1419 - Shake Roof and Stone Facade for Modular Home
January 12-18, 2004 | July 12-18, 2004
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HI. I'M BOB VILA.
WELCOME HOME AGAIN TO OUR
MODULAR CONSTRUCTION PROJECT
OUT HERE IN
NEW MARLBORO, MASSACHUSETTS,
BERKSHIRE HILLS.
LAST WEEK,
WE PUT TOGETHER THE MODULES.
TODAY WE'RE SHOWING YOU
HOW THE SKIN GOES ON--
PUTTING IN AN ENVIROSHAKE ROOF,
SOME CULTURED STONE PRODUCTS.
INSIDE, A LOT OF LITTLE
FINISH DETAILS.
STICK AROUND. IT'S GOOD
TO HAVE YOU HOME AGAIN.
CAPTIONING MADE POSSIBLE BY
SEARS
ALL RIGHT.
WELL, LET'S GET STARTED
BY TALKING WITH
OUR GENERAL CONTRACTOR
HERE--MICHAEL SHIELS,
AND THE BACKFILLING
IS THE MAIN THING
THAT WE WERE WAITING FOR.
LAST WEEK, WE STILL
HAD KIND OF THE HOLE
ALL AROUND THE PERIMETER
OF THE HOUSE.
YES. WE HAD A LOT
OF RAIN LAST WEEK,
AND WE TRUCKED IN
A LOT OF SAND
FOR THE BACKFILL
AND WERE ABLE
TO ACCOMPLISH
ALL OUR DRAINAGE.
SO YOU DIDN'T JUST
PUSH BACK THIS SOIL
THAT'S HERE.
IT HAS A LOT
OF CLAY IN IT.
A LOT OF CLAY
IN THE SAND,
SO, LIKE I SAID, WE
BROUGHT IN ALL THE SAND,
AND I GOT GOOD FILL.
MM-HMM, AND THAT'S
EXCELLENT FOR DRAINAGE.
THEN YOU'VE PUT IN
THESE SUPPORTS,
WHICH ARE FOR
THE PERGOLA DETAIL
THAT'S GOING ON OUT HERE.
THAT'S THE CONCRETE
BASE FOR THE DECK,
AND IT'S ALSO GONNA
HOLD UP THE PERGOLA
THAT'S GONNA HAVE
THE COLUMNS RESTING
ON TOP OF THEM.
RIGHT. YEAH.
THIS TRADITIONAL
PORCH APPROACH
WAS NOT GONNA WORK HERE
BECAUSE OF THE DESIGN
OF THE ROOF OVERHANGS,
SO WE WON'T REALLY
HAVE A PORCH ROOF.
WE'LL HAVE
KIND OF A PERGOLA
THAT CAN SUPPORT
VINES AND THE LIKE.
YES.
DID YOU SAY YOU
WENT DOWN 4 1/2 FEET
WITH THIS THING?
YEAH. THE FOOTERS
FOR THIS ARE DOWN 4 FEET.
WOW, AND THEN
IT WASN'T ONE
MONOLITHIC POUR, THEN?
IT WAS--NO.
THERE'S TWO POURS.
IT HAS STEEL ENFORCING
COMING OUT OF
THE BOTTOM POUR,
AND THEN THERE'S
A COLD JOINT,
AND THIS IS ANOTHER
4 1/2 FEET OF CONCRETE.
WOW. IT'S NOT OVERKILL?
NO. WE NEEDED
TO GET THE BASE,
AND WE NEEDED TO--
THIS IS GONNA BE
CLAD WITH THE STONE.
YEAH, AND IT'S ALSO
THE KIND OF CLIMATE
THAT STUFF CAN HEAVE
IF YOU DON'T GO
THE FULL DISTANCE.
WHAT HAVE
WE GOT HERE?
THAT'S THE BASE
FOR OUR FRONT PORCH.
IT'S ALL PRESSURE-TREATED
LUMBER WE USE,
ANY GROUND CONTACT
OR ANYTHING THAT'S GONNA
BE EXPOSED TO THE WEATHER.
AND HOW DO YOU FASTEN IT
ONTO THE CONCRETE HERE?
WE USE LEAD SHIELDS.
THIS IS DRILLED
INTO THE CONCRETE
AND THEN ANCHORED
FROM THE OUTSIDE.
ALL RIGHT. WELL, I WANT
TO CHECK IN WITH YOU
A LITTLE BIT LATER
AND LOOK AT SOME OF
THE THINGS THAT HAVE TO
BE DONE ON THE INSIDE.
I'LL BE ON THE INSIDE.
SEE YOU LATER.
RIGHT NOW, LET'S SAY HI
TO BRIAN EBERLE
FROM ENVIROSHAKE,
AND YOU'VE GOT
A BRAND-NEW
ROOFING PRODUCT.
HI, BRIAN.
HOW ARE YOU?
GOOD.
THIS IS NOT SOMETHING
THAT WE HAVE WORKED
WITH BEFORE,
AND ESSENTIALLY,
IT'S A SHAKE,
BUT WHAT IS IT?
