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--Captions by VITAC--
www.vitac.com
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00:00:04,620 --> 00:00:07,620
CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
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Narrator: THE FIRST FIREPLACES
WERE STRICTLY FUNCTIONAL
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00:00:55,793 --> 00:00:59,068
FOR HEATING THE HOME,
COOKING MEALS,
5
00:00:59,172 --> 00:01:01,172
AND WARMING WATER FOR BATHING.
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00:01:01,275 --> 00:01:04,965
OVER TIME, FIREPLACES APPEARED
IN OTHER ROOMS OF THE HOUSE
7
00:01:05,068 --> 00:01:07,517
AND ACQUIRED ASCETIC FEATURES
SUCH AS WOOD,
8
00:01:07,620 --> 00:01:09,517
STONE, OR TILE WORK.
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00:01:12,724 --> 00:01:15,793
THIS CERAMIC FIREPLACE
IS A HERITAGE MODEL
10
00:01:15,896 --> 00:01:18,206
INSPIRED BY FIREPLACES
OF THE LATE 19th
11
00:01:18,310 --> 00:01:20,724
AND EARLY 20th CENTURY.
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00:01:20,827 --> 00:01:24,000
CERTAIN TILES
ARE EXACT REPLICAS OF ORIGINALS.
13
00:01:26,000 --> 00:01:30,137
AT THE CERAMIC FACTORY
THEY MIX WATER WITH CLAY,
14
00:01:30,241 --> 00:01:33,931
FELDSPAR, AND SILICA
IN A PUGMILL.
15
00:01:34,034 --> 00:01:37,103
TOGETHER,
THESE FORMULATE A CLAY BLEND.
16
00:01:37,206 --> 00:01:39,310
ONCE THE MIX
IS THE RIGHT CONSISTENCY,
17
00:01:39,413 --> 00:01:41,241
THE OPERATOR PRESSES A BUTTON,
18
00:01:41,344 --> 00:01:43,793
AND THE MILL
SWITCHES TO EXTRUSION MODE.
19
00:01:43,896 --> 00:01:48,172
THIS FORCES THE CLAY BLEND
THROUGH A MANTEL SHAPED DIE
20
00:01:48,275 --> 00:01:52,517
AND PRODUCES A 10- TO 15-INCH
LONG EXTRUDED MANTEL PIECE.
21
00:01:52,620 --> 00:01:54,413
THEY TRIM THE PIECE
WITH A CUTTING WIRE
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00:01:54,517 --> 00:01:57,793
TO THE PRECISE LENGTH REQUIRED.
23
00:01:57,896 --> 00:02:01,758
THEY USE THIS EXTRUSION METHOD
FOR MAKING LONGER PIECES.
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00:02:01,862 --> 00:02:03,517
IF THEY NEED SHORTER ONES
25
00:02:03,620 --> 00:02:06,724
THEY OFTEN CAST THEM
INDIVIDUALLY IN A MOLD.
26
00:02:08,137 --> 00:02:11,137
WHEN CASTING THEY ADD
SIGNIFICANTLY MORE WATER
27
00:02:11,241 --> 00:02:15,172
TO THE CLAY BLEND TO PRODUCE
A LIQUID CLAY CALLED SLIP.
28
00:02:15,275 --> 00:02:18,068
THEY POUR THE SLIP
INTO A PLASTER MOLD.
29
00:02:18,172 --> 00:02:21,862
THE POROUS PLASTER GRADUALLY
ABSORBS MOST OF THE WATER,
30
00:02:21,965 --> 00:02:24,517
LEAVING A LAYER OF CLAY
ABOUT 6 MILLIMETERS THICK
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00:02:24,620 --> 00:02:27,758
ON THE WALLS
OF THE MANTEL-SHAPED CAVITY.
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00:02:27,862 --> 00:02:31,379
AFTER A FEW HOURS,
THEY POUR OUT THE EXCESS SLIP
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00:02:31,482 --> 00:02:35,241
AND OPEN THE MOLD TO EXTRACT
THE CAST MANTEL PIECE.
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00:02:37,310 --> 00:02:40,482
ONCE THE CLAY BECOMES
FIRM ENOUGH TO HANDLE
35
00:02:40,586 --> 00:02:42,620
THEY CAREFULLY TRIM OFF
THE EXCESS
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00:02:42,724 --> 00:02:45,310
AROUND THE OPENING IN THE MOLD.
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00:02:47,172 --> 00:02:49,344
THEN THEY GENTLY SMOOTH DOWN
THE SEAM
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00:02:49,448 --> 00:02:53,655
ALONG THE JUNCTION BETWEEN
THE TWO HALVES OF THE MOLD.
