1418 - Assembling a Modular Home
January 5-11, 2004 | July 5-11, 2004
HI. I'M BOB VILA.
WELCOME HOME AGAIN
TO OUR MODULAR
CONSTRUCTION STORY.
TODAY WE'RE GONNA BE
GIVING YOU A RECAP
OF HOW OUR HOUSE WAS BUILT
IN BOXES
AND, OF COURSE, IT'S BEEN
TRUCKING DOWN THE ROAD
FOR ABOUT 4 OR 5 HOURS
TO GET HERE TO OUR LOCATION.
WE'RE GONNA BE PUTTING
ALL THE DIFFERENT BOXES
INTO THE RIGHT PLACES,
SHOWING YOU HOW IT GETS
BOLTED TOGETHER,
AND BASICALLY CONSTRUCTING
A BIG HOUSE IN ABOUT
HALF AN HOUR.
STICK AROUND. IT'S GOOD
TO HAVE YOU HOME AGAIN.
CAPTIONING MADE POSSIBLE BY
WELL, THE MOMENT WE'VE ALL
BEEN WAITING FOR IS HERE.
WE'RE GETTING OUR HOUSES
PUT INTO PLACE--OR HOUSE,
OUR BOX SECTIONS, RIGHT, GUYS?
AND WE'VE GOT PAT FRICCHIONE
AND DAVE BONIELLO
FROM SIMPLEX INDUSTRIES
JOINING US HERE
IN THE BERKSHIRES.
WHAT DOES
THAT THING WEIGH?
THE BOX ITSELF, BOB,
IS ANYWHERE BETWEEN
15 AND 16 TONS.
THAT'S A LOT
OF TONNAGE.
THAT'S A LOT
OF TONNAGE, YEAH.
BOY. AND OF COURSE,
I'M NOT SURE WHAT'S
IN THAT SECTION.
ISN'T THAT PART
OF THE KITCHEN?
YEAH. THAT HALF
IS THE KITCHEN,
LIVING ROOM,
AND THE DINING
ROOM AREA
IS IN THAT BOX.
SO HAVE WE GOT--
WE'VE GOT ALL OUR
CABINETS AND OUR COUNTERTOPS
IN PLACE THERE,
AND OBVIOUSLY WE'VE GOT
OUR PELLA FRENCH DOORS
LOOKING AT US.
NOTHING HAS BROKEN
ALONG THE WAY?
NO. EVERYTHING HELD UP
FINE IN TRANSPORTATION.
Bob: AND SO WHAT
WE'VE DONE IS WE'VE HIRED
A COMPANY FROM ANOTHER
LOCATION TO BRING
THE CRANE HERE, RIGHT?
Dave: THAT'S CORRECT.
WHAT SIZE CRANE
IS THAT, PAT?
Pat: IT'S AN 80-TON
CRANE, BOB.
ARE WE GONNA
BE ALL RIGHT
WITH AN 80-6ON CRANE?
OH, THAT SHOULD BE FINE.
YEAH? GOOD, GOOD.
YEAH. THERE'S
THE ARCHED WALL.
SO THIS GOES
TOWARDS THE BACK
OF THE FOUNDATION, RIGHT?
THIS IS
THE BACK BOX.
THERE'LL BE
ANOTHER LITTLE PIECE
THAT WE SET
OVER HERE.
THAT LITTLE SMALL
SECTION WILL BE
PUT ON NEXT,
EXTENDING
THAT DINING ROOM
AND MAKING A MUCH
LONGER ROOM.
NOW, THIS HAS COME
A FEW HUNDRED MILES
DOWN THE HIGHWAY,
AND OBVIOUSLY, YOU
JUST DON'T DRIVE
OUT OF THE SIMPLEX PLANT
AND HEAD FOR
THE BERKSHIRES.
WHAT KIND OF PLANNING
HAS TO BE DONE
BEFORE YOU GET HERE?
WELL, WHAT HAPPENS
FIRST IS,
WE ACTUALLY HAVE TO
RUN A ROUTE SURVEY.
BECAUSE THESE BOXES
ARE OVER 14 FOOT WIDE--
THESE ARE
ACTUALLY 15'9" BOXES--
THEY REQUIRE
SPECIAL ROUTING,
MORE THAN
THE NORMAL-WIDTH
BOXES WOULD REQUIRE.
SO WE RUN A ROUTE
SURVEY UP HERE
AND MAKE SURE THAT
WE'RE GONNA CLEAR--
YOU MEAN A PERSON GOES OUT
AND SCOUTS ALL THE ROADS?