WHAT'S IT
MADE OUT OF?
WELL, IT'S MADE FROM
POSTINDUSTRIAL PLASTICS,
AGRICULTURAL FIBERS
SUCH AS FLAX AND HEMP,
AND CRUMB RUBBER
FROM TIRES.
WOW. SO IT'S RECYCLING
OLD SODA BOTTLES
AND OLD
AUTOMOBILE TIRES,
AND THEN WHAT'S
THE NATURAL ELEMENT
THAT YOU TALKED ABOUT?
FLAX OR--
FLAX AND HEMP FIBER.
TYPICALLY, THAT WOULD BE
BURNED OR PLOWED UNDER.
WE'RE ABLE TO RECLAIM
THOSE FIBERS
AND UTILIZE THEM IN
THE MANUFACTURING PROCESS.
WOW. NOW, WHERE
WAS THIS DEVELOPED?
IT WAS DEVELOPED
IN GUELPH, ONTARIO,
BY A CHEMIST
BY THE NAME OF IAN MUIR
AND A TOOL-AND-DIE
GENTLEMAN.
THAT WOULD BE
STUART ROBERTSON.
SO THIS IS CREATED
IN A MOLD?
IT WAS CREATED
IN A MOLD.
THAT'S CORRECT.
IT'S ABOUT 10 YEARS
OF RESEARCH TO SEE IT
TO FRUITION.
MM-HMM, AND WHAT
ARE THE ADVANTAGES
OF USING THIS
OVER USING, YOU KNOW,
A RED CEDAR SHAKE?
THE ADVANTAGE
IS LONGEVITY.
IT'S, YOU KNOW,
GUARANTEED NOT TO WARP,
CRACK, BLISTER,
PEEL, FLAKE.
IT HAS A 50-YEAR
WARRANTY.
50?
50 YEARS, YES,
AND IT'S NOT PRORATED.
THE WARRANTY
IS TRANSFERABLE
FROM ONE OWNER
OF THE HOME TO ANOTHER.
THE PRODUCT
IS MAINTENANCE-FREE
ONCE IT'S APPLIED,
SO THERE'S NO TREATMENTS
OR PRETREATMENTS.
HOW WILL IT WEATHER?
IT STARTS OUT A LITTLE BIT
DARKER IN COLOR,
AND IT WILL GO
TO A LIGHTER GRAY COLOR
SIMILAR TO THAT--
THIS ONE IS
THE WEATHERED ONE?
THIS IS
THE WEATHERED ONE,
AND IT DOES
LIGHTEN UP.
IT LOOKS VERY SIMILAR
TO 3-TO-4-YEAR-OLD
SILVERED CEDAR.
OK, BECAUSE
WHEN YOU PUT IT ON,
IT'S PRETTY BLACK.
IT LOOKS PRETTY MUCH
LIKE A SLATE PRODUCT.
IT'S QUITE A BIT DARKER.
IT'S A DARK
BROWNISH-GRAY COLOR,
AND IT DOES COVERT
TO THIS NATURAL WEATHERED
LOOK OF CEDAR,
AND IT STAYS THAT WAY
ONCE IT REACHES THAT STAGE.
AND THE COST?
THE COST IS COMPARABLE
TO PREMIUM ROOFING
SUCH AS STEEL ROOFING,
SHAKELIKE STEEL ROOFING,
AND COMPARABLE, AS WELL,
TO PREMIUM CEDAR.
BUT IS IT MADE IN CANADA
OR IN THE STATES?
IT'S MADE IN CANADA,
MANUFACTURED IN
CHATHAM, ONTARIO,
AND, YOU KNOW,
BEING THAT IT'S
THE CANADIAN DOLLAR
IS A BIT OF AN ADVANTAGE
THERE, I THINK, FOR FOLKS
IN THE STATES.
WELL, IT'S
AN INTERESTING PRODUCT.
I WANT TO CLIMB UP
ON THE ROOF AND SEE
HOW IT'S INSTALLED.
LET'S SAY HI
TO CHRIS JACKSON,
WHO'S HEADING UP
THE INSTALLATION
UP HERE.
BOY, IT'S NICE AND WARM
UP ON THE ROOF.
HI, CHRIS.
ABSOLUTELY.
HOW ARE YOU, BOB?
YOU GOT YOUR HARNESS ON.
THAT'S GOOD.
HOW EASY IS IT
TO INSTALL THIS TYPE
OF A ROOFING PRODUCT?
ACTUALLY, THE PRODUCT IS
FAIRLY EASY TO INSTALL.
WE FOLLOW, BASICALLY,
THE GUIDELINES
OF REAL CEDAR,
WHICH YOU CAN
NAIL IT BY HAND--
AS YOU CAN SEE
THE GUYS ARE DOING
BEHIND ME HERE--
OR WE CAN USE
AN ACTUAL GUN.
WITH WHAT KIND
OF NAILS?