39
00:02:53,758 --> 00:02:55,758
ON THE OPPOSITE SIDE
OF THE POUR HOLE,
40
00:02:55,862 --> 00:02:59,034
THEY CUT OUT A MATCHING HOLE.
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00:02:59,137 --> 00:03:01,689
THIS WILL HELP THE CLAY
DRY FASTER
42
00:03:01,793 --> 00:03:05,241
BY ENABLING AIR TO FLOW THROUGH
THE INSIDE OF THE PIECE.
43
00:03:06,896 --> 00:03:08,586
TO COMPENSATE FOR SHRINKAGE,
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00:03:08,689 --> 00:03:12,413
THE MOLDS AND EXTRUSION DIES
ARE DESIGNED 11% LARGER
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00:03:12,517 --> 00:03:15,000
THAN THE SIZE
OF THE FINISHED PIECE.
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00:03:15,103 --> 00:03:17,827
CLAY SHRINKS AS IT DRIES.
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00:03:17,931 --> 00:03:20,344
TO MAKE THE FIREPLACE'S
CERAMIC TILES,
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00:03:20,448 --> 00:03:23,551
THEY PRODUCE A RUBBER MOLD
OF TWO ADJOINING TILES
49
00:03:23,655 --> 00:03:25,689
AND PLACE IT
INSIDE A METAL CASING.
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00:03:25,793 --> 00:03:29,068
THEY ALSO INCLUDE A RELEASE
SYSTEM TO HELP WITH EXTRACTION.
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00:03:29,172 --> 00:03:30,482
THEY FILL THE CASING
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00:03:30,586 --> 00:03:32,965
WITH AN EXCEPTIONALLY STRONG
TYPE OF PLASTER.
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00:03:33,068 --> 00:03:35,068
IT SETS IN ABOUT HALF AN HOUR,
54
00:03:35,172 --> 00:03:37,620
TAKING ON THE SHAPE
OF THE RUBBER MOLD.
55
00:03:37,724 --> 00:03:39,344
THIS PLASTER CASTING
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00:03:39,448 --> 00:03:42,551
IS THE DIE THEY'LL NOW USE
TO PRODUCE THE TILES.
57
00:03:42,655 --> 00:03:45,448
THEY MOUNT THE DIE
ON WHAT'S KNOWN AS A RAM PRESS
58
00:03:45,551 --> 00:03:48,758
BECAUSE IT LITERALLY RAMS
A BLOCK OF CLAY IN THE DIE
59
00:03:48,862 --> 00:03:51,965
AND COMPRESSES IT
WITH 30 TONS OF PRESSURE.
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00:03:54,448 --> 00:03:58,551
THE TILE DIE IS ALSO 11% LARGER
THAN THE FINAL SIZE
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00:03:58,655 --> 00:04:02,620
TO COMPENSATE FOR SHRINKAGE
DURING DRYING AND FIRING.
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00:04:02,724 --> 00:04:04,448
THEY REMOVE EXCESS CLAY
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00:04:04,551 --> 00:04:08,931
AND SEND IT BACK TO THE PUGMILL
TO BE RECYCLED.
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00:04:09,034 --> 00:04:11,379
THEN THEY POSITION A BOARD
UNDER THE DIE
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00:04:11,482 --> 00:04:13,448
AND ACTIVATE THE RELEASE SYSTEM,
66
00:04:13,551 --> 00:04:17,241
WHICH EXTRACTS THE CLAY
WITH A BLAST OF COMPRESSED AIR.
67
00:04:21,586 --> 00:04:24,793
THEY TRIM OFF THE EXCESS CLAY.
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00:04:28,344 --> 00:04:29,965
ONCE DRY,
69
00:04:30,068 --> 00:04:33,241
THE TILES AND MANTEL PIECES
ARE READY TO BE GLAZED.
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00:04:34,655 --> 00:04:36,344
GLAZE IS A CHEMICAL FORMULA
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00:04:36,448 --> 00:04:38,758
CONTAINING FINELY GROUND SILICA
72
00:04:38,862 --> 00:04:41,000
COMBINED
WITH DIFFERENT COMBINATIONS
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00:04:41,103 --> 00:04:45,034
OF METALLIC ELEMENTS
TO PRODUCE SPECIFIC COLORS.
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00:04:45,137 --> 00:04:46,448
THEY USE A SPRAY GUN
75
00:04:46,551 --> 00:04:50,068
TO APPLY GLAZE TO THE MANTELS
AND A TUBE TIP APPLICATOR
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00:04:50,172 --> 00:04:51,931
TO GLAZE THE TILES.