YES. ACTUALLY,
ONE OF OUR FLAG DRIVERS
WOULD GO OUT IN ADVANCE,
RUN THE TRIP,
AND MAKE SURE THAT
THE OVERPASSES ARE ALL
THINGS THAT WE CAN CLEAR
AND MAKE SURE THERE'S
NO PROBLEMS ALONG
THE WAY
THAT MIGHT NOT NORMALLY
BE KNOWN ABOUT
IF YOU JUST TOOK
THE MAP OUT AND LOOKED
AT THE ROUTE.
YEAH, SURE. AND, PAT,
THIS IS INTERSTATE
COMMERCE, ISN'T IT?
THAT IS CORRECT.
WHAT HAPPENS WHEN YOU GO
FROM ONE STATE TO THE NEXT?
WELL, WHAT WE NEED
TO DO IS,
THEN OUR DISPATCH OFFICE
NEEDS TO GET THAT INFORMATION
FROM THE ROUTE SURVEY
AND APPLY FOR A PERMIT,
AND EVERY STATE HAS
THEIR OWN PERMIT OFFICE,
AND THEY TELL
THE PERMIT OFFICE
WHICH ROUTES
WE WANT TO GO ON.
SO THEN, IN ADDITION
TO THAT,
YOU KNOW, THERE'S
ALSO RESTRICTIONS
OF ROADS
AND ALSO TIMES
THAT WE HAVE TO TRAVEL
ACROSS THESE ROADS.
YEAH. AND SOME OF THESE
ROADS, LIKE RIGHT HERE
IN THE RURAL BERKSHIRE HILLS,
ARE TIGHT, AND THEY HAVE
A LOT OF HAIRPIN TURNS.
WE ALSO HAVE
AN ESCORT CAR.
WE HAVE AN ESCORT
CAR IN THE FRONT
AND IN THE REAR,
AND THEN WHEN WE GOT
A COUPLE OF MILES
FROM THIS SITE HERE,
SINCE THE ROADS
WERE SO NARROW,
WE ALSO HAD TO HAVE
A STATE POLICE ESCORT.
Bob: DAVE, ARE THE TRUCKS
THAT YOU USE FOR PULLING
THESE BOXES ON FRAMES--
IS THERE ANYTHING
UNUSUAL ABOUT THE TRUCKS?
YEAH, BOB. THEY'RE
ACTUALLY MODIFIED
TO BE ABLE TO
HITCH UP TO THE CARRIERS
AND HOOK THEM AND TAKE
THEM ALONG.
THEY'RE TYPICAL
OVER-THE-ROAD TRUCKS,
BUT IF YOU LOOK
AT OUR TRUCKS,
THE BOXES ON THEM
ARE SHORTER
SO THAT WE'RE ABLE
TO JOCKEY AROUND
THESE SITES A LOT BETTER
THAN A NORMAL TANDEM
TRUCK WOULD.
SO THE TURNING
RADIUS AND EVERYTHING
IS A LOT SHORTER.
EXACTLY.
GREAT.
Bob: ALL RIGHT. SO HERE
WE CAN SEE OUR SUPERIOR
WALLS FOUNDATION,
WHICH WE PUT IN
JUST A WEEK AGO,
AND THIS 15-TON SECTION
IS ABOUT TO SIT DOWN
PERFECTLY
ON OUR PRESSURE-TREATED SILL.
THESE GUYS KNOW WHAT THEY'RE
DOING WITH THIS CRANE
BUSINESS, DON'T THEY?
THEY SURE DO.
Bob: NOW, WHAT HAVE
THEY RIGGED HERE?
I SEE CABLE, BUT...
Dave: RIGHT. THERE'S CABLE,
AND WHAT WE HAVE--
THE APPARATUS UP HIGH
IS SPREADER BARS.
AND THE CABLE
IS RUN THROUGH
THE SPREADER BARS
AND BASICALLY
COMES DOWN AND WRAPS
AROUND THE BOX.
THEY DRILL HOLES
IN THE OUTSIDE
BANDS HERE,
AND THEY'LL RUN
THE CABLE THROUGH.