WE USE GALVANIZED
ROOFING NAILS--
INCH AND 3/4
ON NEW CONSTRUCTION,
OR WE CAN USE TWO
INCHES ON BRAND-NEW
CONSTRUCTION.
AND I NOTICED--
I DIDN'T REALIZE BEFORE.
I THOUGHT THEY WERE ALL
UNIFORM IN SIZE,
BUT I GUESS YOU'RE
SPLITTING THEM UP HERE
SO THAT YOU CAN HAVE
THE LOOK OF VARIOUS
DIFFERENT DIMENSIONS.
YES. ACTUALLY WE HAVE
3 DIFFERENT PROFILES
THAT WE OFFER.
WE HAVE A 6"-6",
WE HAVE A SOLID 12",
AND THEN WE HAVE
WHAT WE CALL A 4"-8",
WHICH YOU CAN SEE
RIGHT THROUGH HERE.
HOW DO YOU SPLIT THEM?
DO YOU HAVE TO USE A SAW,
OR DO YOU HAVE TO USE
A KNIFE, OR WHAT?
DEPENDING ON WHICH
PART OF THE ROOF
YOU'RE WORKING ON--
IN OUR VALLEYS,
WHAT WE DO IS,
WE CAN USE A HAND SAW.
WE JUST MAKE
A TEMPLATE PLATE
ON OUR SYSTEM,
OR WE HAVE THE ABILITY
TO SNAP IT RIGHT
LIKE THIS.
SO YOU CAN JUST
SPLIT THEM LIKE YOU WOULD
AN ORDINARY WOOD SHINGLE.
ABSOLUTELY.
DO YOU HAVE TO WORRY
ON A ROOF LIKE THIS,
ESPECIALLY
WITH THE DARK COLOR,
ABOUT EXPANSION
AND CONTRACTION
AS IT HEATS UP
AND THEN COOLS DOWN?
ACTUALLY, OUR TESTING
METHODS HAVE ALLOWED US
TO HAVE VERY, VERY
MINIMAL EXPANSIONS,
LESS THAN 2%.
WHAT WE DO IS,
WE HAVE A WATER TEST
FOR 72 HOURS,
AND WHAT IT DOES IS,
IT GAINS LESS THAN
.08/100 OF A POUND.
IT'S INTERESTING,
ALL THIS NEW PRODUCT
THAT'S OUT THERE.
HAVE YOU WORKED
WITH THIS TITANIUM-UDL
INTERWRAP PRODUCT BEFORE?
YES, I HAVE.
I'VE HAD 2 OR 3
DIFFERENT COMPANIES
USE THIS AS THEIR
UNDERLAYMENT,
AS A COMPLETE
UNDERLAYMENT
FOR THE ROOF SYSTEM,
AND IT'S WORKED
FAIRLY WELL.
IT'S VERY INTERESTING.
ABSOLUTELY.
WHEN WE WERE STILL
AT THE SIMPLEX PLANT
A COUPLE OF WEEKS AGO,
WE LEARNED A LITTLE BIT
ABOUT THE PRODUCT WITH
ONE OF THE FELLOWS THERE.
TAKE A LOOK.
ALL RIGHT, DAVE.
SO THIS IS ONE OF
THE NEAT THINGS ABOUT
THESE MODULAR HOUSES
IS THAT PART OF
THE ROOF WILL JUST
FOLD INTO PLACE.
YEAH. AGAIN, THAT'S
THAT GREAT HINGE DESIGN
WE TALKED ABOUT EARLIER.
AND INSTEAD
OF PUTTING FELT PAPER,
LIKE WE NORMALLY DO
IN MANY CONSTRUCTION
PROJECTS, ON THE ROOF,
WE GOT
SOMETHING ELSE.
THIS IS A NEW PRODUCT
FROM INTERWRAP,
AND IT'S CALLED
TITANIUM-UDL,
A SYNTHETIC ROOFING
UNDERLAYMENT.
WHAT DO YOU
KNOW ABOUT IT?
WELL, BOB, THE THINGS
THAT WE'RE EXCITED
ABOUT WITH IT IS,
IT'S VERY
TEAR-RESISTANT,
AND THE FACT IS THAT
WE'RE SENDING BOXES
DOWN THE ROAD
AND THERE'S A LOT
OF WIND SOMETIMES.
THIS IS GONNA BE
A GREAT PRODUCT FOR US
TO SHIP HOUSES WITH.
YEAH, AND YOU USE
A DIFFERENT KIND OF NAILER
WITH IT, DON'T YOU?
YEAH. THIS IS
A REALLY NEAT GUN.
IF YOU LOOK AT THIS GUN,
THE GUN HAS THE CAP
BUILT IN WITH THE NAIL
SO WHEN THEY SHOOT IT,
IT AUTOMATICALLY SHOOTS
THE CAP AND THE NAIL
AT THE SAME TIME.
01
I THINK THEY'D LIKE
TO HAVE IT UP THERE.
AND INSTEAD OF
BEING 3 FEET WIDE,
IT'S 4 FEET WIDE.
Dave: SO AGAIN,
IT SAVES TIME.