77
00:04:54,724 --> 00:04:58,620
THE TILES DESIGN HAS RAISED
BORDERS BETWEEN ITS COMPONENTS.
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00:04:58,724 --> 00:05:00,965
THESE ARE CALLED CUENCA LINES.
79
00:05:01,068 --> 00:05:02,793
THEY PREVENT THE DIFFERENT
COLORED GLAZES
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00:05:02,896 --> 00:05:05,241
FROM FLOWING INTO EACH OTHER.
81
00:05:10,758 --> 00:05:12,689
THE GLAZED MANTEL PIECE
AND TILES
82
00:05:12,793 --> 00:05:18,551
NOW GO INTO A GAS-FIRED KILN
FOR 12 TO 14 HOURS.
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00:05:18,655 --> 00:05:21,965
THE HIGH TEMPERATURE,
2,100 DEGREES FAHRENHEIT,
84
00:05:22,068 --> 00:05:23,931
TRIGGERS CHEMICAL REACTIONS
85
00:05:24,034 --> 00:05:25,965
WHICH HARDEN AND STRENGTHEN
THE PIECES.
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00:05:26,068 --> 00:05:29,000
THE CLAY'S MINERAL COMPOSITION
TRANSFORMS
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00:05:29,103 --> 00:05:31,206
INTO A COMPLETELY NEW
CONFIGURATION
88
00:05:31,310 --> 00:05:33,206
OF CRYSTALS AND GLASS.
89
00:05:33,310 --> 00:05:37,172
AS FOR THE GLAZE, ITS PRECISE
FORMULATION OF METALLIC ELEMENTS
90
00:05:37,275 --> 00:05:39,275
PRODUCES A SPECIFIC COLOR,
91
00:05:39,379 --> 00:05:41,827
AND THE SILICA MELTS
INTO A GLASS SURFACE.
92
00:05:41,931 --> 00:05:44,620
THE CERAMICS
ARE NOW SMOOTH AND SHINY
93
00:05:44,724 --> 00:05:47,965
AND READY TO TRANSFORM
AN OTHERWISE ORDINARY FIREPLACE
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00:05:48,068 --> 00:05:50,965
INTO A WORK OF ART.
95
00:06:00,413 --> 00:06:02,206
Narrator: MANY WINEMAKERS
CHOOSE TO SEAL THEIR BOTTLES
96
00:06:02,310 --> 00:06:05,827
WITH SYNTHETIC CLOSURES INSTEAD
OF NATURAL CORK FROM TREE BARK.
97
00:06:05,931 --> 00:06:07,586
THIS PREVENTS CORK TAINT,
98
00:06:07,689 --> 00:06:09,482
WHICH HAPPENS WHEN NATURAL CORK
99
00:06:09,586 --> 00:06:12,172
GETS CONTAMINATED
BY THE TCA MOLECULE.
100
00:06:12,275 --> 00:06:15,965
CORK TAINT IS COMPLETELY
HARMLESS TO HUMANS,
101
00:06:16,068 --> 00:06:18,620
BUT SPOILS THE TASTE
OF THE WINE.
102
00:06:20,689 --> 00:06:23,551
THIS ENGINEERED CORK
IS ENTIRELY SYNTHETIC
103
00:06:23,655 --> 00:06:27,448
AND THEREFORE RESISTANT
TO TCA CONTAMINATION.
104
00:06:27,551 --> 00:06:30,655
IT'S MADE OF A FOOD-GRADE
POLYETHYLENE FOAM CORE
105
00:06:30,758 --> 00:06:34,517
ENCASED
IN ELASTICIZED POLYMER SKIN.
106
00:06:34,620 --> 00:06:38,551
BOTH MATERIALS CONTRACT
TO SQUEEZE INSIDE THE BOTTLENECK
107
00:06:38,655 --> 00:06:40,172
BUT THEN REGAIN
THEIR ORIGINAL SHAPE
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00:06:40,275 --> 00:06:42,379
TO SEAL THE OPENING.
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00:06:42,482 --> 00:06:43,827
TO MAKE THE FOAM CORE,
110
00:06:43,931 --> 00:06:47,448
THEY MIX TALC WITH PELLETS
OF LOW DENSITY POLYETHYLENE,
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00:06:47,551 --> 00:06:49,931
A PLIABLE TYPE OF PLASTIC.
112
00:06:50,034 --> 00:06:52,896
THEN THEY ADD PELLETS
OF DARK BROWN AND BEIGE COLORANT
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00:06:53,000 --> 00:06:56,344
TO MIMIC THE WOOD GRAIN LOOK
OF NATURAL CORK.