SO REALLY THE MEAT
OF THE BAND
IS WITH THE CABLES
UP UNDERNEATH,
AND THIS ALLOWS
THEM, THEN,
WITH THE HOLE IN THERE,
IT ALLOWS THEM TO BE
ABLE TO PULL THAT CABLE OUT
AFTER THE BOX
IS SET DOWN
SO THEY CAN FIT IT
RIGHT ON TOP OF THAT--
Pat: AND THERE'S ALSO
PICK POINTS THAT WE NEED
TO BE CONCERNED WITH.
Bob: WHAT POINTS?
WE CALL THEM
PICK POINTS,
AND WHAT THEY ARE
IS THE FACT THAT
WHERE WE'RE ACTUALLY
GONNA PUT THE CABLES
THEMSELVES AT.
AND SO WE NEED
TO TAKE MEASUREMENTS
AND WE NEED TO CALCULATE
WHERE THESE PICK POINTS
SHOULD
BE.
AND THAT REFERS TO
WHERE YOU'RE PICKING
IN TERMS OF THE STRUCTURE
AND IN TERMS OF
THE AMOUNT OF STRESS
THAT YOU'RE PUTTING
ON IT.
Pat: EXACTLY, BECAUSE
YOU DON'T WANT TO PUT
A LOT OF,
YOU KNOW, STRESS
ON A CERTAIN AREA
OF THE HOUSE ITSELF.
SO YOU WANT TO
REDISTRIBUTE
OUR PICK POINTS,
WE CALL IT.
NOW, ON THE INSIDE,
I NOTICE THAT THEY'RE
PUTTING UP
SOME TEMPORARY
SUPPORTS, RIGHT?
THESE STEEL POSTS?
RIGHT. EXACTLY.
WHAT THEY'LL DO IS,
THEY'LL PUT THEM IN,
AND THEN THEY'LL TRY
TO LEVEL THE HOUSE OFF
AS BEST THEY CAN,
AND THEN AFTER
IT'S LEVELED OFF,
THEY'LL COME
AND THEN THEY'LL PUT
THE JACK POSTS IN.
IS THE NEXT SECTION
THE ONE THAT CORRESPONDS
TO THIS TOWARDS THE FRONT?
Dave: ACTUALLY,
WHAT WE'LL DO IS,
WE'LL TAKE THAT
SMALL LITTLE PIECE
AND PUT THAT
ON THE BACK HERE FIRST.
RIGHT HERE,
RIGHT?
Pat: THE EXTENSION
OF THE DINING ROOM,
AND THEN THEY'LL PUT
THE FIRST BOX IN
WITH THE LIVING ROOM
AND STAIR AREA.
GREAT. LET'S GO
TAKE A LOOK.
Bob: NEXT WE'LL GO
INSIDE THE HOUSE
AND SEE HOW THE INTERIOR
LAYOUT IS COMING TOGETHER.
Bob: THE CRANE IS SETTING
THE SECOND MODULE
FOR THE FIRST FLOOR.
THIS IS THE BOX THAT CONTAINS
THE FRONT DOOR FOR OUR HOUSE.
ONCE THIS MODULE IS IN PLACE,
WE'LL BE ABLE TO TAKE
A LOOK AT THE HOUSE
ON THE INSIDE.
DAVE, THIS IS WHAT
YOU CALL THE MARRIAGE POINT
BETWEEN THE TWO BOXES,
RIGHT?
YEAH. THAT'S CORRECT, BOB.
YOU CAN SEE RIGHT HERE
WE HAVE THE COME-ALONG
ON HERE,
AND WE'RE GETTING READY
TO PULL THESE TWO BOXES
TOGETHER.
SO AS IT'S BEING
LOWERED BY THE CRANE,
THAT PIECE OF CHAIN
ON THE COME-ALONG
IS BRINGING THE TWO
TOGETHER
SO THAT WHEN
THEY SIT DOWN,
THERE'S NO CRACK
IN BETWEEN.
Dave: EXACTLY. THEY
TAKE IT NICE AND EASY
AND GENTLY DROP
THE BOX DOWN,
AND AS IT'S REACHING
THE SILL PLATE,
THEY'RE GETTING THIS
AS TIGHT AS WE CAN
POSSIBLY GET IT.
Bob: THIS PLACE IS HUGE!
IT IS, ISN'T IT, BOB?
YOU KNOW, WHEN YOU WERE
IN THE FACTORY
LOOKING AT
THE DIFFERENT BOXES,
YOU HAD NO IDEA
UNTIL YOU WERE
IN THIS SPACE ITSELF
AND YOU REALIZE.
SO THIS IS
THE MARRIAGE WALL.