THAT SAVES TIME
AND GOES A LOT QUICKER
AND DOESN'T WEIGH MUCH.
I MEAN, IT DOESN'T
WEIGH MUCH AT ALL.
IT'S
A GREAT PRODUCT.
SO YOU WERE SAYING IT'S
PRETTY TEAR-RESISTANT,
AND THAT IS A BIG DEAL
BECAUSE WHEN YOU GOT
A FRAME UP
AND YOU'RE JUST
COVERING IT UP
WITH FELT, FOR EXAMPLE--
WHICH IS REALLY
A TRADITIONAL PRODUCT,
AND IT'S A GREAT PRODUCT,
BUT HIGH WINDS
CAN DAMAGE IT.
AND WE ARE SHIPPING
THIS PRODUCT
OVER THE ROAD,
AND THIS PARTICULAR
HOUSE DOESN'T HAVE
A ROOF COVERING
GOING OVER IT, SO
IT'S GONNA BE EXPOSED.
SO THIS IS GONNA
CUT DOWN ON ANY KIND
OF RISK FOR US,
AS FAR AS WEATHER.
OK.
SO YOU'RE KEEPING
THEM ABOUT A QUARTER-INCH
APART, RIGHT?
YES, I AM.
I LIKE TO HAVE THE SAME
CONSISTENCY AS WHAT WE
HAVE ON OUR KEYWAYS.
IT LOOKS
FAIRLY CONSISTENT.
SO IT'S
MOSTLY AESTHETIC.
ABSOLUTELY.
SO, CHRIS,
THE PLACEMENT OF THE NAILS
IS ALWAYS WHERE,
IN RELATIONSHIP TO
THE SHINGLE BEFORE IT?
WHAT WE HAVE
ON THE BACK HERE IS,
WE HAVE WHAT WE CALL
A NAILING STRIP.
IT'S ROUGHLY
ONE FINGER BELOW
OUR DEFINITION LINE,
AND WE'RE PRETTY
CONSISTENT ACROSS
THE BOARD THROUGH THERE.
OK, SO THAT
DEFINITION LINE
IS YOUR GUIDE.
YES,
AND THEN WE HAVE OUR
9-INCH EXPOSURE LINE,
AS YOU CAN SEE,
THROUGH HERE.
THAT'S WHAT WE
RECOMMEND ON THAT.
THEY CAN BE
INSTALLED AT 7 INCHES
AND AT 9 INCHES.
AT 7 OR 9 INCHES
TO THE WEATHER.
THAT'S CORRECT.
THAT'S CORRECT.
LARGELY, IT'S ABOUT
AESTHETICS, TOO,
ABSOLUTELY.
THE SCALE OF THE ROOF
VERSUS HOW MUCH EXPOSURE
YOU'VE GOT.
WHAT ABOUT THE RIDGE CAPS
THAT YOU'RE PUTTING
ON THERE?
CAN YOU BEND THOSE
ON SITE?
ACTUALLY, NO.
OUR RIDGE CAPS
ARE PREMANUFACTURED
RIGHT AT OUR FACTORY.
WHAT WE DO IS,
WHEN A CUSTOMER CALLS
AND PUTS AN ORDER IN
FOR A SPECIFIC
PITCH ON HIS ROOF,
WE'LL ACCOMMODATE THAT
WITH ANYWHERE FROM
A 3/12 UP TO A 16/12.
YEAH. WE GOT
A 12 PITCH HERE...
WE HAVE
A 12/12 HERE.
AND SO YOU HAVE
TO SPECIFY THEM.
THERE'S ABSOLUTELY
NOT ENOUGH GIVE
THAT YOU CAN BEND THEM
IN THE FIELD.
WHAT WE DO IS, WE
TAKE OUR SOLID 12,
AND WE PUT IT OVER
TOP OF A TEMPLATE,
AND IT'S BENT
INTO PLACE, PUT THROUGH
A COOLING PROCESS,
AND THAT'S
HOW IT COMES OUT.
HEY, ONE LAST QUESTION--
WHAT'S THE COST
OF A ROOF LIKE THIS?
THE PRICE IS BETWEEN
275 AND 290 A SQUARE.
THAT'S COMPARABLE
WITH RED CEDAR.
ACTUALLY, IT'S REALLY,
REALLY COMPARABLE
WITH RED CEDAR.
WE'RE RIGHT IN
THE EXACT SAME BALLPARK.
OK. IT'S AN INTERESTING
PRODUCT. THANK YOU.
EXCELLENT.
THANK YOU.
NEXT, WE'LL BE APPLYING
A CULTURED STONE PRODUCT
TO THE EXPOSED FOUNDATION WALLS.
WE'RE ON THE BACK SIDE
OF THE HOUSE NOW.
IN OUR HOUSE LOT,
THE TERRAIN REALLY SLOPES.
THE GRADE GOES DOWN ABOUT
15 DEGREES ON THE BACK SIDE,
WHICH MEANS THAT WE HAVE A LOT
OF EXPOSED FOUNDATION WALL.
