROJECT ON TIME IS--
AND ALSO
THE WEATHER
IS NOT AN ISSUE,
BECAUSE WE CAN TAKE
A BEAUTIFUL DAY
LIKE TODAY
AND HAVE THIS THING
ALL LAID OUT.
YEAH. WE POUR THESE
IN A PLANT,
AND WE HAVE
A CONTROLLED ATMOSPHERE
WHERE WE POUR
THE CONCRETE.
FROM THE FRONT,
IT LOOKS LIKE
IT'S A STUD,
BUT IT'S ACTUALLY
CEMENT THAT I'M
SEEING HERE, RIGHT?
YEAH, IT'S A STEEL
REINFORCED CONCRETE STUD,
HAS A WOODEN
FURRING STRIP ON IT,
IT HAS DOW
STYROFOAM ON IT.
AND I'M NOTICING
THAT THESE ARE DRILL
OUTS FOR WIRING.
THEY'RE DRILL OUTS
FOR SECONDARY WIRING
AND SECONDARY
PLUMBING,
AND WE ALSO HAVE
HOLES AT THE TOP
FOR THE WOODEN SILL PLATE
TO BE NAILED DOWN
SO--WHICH IS
ANOTHER BENEFIT,
ALSO THE WIRING TO
COME DOWN FROM THE TOP.
THE CONCRETE IS POURED
ONTO THE INSULATION,
AND THE 2 ARE
BONDED TOGETHER
WHICH MAKES IT
A COMPOSITE.
THERE'S AN ADHESIVE
THERE THAT BONDS
THAT 2 TOGETHER.
YOU CAN IMAGINE
HOW DRY IT IS
WHEN YOU PUT HAND ON
THIS INSULATION.
THAT HOW DRY THE CONSUMER
GETS HIS PRODUCT.
SO WE'RE SOLVING
ALL OF OUR
WATER PROBLEMS.
WHAT ABOUT
THE COSTS?
WHAT'S INVOLVED?
I MEAN, AN AVERAGE
FOUNDATION FOR
SOMETHING LIKE THIS
MIGHT COST AROUND
$24-25,000.
WHAT ABOUT
FOR THIS PROJECT?
WE WOULD COME IN A COUPLE
THOUSAND DOLLARS
LESS THAN THAT.
AND IN SOME CASES,
IN THIS PARTICULAR CASE,
WE DID.
BUT IN SOME CASES,
WHY, WE'RE RUNNING
PRETTY CLOSE TO THE SAME.
AND YOUR COST INCLUDES
THE ADDITIONAL BENEFIT
OF ALREADY HAVING
THE WINDOWS ALL ROUGHED
OUT AND READY TO GO.
YES, IT DOES.
WOW. THIS IS GREAT.
THANKS A LOT, MEL.
YOU'RE QUITE WELCOME.
Bob: WE'LL BE BACK
IN A MOMENT
WITH A PREVIEW
OF OUR NEXT SHOW.
DON'T GO AWAY.
WELL, CHRIS, WHAT DO
YOU THINK OF THAT
FOUNDATION SYSTEM?
VERY SLICK.
LOT OF INTERESTING
APPLICATIONS.
FOR SURE. COME HOME
AGAIN NEXT TIME.
WE'LL BE
IN THE FACTORY
IN PENNSYLVANIA
WATCHING THE HOUSE
GET BUILT.
TILL THEN,
I'M BOB VILA.
AND I'M CHRIS VILA.
IT'S GOOD TO HAVE
YOU "HOME AGAIN."
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