THIS IS WHERE THE TWO
BOXES COME TOGETHER,
AND WE'RE LOOKING
AT A TEMPORARY POST,
BUT THE REST OF THE STEEL
COLUMNS, THE LALLY COLUMNS,
ARE RIGHT HERE,
AND THEY'LL GO UP
LATER TODAY.
WHERE'S THE STAIRCASE
ACCESS TO THE BASEMENT?
THE STAIRWELL
IS RIGHT HERE, BOB.
YOU SEE WHERE
THAT PLYWOOD IS?
OH, OF COURSE.
THEY'LL CUT
THAT PLYWOOD OUT,
AND THEN THEY'LL BUILD
THE STEPS RIGHT HERE
ON SITE.
SO THIS IS GOING TO HAVE
ALL SORTS OF DIFFERENT
LIVING SPACES,
INCLUDING
AN EXERCISE ROOM
AND A FAMILY AREA
OVER HERE
AND A BIG TV DEN
AT THE FAR END.
LET'S GO LOOK AT THINGS
FROM THE TOP SIDE.
BOY, THIS IS
IMPRESSIVE, THOUGH.
WHAT YOU DON'T REALLY
GET WHEN YOU SEE
THOSE BOXES
FLYING THROUGH THE AIR
IS THAT ON THE INSIDE,
THEY'RE TOTALLY FINISHED,
EXCEPT FOR A FEW
LITTLE THINGS.
NOW, WHAT GOES
ON HERE?
Pat: WELL, BOB,
WE CALL THIS
THE MARRIAGE WALL,
AND WHAT THEY'RE
GONNA DO NOW,
THEY'LL INSULATE THIS,
THEY'LL PUT SOME METAL
STRAPPING ON,
AND THEN THEY'LL PUT
THE SHEETROCK RIGHT
OVER IT AND FINISH IT.
THAT LITTLE BIT
OF A GAP IS NOT
A PROBLEM?
AND IF YOU LOOK
DOWN AT THE FLOOR,
THERE REALLY IS
NO GAP.
THE TWO BOXES
HAVE COME TOGETHER,
AND THEN WE'VE GOT TO
CONTINUE PUTTING IN
OUR BELLAWOOD FLOOR.
YOU REALLY PROTECT
EVERYTHING VERY
CAREFULLY, DON'T YOU?
YES. IT'S A PRETTY
FINISHED FLOOR,
AND AS YOU CAN SEE,
WE'RE ALL WALKING
ON IT,
SO WE WANT TO TRY
TO PROTECT IT.
AND THE OTHER THING,
WHEN YOU'RE
IN THE FACTORY
MAKING THESE
RECTANGULAR BOXES,
YOU KIND OF THINK,
WELL, EVERYTHING'S
GONNA BE A RECTANGLE,
BUT WHEN YOU MARRY THEM,
YOU START TO GET
A SENSE OF THE VOLUME
OF THE SPACE.
AND THIS IS THE KITCHEN
OPEN TO THE DINING AREA.
AND HERE AGAIN YOU'VE
GOT TEMPORARY STUFF.
Dave: RIGHT. THAT
WILL ALL GET REMOVED.
Pat: THAT WILL COME OUT
NOW THIS EXPANDS.
AND THIS WILL BE
THE BUMP THAT WE JUST
PUT IN A FEW MINUTES AGO.
AND THEN THIS ENTIRE AREA
IS A LIVING ROOM.
WHAT'S THE DIMENSION HERE?
THIS IS ROUGHLY
30 BY...
Dave: 30 BY ABOUT
17 OR 18 FOOT WIDE.
THIS IS A BIG
LIVING ROOM.
YES. IT'S HUGE.
AND HERE IS WHERE
YOU'VE GOT
A COMPLICATED
MARRIAGE, DON'T YOU?
WELL, THIS IS JUST
TEMPORARY STUDDING
THAT WE HAVE IN HERE
JUST TO, YOU KNOW,
KEEP THE BOXES
TOGETHER
AS THEY'RE BEING
TRANSPORTED
AND SET ON SITE.
NOW, THEY'LL ALL
COME OUT,
AND THEN WE'LL BE
ABLE TO FINISH THIS
WITH A NICE FLAT
CEILING.
Bob: BUT
THE EXTRAORDINARY THING
IS THAT ONCE
IT'S ON SITE,
YOU'VE GOT ALL OF THESE
FASTENERS THAT ARE PUT IN,
THESE BOLTS GOING THROUGH
THAT THEY CAN GET AT
FROM THE TOP SIDE.