IT DOESN'T LOOK LIKE
A CONCRETE FOUNDATION
BECAUSE IT WAS SUPERIOR WALLS'
PREFAB FOUNDATION,
AND RIGHT NOW, WE'RE INSTALLING
A NEW MAN-MADE STONE
FROM OWENS-CORNING.
LET'S SAY HI
TO MARK MURPHY.
HI, BOB.
MARK, HOW ARE YOU?
GOOD TO SEE YOU.
THIS IS LOOKING
VERY GOOD.
WE'VE GOT A CREW OF
8 GUYS HERE, AND THEY'RE
DOING A TERRIFIC JOB.
WHAT IS THIS
PARTICULAR STONE CALLED?
THIS IS CULTURED STONE
FROM OWENS CORNING.
THIS IS A MANUFACTURED
PRODUCT DESIGNED TO GO
RIGHT ON THE FOUNDATION
TO CREATE THE LOOK
THAT THE ENTIRE FOUNDATION
IS ACTUALLY BUILT
OUT OF FIELDSTONE
AND LEDGESTONE.
AND IN TERMS
OF THE SHADING
AND THE COLORATION,
IT COMES
REAL CLOSE TO SOME
OF THE BOULDERS
THAT I'VE GOT
ON THE LOT HERE.
ABSOLUTELY.
VERY INDIGENOUS, BOB,
TO THE AREA OF NEW ENGLAND,
IF YOU LOOK BACK
AND TAKE A LOOK AT SOME
OF THE LARGER STONES.
WHAT'S IT
MADE OUT OF?
CULTURED STONE BEING
A MANUFACTURED PRODUCT,
IT'S MADE OUT OF 3 THINGS.
FIRST OF ALL, WE TAKE
A MOLD OF A NATURAL STONE,
AND WHAT WE DO IS
PUT IN PORTLAND CEMENT
AS THE MAIN INGREDIENT.
SECONDLY, WE DIFFUSE
THE WEIGHT, BOB,
WITH A PRODUCT
CALLED PUMICE,
WHICH IS A VOLCANIC STONE,
TO MAKE IT LIGHTER,
AND THIRDLY, WE PUT IN
MINERAL OXIDES--
SPECIFICALLY, IRON OXIDES--
TO GIVE IT THE COLOR
THAT WE'RE LOOKING FOR.
HOW DO YOU MAKE IT?
WE MAKE IT
IN A MOLD PROCESS.
WE ACTUALLY EXTRACT STONES
OUT OF THE EARTH.
WE GO TO A STONE QUARRY
AND GET A SERIES OF STONES,
AND THEN WE PUT THEM OUT
ON A LARGE TEFLON TABLE
AFTER THEY'VE BEEN WASHED
AND READY TO GO,
AND WE'D SPRAY THEM
WITH A FINE MIST OF LATEX.
THE LATEX WILL ACTUALLY GO
INTO THE NOOKS AND CRANNIES
AND GET SOME
OF THE CHARACTER
OF THE STONE, BOB,
SO THAT WE CAN MAKE IT
LOOK IDENTICAL TO WHAT'S
OUT IN THE FIELD,
AND THEN ONCE WE'VE
COVERED THE ENTIRE TABLE
IN THESE STONES
WITH THIS LATEX MEMBRANE,
WE FLIP THAT UPSIDE DOWN,
AND WE ADD THOSE
3 INGREDIENTS.
SO THOSE
ARE YOUR MOLDS.
EXACTLY. THAT'S REALLY
THE BUSINESS.
WHAT ARE
THESE TWO GUYS?
THESE ARE CALLED
CLONE STONES, BOB,
AND I SHOW THESE TO KIND OF
LEGITIMIZE THE BUSINESS
FOR FOLKS THAT DON'T
KNOW WHAT MANUFACTURED
STONE IS ALL ABOUT.
THESE ARE BOTH
SOUTHERN LEDGESTONES--
AS YOU LOOK AT THEM,
VERY SIMILAR,
NEARLY IMPOSSIBLE
TO TELL THE DIFFERENCE.
THEY LOOK
PRETTY IDENTICAL.
I'M GONNA HAVE YOU TRY
TO TELL THE DIFFERENCE.
THERE'S ONE IN ONE HAND.
IT'S GOT THE COLORATION,
YEAH, ON THE SAME SIDE,
BUT THIS IS CLEARLY
A LOT HEAVIER.
CONSIDERABLY HEAVIER.
OK, AND ON THE BACK
SIDE, YOU CAN SEE
WHERE IT'S BEEN CUT.
YOU NOTICE, I DIDN'T
SHOW YOU THE CLONE STONES
FROM THE BACK
SIMPLY BECAUSE
OF THAT EXACT REASON.
VERY NEAT.
NOW LET'S TALK
ABOUT INSTALLATION
A LITTLE BIT.
THIS IS OUR FOUNDATION.