CORRECT.
AND SO ALL OF THIS
HAS BEEN THOUGHT ABOUT.
IT'S ALL BEEN
ENGINEERED.
IT'S ALL BEEN
ENGINEERED. EXACTLY.
Bob: ALL RIGHT.
IT'S CONFUSING TO SEE
A SECOND-STORY SECTION
THAT LOOKS LIKE THIS,
BUT ESSENTIALLY,
IT'S A BIG SHED DORMER
INTO A GABLE END--
I MEAN, INTO A GABLED ROOF.
Dave: THAT'S CORRECT.
AND THE OTHER THING
THAT MAKES IT LOOK CONFUSING
IS THE DOOR THAT'S IN THERE
BECAUSE YOU'RE
NOT USED TO SEEING
A DOOR ON THE SECOND FLOOR,
BUT THAT DOOR
IS GONNA OPEN UP
AND GO OUT OVER
THAT LITTLE BUMP
OUT THERE
WE HAD IN THE DINING ROOM.
THAT FLOOR WILL EVENTUALLY
BE BUILT UP TO MEET THAT,
AND THERE WILL BE
A LITTLE OUTSIDE CAROUSEL.
Bob: A LITTLE OUTSIDE
BALCONY OR TERRACE GOES THERE.
AND OF COURSE,
WE'RE LOOKING AT ALL THIS
COMPLICATED ROOF FRAMING,
WHICH IS HINGED
AND FLIPS INTO PLACE,
SO THERE'S QUITE A BIT
OF WORK TO BE DONE
WITH THIS SECTION
ONCE IT'S IN PLACE.
Dave: THAT'S CORRECT,
BUT AGAIN,
THE BEAUTY
OF THIS SYSTEM IS,
THE HINGES ALLOW IT
TO JUST FOLD RIGHT DOWN,
THE EVE AREAS, AND THEN
THE UPPER FLIP AREA
WHERE IT CONTINUES
UP TO THE RIDGE AGAIN
WILL FOLD OVER,
AND THE PLYWOOD'S
ALREADY INSTALLED
ON A GOOD PART OF THAT,
SO WE'LL JUST HAVE
STRIPS THAT HAVE TO BE
PLACED IN
THAT WILL TIE THE BOTTOM
TO THE MIDDLE
AND THE TOP
TO THE MIDDLE OF
THE ROOF STRUCTURE.
AND OF COURSE,
THIS DID NOT TRAVEL
DOWN THE HIGHWAY
THE WAY WE'RE LOOKING
AT IT HERE.
IT'S ALREADY BEEN
UNWRAPPED, IF YOU WILL,
BUT THE OTHER SECTION,
WHICH IS STILL NOT IN PLACE,
IS SHRINK-WRAPPED,
ESSENTIALLY,
SO THAT WHEN IT'S
COMING DOWN THE HIGHWAY,
NOTHING'S GONNA
FLY AWAY.
THAT'S CORRECT.
WE'VE GOT TO
PROTECT THE UNIT
FROM THE ELEMENTS,
SO ALL THIS ROOF
STRUCTURE IS, AGAIN,
SHRINK-WRAPPED,
BUT YOU CAN SEE
WE'VE LEFT A LITTLE BIT
OF THE FRAMING IN HERE
IN THESE LARGE OPENINGS.
THAT'S JUST TEMPORARY
FRAMING.
AND AGAIN, THAT WILL
ALL BE REMOVED ONCE
THAT BOX IS SET DOWN.
THE STUDS WILL BE
TAKEN OUT,
AND THEY'LL ALL BE
OPENED UP INTO
THE OTHER HALF
WHEN IT MATES
UP TO IT.
ALL RIGHT. SO THE THIRD
OF THE 4 PRINCIPAL BOXES
ARE NOW
IN PLACE,
AND BEFORE THE OTHER
ONE GETS HERE
AND MARRIES THIS ONE,
LET'S GET A LITTLE
BIT OF AN IDEA
OF STRUCTURALLY WHAT
WE'RE LOOKING AT HERE.
THERE'S MORE TO IT
THAN YOU'D EXPECT, RIGHT?
YEAH, BOB. WHAT'S A LITTLE
DIFFERENT ABOUT OUR
TECHNOLOGY HERE IS,
WE BUILD A SEPARATE CEILING
FROM THE FLOOR SYSTEM.
SO THIS DOES TWO THINGS.
IT ENABLES US TO INSTALL
THE DRYWALL IN THE PLANT
AND HAVE A FINISHED
CEILING DOWNSTAIRS.
THEN WE PUT
THE SECOND BOX--
THIS OTHER BOX ON TOP
WITH THE SEPARATE
FLOOR SYSTEM.
SO HERE WE'RE LOOKING
AT THE WIDTH
OF THE FLOOR SYSTEM,
AND HERE WE'VE GOT
THE ADDITIONAL WIDTH
OF THE CEILING SYSTEM
FOR THE FIRST FLOOR.
CORRECT. SO THE NEXT
BOX IS GONNA SIT
ON TOP OF THIS PLATE
THAT'S ON TOP OF
THE CEILING BELOW.
THE BEAUTY OF THIS IS,
THIS FLOOR SYSTEM
NOW IS GONNA ACT INDEPENDENT
OF THE CEILING BELOW,
AND WHEN YOU HAVE
THE KIDS UPSTAIRS
RUNNING AROUND
OR THERE'S PEOPLE
UPSTAIRS,
YOU'RE NOT GONNA
HEAR THAT NOISE
BECAUSE OF
THE FRAMING MEMBER
BEING A DIFFERENT MEMBER
THAN THE CEILING
MEMBER BELOW.
THAT'S A BEAUTIFUL THING
IN THE MODULAR TECHNOLOGY.
AND YOU CAN USE
THE MODULAR TECHNOLOGY,
FOR EXAMPLE,
FOR A TWO-FAMILY
HOUSE SO THAT YOU WOULD
ALSO HAVE NOISE ABATEMENT
BETWEEN ONE UNIT
AND THE UNIT DOWN BELOW.
Dave: THAT'S A GREAT
EXAMPLE OF WHERE
OUR TECHNOLOGY REALLY DOES
EXCEED STICK-BUILT.
Bob, voice-over: NOW,
AS THE CRANE SETS THIS NEXT
MODULE
FOR THE SECOND FLOOR,
IT'LL FORM ANOTHER
MARRIAGE WALL.
THIS FLOOR WILL HAVE
TWO BEDROOMS, A BATH,
AND A BALCONY.
WE HAVE A GREAT
SITE CREW,
AND THIS WHOLE PROCESS
IS HAPPENING VERY FAST.
[HAMMERING]
COMING UP NEXT,
WE'RE READY TO SET
THE MASTER BEDROOM MODULE
AND COMPLETE
OUR MODULAR HOUSE.
NEXT TIME ON
"BOB VILA'S HOME AGAIN,"
IT'S A BIG DAY AT OUR MODULAR
CONSTRUCTION PROJECT
IN THE BERKSHIRE HILLS
OF WESTERN MASSACHUSETTS.
ALL OF THE BOXES
FOR THE HOUSE
WILL HAVE TRAVELED
OVER THE ROAD FROM THE PLANT
IN PENNSYLVANIA
TO THE BUILDING SITE.
WE'LL USE A CRANE TO STACK
THE MODULES AND ASSEMBLE
ALL THE PIECES.
WE'LL BE ABLE TO WALK
AROUND THE INTERIOR
AND SEE HOW THE FLOOR PLAN
COMES TOGETHER,
AND FINALLY, WE'LL RAISE
THE ROOF AND FINISH
SETTING THE HOUSE
IN JUST ONE DAY.
SO DON'T MISS IT. THAT'S
NEXT TIME ON "HOME AGAIN."
NEXT TIME ON
"BOB VILA'S HOME AGAIN,"
ALL OF THE SECTIONS
FOR OUR MODULAR HOME ARRIVE
AT THE BUILDING SITE.
AND WE'LL LITERALLY ASSEMBLE
THE HOUSE IN ONE DAY.
DON'T MISS IT.
MICHAEL SHIELS IS
OUR GENERAL CONTRACTOR HERE,
AND HAVE YOU EVER SEEN
ANYTHING LIKE THIS?
NO. THIS IS QUITE
A PROJECT, BOB.
VERY EXCITING.
AND WHAT HAVE YOU
GOT DONE UP TILL NOW
IN TERMS OF THE REST
OF THE GROUNDWORK?
WELL, WE'VE INSTALLED
OUR PLUMBING INSIDE
IN THE LOWER SECTION.
WE'VE GOT OUR
INSPECTIONS FOR THAT.