BRENDEN IS INSTALLING,
AGAIN, A BLEND OF
DRESSED FIELDSTONE,
WHICH WOULD BE
THE LARGER STONES,
AND THEN OUR SOUTHERN
LEDGESTONES THROUGHOUT.
THIS COLOR HERE
SPECIFICALLY IS
CALLED BUCKS COUNTY
SOUTHERN LEDGESTONE
AND DRESSED FIELDSTONE,
AND WE USE
A TYPE "N" MORTAR--
BRENDEN HAS
A TYPE "N" MORTAR
MIXED UP RIGHT HERE--
AND BACK BUTTER
THE STONES
AND GO RIGHT UP
AGAINST THE FOUNDATION.
NOW WHAT IS
A TYPE "N" MORTAR?
TYPE "N" MORTAR MIX
IS WHAT YOU SEE HERE.
IT'S PORTLAND MIXED
WITH APPROXIMATELY
3 SCOOPFULS OF SAND,
AND THEY'RE YOUR
STANDARD-APPLICATION--
IT'S STANDARD.
IT'S A STANDARD MORTAR.
NOW, WITH THIS PARTICULAR
TYPE OF FOUNDATION,
YOU DON'T HAVE
THE SMOOTHNESS OF CONCRETE.
RIGHT. EXACTLY.
A LOT OF POURED
FOUNDATIONS,
AS YOU KNOW,
ARE VERY SLIPPERY
AND NONPOROUS.
THIS PARTICULAR
FOUNDATION IS IDEAL
FOR INSTALLING
CULTURED STONE,
AS YOU CAN SEE.
AS YOU DRAG YOUR HAND
ACROSS THIS FOUNDATION,
VERY TACKY,
VERY POROUS, IDEAL
FOR INSTALLING STONE.
IT'S ALMOST LIKE
A SCRATCH COAT.
OH, IT'S PERFECT.
NOW, THE ACTUAL PICKING
AND CHOOSING OF THE PIECES
IS SOMETHING THAT'S
TOTALLY UP TO BRENDEN
AND ALL HIS COLLEAGUES HERE.
THEY KIND OF CREATE
THE PATTERN AND THE DESIGN
AS THEY GO ALONG.
EXACTLY.
THAT'S PART OF
THE ARTISTRY OF MASONRY
WORK IN GENERAL.
IF YOU TAKE
ALL THE STONES
THAT WE HAVE HERE,
THEY'RE ALL SPREAD OUT
IN A WORK AREA.
THE GUYS WILL SELECT
THEM AS THEY GO ALONG,
AND JUST TURNS OUT
TO BE A BEAUTIFUL LOOK
AND A VERY
ARTISTIC IMPRINT
THAT THE INDIVIDUAL
MASON CAN PUT
ON THE JOB.
CAN YOU
USE THIS INDOORS?
REGARDLESS OF
THE SUBSTRATE, BOB.
INDOORS, OUTDOORS,
DOES NOT MATTER.
WE CAN GO OVER
BLOCK FOUNDATION,
POURED FOUNDATION,
CAN GO OVER PLYWOOD.
YEAH. THE MAIN REASON
I ASK IS THE WEIGHT FACTOR.
IF IT DOESN'T WEIGH MUCH,
I WOULD THINK YOU'D BE ABLE
TO PUT IT ON
AN INSIDE PARTITION
AND NOT HAVE TO WORRY
ABOUT STRUCTURAL LOADS.
AS YOU CAN SEE HERE
AT THE BOTTOM,
WE'RE ACTUALLY BRACING
IT UP JUST TO GET
OUR CORE STARTED,
BUT THERE'S ABSOLUTELY
NO NEED FOR SILL.
THERE'S NO NEED
FOR A LEDGE OR ANY TYPE
OF ANGLE IRON
BECAUSE THERE'S
NO LOAD-BEARING
AT ALL GOING ON.
SO WHEN IT'S TAKEN AWAY
AND WE BRING THE GRADE
UP TO NORMAL,
THAT'LL JUST
SIT ON GRADE.
IT'LL SIT
RIGHT ON GRADE,
AND PRETTY MUCH
EVERYBODY THAT LOOKED
AT THIS PROJECT
WOULD THINK
THE ENTIRE FOUNDATION
IS ACTUALLY MADE
OUT OF THESE STONES.
WHAT ABOUT
THE COST, MARK?
THE COST,
RELATIVELY SPEAKING,
WHEN CULTURED STONE
IS INSTALLED
IS ROUGHLY 50% THE COST
OF NATURAL STONE.
INTERESTING,
AND, OF COURSE,
I SUPPOSED THAT HAS TO DO
WITH EASE OF INSTALLATION...
THAT'S PROBABLY
THE BIGGEST THING, BOB,
IS THESE GUYS YOU
CAN SEE WORKING HERE
JUST BUSTING OUT
AN INCREDIBLE AMOUNT
OF SQUARE FOOTAGE
IN A SHORT
PERIOD OF TIME.
IF WE WERE
TO INCORPORATE
NATURAL STONE
INTO THIS EQUATION,
LABOR WOULD
JUST BE A KILLER,
IN TERMS OF TIME.