WE PUT OUR SLAB INSIDE
BEFORE THE MODULARS
ARE SET,
COMPLETED ALL THE FOOTING
DRAINS AROUND THE FOUNDATION,
AND WE'VE PUT IN THE SILLS
IN PREPARATION
FOR THE MODULAR SET.
AND A MINUTE AGO,
WE SAW THEM SETTING
THE SIXTH PIECE,
I GUESS,
WHICH COMPRISES
THE SUN ROOM
THAT WE HAVE, RIGHT?
AND THE SUN ROOM
IS APPROXIMATELY
WHAT DIMENSION?
IT'S 17x20.
17x20. YEAH.
ALL THESE BOXES
ARE A GOOD SIZE.
IT'S A VERY LARGE
HOUSE.
OK, AND NOW
WE'RE ABOUT TO SEE--
OH, I WANTED
TO MENTION,
HAVE YOU EVER
SEEN THEM DO THIS?
THESE ARE THE FRAMES
THAT EACH AND EVERY
ONE OF THESE BOXES
ARRIVED ON,
AND I WAS WONDERING
WHAT THEY WERE
GONNA DO
WITH THE EMPTY ONES,
AND THE CRANE
JUST STACKED THEM
ALL UP.
EFFICIENT WAY
TO GET THEM BACK
TO THE FACTORY.
ONLY ONE CAB NEEDED
FOR ALL 3 BOXES.
EXACTLY.
WELL, HERE COMES
NUMBER 7.
NOW, THIS BOX IS
THE WHOLE MASTER
BEDROOM AND BATH, RIGHT?
THAT'S CORRECT.
SO IT'S GOT THE ADDED
WEIGHT OF A LOT
OF PLUMBING?
A LOT OF PLUMBING,
A LOT OF TILE HAS
BEEN INSTALLED IN THIS BOX.
THE FINISHED FLOOR
IN THE MASTER BEDROOM
HAS ALREADY BEEN
INSTALLED.
MM-HMM.
BOY, IT'S HARD
TO BELIEVE
THAT YOU CAN STEER
THIS BOX INTO PLACE
JUST WITH TWO ROPES
AND TWO GUYS.
RIGHT. WITH THE CABLES
AT A CENTER POINT THERE,
THEY CAN PRETTY MUCH
PIVOT.
YEAH. THAT'S A VERY
INTERESTING RIG
UP THERE.
NOW, THIS IS ABOUT
15 TONS, RIGHT?
THAT'S CORRECT.
Bob: NOW, MIKE, WHY
WOULDN'T YOU WANT
TO BACKFILL
BEFORE YOU SET
THE BOXES DOWN
ON THE FOUNDATION?
THE FOUNDATION
THAT WE'VE USED HERE
IS A SUPERIOR WALL.
IT'S PRE-ENGINEERED
AND PRE-CAST,
SO WHEN WE SET IT,
IT RELIES ON THE WEIGHT
OF THE BOX
TO KEEP IT FROM MOVING.
THE STANDARD APPLICATION
FOR A FOUNDATION
WOULD BE POUR
THE FOUNDATION,
BACKFILL,
AND THEN YOU CAN
WORK CLOSER
TO THE BOX,
BUT BECAUSE OF
THE ENGINEERED
SYSTEM HERE,
WE NEED THE WEIGHT
OF THE BOX
TO STABILIZE THE WALL.
Bob: TO STABILIZE IT
BEFORE YOU PUT
THE PRESSURE
OF THE SOIL
BACK IN.
THAT'S RIGHT, BOB.
Bob: AND WE HAVE LIFTDOWN!
ALL RIGHT. THAT IS
A CLEVER WAY
OF GETTING
THOSE TRAILERS
BACK OUT OF HERE.
NOW, I NOTICE
THE ROOF IS ALREADY
STARTING TO GO UP,
BUT I WANTED
TO ASK YOU
ONE LAST QUESTION.
FROM THE BUILDER'S
PERSPECTIVE,
WHAT'S THE ADVANTAGE
OF GOING MODULAR?
PRODUCTION TIME.
OUR PRODUCTION TIME
IS CUT IN HALF.
REALLY?
SO THAT MAKES
ALL THE DIFFERENCE.
PRODUCTION TIME
AND COST PER SQUARE FOOT
IS CHEAPER.
IS CHEAPER BY
10, 20...
THAT'S GREAT.
ALL RIGHT.
WHEN WE COME BACK, WE'LL SEE HOW
THE MODULAR HINGE SYSTEM
SIMPLIFIES RAISING THE ROOF.