AND WE'RE GOING
AROUND THE CORNER,
AND IT'S COMING UP
REAL NICELY OVER HERE.
IS THERE A WARRANTY
ON THIS PRODUCT?
OWENS CORNING HAS
A 50-YEAR WARRANTY
ON THE PRODUCT
AGAINST
PRODUCT FAILURE.
SO IF THE PRODUCT
WAS TO DISINTEGRATE
OR ANYTHING LIKE THAT
WOULD HAPPEN
TO THE PRODUCT
IN THE FIELD,
WE WOULD HONOR
A WARRANTY ON THAT.
THANKS A LOT, MARK.
THANK YOU, BOB.
ALL RIGHT.
COMING UP,
WE'LL HAVE A PROGRESS REPORT
ON THE INTERIOR FINISHES,
INCLUDING THE MASTER BATH.
NEXT TIME
ON "BOB VILA'S HOME AGAIN,"
WE'LL HAVE LOTS OF PROGRESS
ON OUR MODULAR PROJECT
IN THE BERKSHIRE HILLS
OF WESTERN MASSACHUSETTS.
WE'LL BE PUTTING IN
AN ENVIROSHAKE ROOF.
THIS GREEN PRODUCT
IS MADE IN CANADA
FROM RECYCLED MATERIALS
AND COMES WITH
A 50-YEAR WARRANTY.
ALSO, WE'LL BE INSTALLING
CULTURED STONE
ON THE EXPOSED FOUNDATION WALLS.
IT'S MUCH LIGHTER
AND MORE ECONOMICAL
THAN NATURAL STONE.
AND WE'LL HAVE A LOOK
AT THE INTERIOR FINISH DETAILS.
SO DON'T MISS IT.
THAT'S NEXT TIME
ON "HOME AGAIN."
NEXT TIME
ON "BOB VILA'S HOME AGAIN,"
IT'S CULTURED STONE,
AN ENVIROSHAKE ROOF,
AND LOTS OF INTERIOR
FINISH WORK.
DON'T MISS IT.
SO, MICHAEL, IS THIS
THE FIRST MODULAR HOUSE
YOU'VE EVER BUILT?
NO.
WE BUILT SEVERAL.
SO YOU KNOW HOW
TO PUT THEM TOGETHER,
BUT BASICALLY,
PEOPLE THINK OF
A DOUBLE WIDE.
WE'VE GOT 4,
2 AND 2,
AND THEN WE GOT
ANOTHER MODULE THERE
AND ANOTHER ONE
ON THE OTHER SIDE,
AND THIS IS WHAT YOU CALL
THE MARRIAGE POINT, RIGHT?
THAT'S RIGHT.
WHAT'S
GOING ON HERE?
THE CONNECTION
OF THE TWO BOXES.
WE'RE PUTTING UP
GUSSET PLATES,
SECURE THE WALLS
TOGETHER,
AND THEY'LL BE
PUTTING THE DRY WALL
ON TOP OF THAT.
NOW, YOU'RE LOOKING
AT 1, 2, 3, 4 MICROLAMS,
WHICH ARE ENGINEERED
WOOD PRODUCTS,
AND THEY, OF COURSE,
MEAN THERE'S
REALLY GONNA BE
NO MOTION THERE.
THAT'S CORRECT.
THERE'S
A BIG SPAN, TOO.
YES, 18 FEET
ACROSS HERE,
AND THEN WE SECURE
THE TWO OF THEM
WITH HALF-INCH
ANCHOR BOLTS IN BETWEEN.
YEAH. I CAN SEE
THE BOLTS UP THERE,
AND THEN HE'S DOING
ESSENTIALLY THE SAME
THING DOWN HERE
ON THE VERTICAL MEMBERS.
YEAH.
WE PUT THE GUSSETS
EVERY 16 INCHES
TO SECURE THERE'S
NO MOVEMENT IN THE WALL.
NOW, WHAT HAPPENS
WITH THE FLOOR?
THESE GET LIFTED OUT?
YEAH. THIS WAS
THE TEMPORARY WALL
BETWEEN THE TWO BOXES.
WE'LL REMOVE
THESE PLATES WHEN WE'RE
ALL FINISHED IN HERE
AND THEN JUST PATCH IN
THE HARDWOOD FLOORING
THAT'S ALREADY BEEN
APPLIED ON EITHER SIDE.
YEAH, SO THAT THIS
IS GOING TO BE
30 BY 15, I THINK.
THAT'S CORRECT.
VERY-GOOD-SIZED
LIVING ROOM.
OK, AND THEN
THE SUNROOM ITSELF IS--
YOU CAN SEE
THE DOUBLE WALLS HERE.
IT'S AN ADDITIONAL BOX.
YEAH, THIS IS
ANOTHER MARRIAGE WALL.
ANOTHER MARRIAGE WALL,
AND HOW HAS THIS
BEEN ATTACHED
TO THE OTHER ONE?
THIS IS SECURED AT THE TOP
AND THE LOWER PLATES,
WHERE IT'S SECURED
AT THE FOUNDATION
AND AT THE CEILING HEIGHT.
OK, AND WHAT IS
THE CEILING HEIGHT?
I MEAN, ARE YOU
GONNA DRY-WALL RIGHT
OVER THESE 2-BY-6s?
OH, NO. THESE ARE
TEMPORARY WHILE SHIPPING.
THESE WILL BE REMOVED,
AND THEN WE'LL HAVE
A VAULTED CEILING HERE.
SO WE'LL HAVE INSULATION,
AND THEN THE DRY WALL
IS APPLIED TO
THE RAFTERS ABOVE.
WOW. WHAT'S THE SIZE
OF THE ROOM?
14 BY 16.
AND THE RIDGE?
THAT'S A 14-INCH MICROLAM,
THE SPANNING OF THE ROOM.
BECAUSE IT'S
ENGINEERED WOOD, WE DON'T
NEED ANY COLLAR TIES.
SO YOU'RE GONNA
HAVE ONE VERY NICE
ROOM HERE.
IT'S A GREAT SIZE.
YEAH, ABOUT
AN 18-FOOT-HIGH
CATHEDRAL CEILING.
THAT'S WHAT IT IS.
SO LET'S TAKE
A LOOK AT THE LAST
INDEPENDENT BOX,
WHICH IS
THE MASTER SUITE.
OK.
ALL RIGHT.
SO THE MASTER SUITE,
THE ACTUAL BOX,
WAS WHAT DIMENSION?
THIS IS 16 BY 40.
AND IT'S BEEN DIVIDED
INTO MASTER BATH,
MASTER BEDROOM.
THAT'S CORRECT.
SO THIS IS
16 BY, WHAT, 20?
YES.
AND I DIDN'T REALIZED
THAT THEY HAD PUT IN A--
OH, THAT'S
A BIT OF A DROP,
AND THE GUYS ARE
STILL PUTTING ON
THAT BEAUTIFUL
CULTURED STONE
DOWN THERE,
BUT WHAT
HAPPENS HERE?
WE'RE GONNA HAVE
A PRIVATE BALCONY
OFF OF THE MASTER BATHROOM
THAT'S GONNA BE 10 BY 4.
SO IT'S JUST
A "ROMEO AND JULIET"
BALCONY.
NOTHING--
IT'S NOT GONNA CONNECT
TO THE MAIN DECK, NO.
OK. I LIKE
THE TREY CEILING.
YES. REALLY NICE.
IT MAKES THE ROOM
FEEL A LITTLE BIGGER,
MUCH MORE OPEN.
WE SAW THEM
MAKING ALL THESE
IN THE FACTORY,
BUT WHEN THEY ALL
COME AND GET ASSEMBLED,
THAT'S WHEN IT REALLY
MAKES THE DIFFERENCE.
REALLY
COMES TOGETHER.
BIG WALK-IN OVER THERE
AND HUGE MASTER
BATHROOM IN HERE.
THE 4-SIDED TREY, HUH?
THAT'S VERY NICE.
YES.
AND THIS BUSINESS,
THIS DETAIL, IS VERY,
VERY INTERESTING, ALSO.
WE INCORPORATED
SOME PANELING IN HERE,
MAKE IT A LITTLE BIT
MORE INTERESTING.
LOOKS LIKE
A WAINSCOT,
AND THEN WE'VE GOT
KOHLER'S HIS-AND-HER
VANITIES, I GUESS,
ALREADY IN PLACE
AND A MARVELOUS BATHTUB.
WAS THAT PUT
IN THE FACTORY,
OR DID THAT--
THIS WAS ALL INSTALLED
IN THE FACTORY,
INCLUDING
THE TILE FLOORS.
WOW, AND NO DAMAGE
ON THE ROAD, RIGHT?
NOPE.
EVERYTHING
ARRIVED OK.
NO. THE ONLY THING
WE'RE GONNA DO HERE
IS GROUT THE FLOOR TILE.
AND WHAT DO YOU DO
THROUGH THESE
FRENCH DOORS?
THIS IS ANOTHER DECK
ON THE OUTSIDE
THAT WILL BE 10 BY 14.
OVERLOOKING THE WOODS,
SO PLENTY OF PRIVACY.
PRIVACY WOULD NOT
BE AN ISSUE.
NO.
OK.
WE'LL BE BACK IN A MOMENT
WITH A PREVIEW OF OUR NEXT SHOW.
STICK AROUND.
COME HOME AGAIN NEXT TIME.
WE'RE GONNA BE PUTTING
A METAL ROOF UP ON THE MAIN
PORTION OF THE HOUSE,
ALSO PREFABBED SHINGLE PANELS,
AND WE'RE TAKING YOU
TO THE MOUNT--
THE HOME OF EDITH WHARTON,
WHICH HAS BEEN
GORGEOUSLY RESTORED.
TILL THEN, I'M BOB VILA.
IT'S GOOD TO HAVE YOU
HOME AGAIN.
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