ALL RIGHT. NOW,
AT THIS POINT,
THIS IS GOING
LIKE GANGBUSTERS,
WHAT ARE THEY DOING
UP THERE?
Pat: RIGHT NOW, BOB,
WHAT THEY'RE DOING
IS THEY'RE GONNA BE
PUTTING IN THE GABLE
END PANELS THERE,
THOSE SMALL TRIANGLE
PIECES.
AND THEN ONCE THEY PUT
THOSE TWO PIECES
IN PLACE,
THEN THEY'RE GONNA
FLIP THE TOP HALF
OF THAT ROOF SECTION
ONTO THE GABLE.
Bob: ALL RIGHT.
Dave: YEAH, BOB, AGAIN,
IF YOU REMEMBER,
THESE ROOF SECTIONS
WERE BUILT IN THE PLANT,
AND AT THAT TIME,
WE POINTED OUT
THE HINGE SYSTEM.
IT'S A DOUBLE
FOLDING HINGE,
SO WHAT IT DOES IS
IT ALLOWS THE ROOF
TO PIVOT IN TWO
POSITIONS,
AND THE ROOF ACTUALLY,
AS YOU CAN SEE,
IT LAYS DOWN FLAT.
AND AGAIN, THESE ARE
THINGS THAT ARE DONE
FOR OUR INDUSTRY
TO HELP PROVIDE
THE OPPORTUNITY
FOR THE ROOF SYSTEM
TO BE BELOW
SHIPPING HEIGHT.
RIGHT. SO, WHAT
WE'RE LOOKING AT NOW
IS THE UNDERSIDE,
WHICH WILL BE
THE ATTIC, IF YOU WILL,
AND WHAT I'M CURIOUS
ABOUT IS, HOW ARE THEY
GONNA FLIP IT UP THERE?
THAT'S A LARGE
SECTION OF ROOF.
WELL, THEY MAY GET
SOME ASSISTANCE
FROM THE CRANE HERE.
HE'LL STRAP ON IT
AND PULL IT UP.
Pat: AND THEN ONCE
THEY DO FLIP IT OVER,
YOU SEE THERE'S
SOME DROP IN--
OR THERE ARE
SOME KNEE WALLS
THAT WILL FLIP DOWN,
AND THEY'LL REST
RIGHT ONTO
THE CENTER PIECE.
YUP, I SEE THAT.
IT'S REALLY STARTING
TO TAKE THE SHAPE
OF A HOUSE NOW.
Dave: YES, IT IS.
SO AGAIN, BOB,
WE HAVE THOSE STRIPS
OF PLYWOOD
WE'LL BE PUTTING IN
ON THE LOWER SECTION
DOWN HERE
AND ON THE UPPER
SECTION.
THEY'RE
ALREADY-RIPPED STRIPS.
THEY'LL GO IN,
AND WHAT THAT'S
GONNA DO IS
IT'S GONNA TIE, AGAIN,
THE UPPER FLIP
DOWN INTO THE MAIN
BODY OF THE HOUSE ROOF,
AND THEN THIS LOWER
FLIP AGAIN WILL BE TIED
BACK INTO THE MAIN
BODY OF THE HOUSE ROOF,
AND THEN WE'LL JUST
TAKE THAT TITANIUM
WRAP, THEN,
AND FOLD IT BACK,
AND IT'LL JUST GO
RIGHT BACK OVER.
Bob: WELL, IN REAL TIME,
WE WERE LOOKING AT MORE
LIKE A
12-HOUR DAY
FOR THIS FANTASTIC TEAM
OF HOUSE-BUILDERS
TO PUT ALL THESE PARTS
TOGETHER.
THE LAST PIECES
THAT CAME ON SITE
INVOLVED THE ROOF SYSTEM
FOR THE MASTER BEDROOM WING--
THAT BOX THAT'S ISOLATED
ON THE RIGHT OVER HERE--
AND, IN FACT, WE ALSO HAD
A PANELIZED ROOF SYSTEM
THAT WENT ON AT THE OTHER END,
WHERE THE SUN ROOM IS LOCATED.
AND WE GOT A HOUSE.
WE'RE RUNNING OUT OF TIME.
COME HOME AGAIN NEXT WEEK,
WHEN WE'RE GONNA BE SHOWING YOU
SOME OF THE PRETTY DETAILING
THAT WILL GO ON OUR HOUSE.
TILL THEN, I'M BOB VILA.
IT'S GOOD TO HAVE YOU
HOME AGAIN.
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