114
00:06:58,034 --> 00:07:00,206
FOR EACH CUSTOMER'S
ORDER OF CORKS,
115
00:07:00,310 --> 00:07:03,241
A COMPUTERIZED SYSTEM
AUTOMATICALLY RELEASES
116
00:07:03,344 --> 00:07:05,482
THE RIGHT AMOUNT
OF EACH INGREDIENT
117
00:07:05,586 --> 00:07:08,034
INTO AN INDUSTRIAL BLENDER.
118
00:07:08,137 --> 00:07:12,275
THE BLENDER FEEDS A SPECIALLY
DESIGNED DUAL EXTRUSION MACHINE.
119
00:07:12,379 --> 00:07:15,758
THE MACHINE MELTS THE FOAM MIX
TO A LIQUID STATE
120
00:07:15,862 --> 00:07:18,206
THEN INJECTS CARBON DIOXIDE.
121
00:07:18,310 --> 00:07:19,724
THIS PRODUCES BUBBLES,
122
00:07:19,827 --> 00:07:23,517
WHICH CREATE THE CELLULAR
STRUCTURE OF THE FOAM.
123
00:07:23,620 --> 00:07:26,379
THE LIQUID FOAM ENTERS THE
MACHINE'S HORIZONTAL EXTRUDER,
124
00:07:26,482 --> 00:07:30,896
WHILE ELASTICIZED POLYMER ENTERS
THE MACHINE'S ANGLED EXTRUDER.
125
00:07:31,000 --> 00:07:32,310
BOTH EXTRUDERS
126
00:07:32,413 --> 00:07:35,103
SQUEEZE THEIR MATERIALS
THROUGH THE SAME SHAPING DIE,
127
00:07:35,206 --> 00:07:38,586
WHICH OUTPUTS A CONTINUOUS ROD
OF SKIN-ENCASED FOAM.
128
00:07:38,689 --> 00:07:42,448
THE FOAM CORE
IMMEDIATELY EXPANDS.
129
00:07:42,551 --> 00:07:44,620
THE ELASTIC SKIN
STRETCHES WITH IT.
130
00:07:44,724 --> 00:07:47,517
A WATER BATH COOLS THE ROD,
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00:07:47,620 --> 00:07:50,827
HALTING THIS EXPANSION
AT A SPECIFIC DIAMETER.
132
00:07:50,931 --> 00:07:53,034
THEN, AN UNDERWATER
ULTRASONIC GAUGE
133
00:07:53,137 --> 00:07:56,448
MEASURES THE THICKNESS
OF THE OUTER SKIN
134
00:07:56,551 --> 00:07:59,137
TO MAKE SURE
IT MEETS SPECIFICATIONS.
135
00:08:00,241 --> 00:08:03,034
THE ROD EXITS THE WATER BATH
136
00:08:03,137 --> 00:08:06,620
AND CONTINUES COOLING
AND SHRINKING AS IT DRIP DRIES.
137
00:08:08,931 --> 00:08:12,896
A LASER GAUGE THEN VERIFIES
THAT THE ROD IS PERFECTLY ROUND
138
00:08:13,000 --> 00:08:16,206
AND MEASURES A SPECIFIC DIAMETER
BY THIS POINT.
139
00:08:17,620 --> 00:08:19,000
WHEN ANY OF THE MEASURING GAUGES
140
00:08:19,103 --> 00:08:22,482
DETECTS AN AREA THAT DOESN'T
MEET SPECIFICATIONS,
141
00:08:22,586 --> 00:08:25,448
THAT PART OF THE ROD
IS FLAGGED IN THE SYSTEM
142
00:08:25,551 --> 00:08:28,689
AND IS DISCARDED AT THE END
OF THE PRODUCTION LINE.
143
00:08:31,862 --> 00:08:35,862
THE ROD NOW ENTERS
THE FINAL COOLING PHASE.
144
00:08:35,965 --> 00:08:40,344
IT TRAVELS IN SEVERAL LOOPS PAST
NOZZLES SPRAYING COLD WATER.
145
00:08:45,551 --> 00:08:49,172
AS THE ROD COOLS,
IT SHRINKS TO ITS FINAL SIZE,
146
00:08:49,275 --> 00:08:53,344
A DIAMETER OF BETWEEN
22 AND 23 MILLIMETERS.
147
00:08:53,448 --> 00:08:55,034
IT'S DESIGNED TO FIT SNUGLY
148
00:08:55,137 --> 00:08:59,275
INSIDE THE STANDARD
18.5-MILLIMETER BOTTLE OPENING.
149
00:09:02,034 --> 00:09:05,448
THEY HAD TO CALCULATE EXACTLY
HOW WIDE TO EXTRUDE THE ROD
150
00:09:05,551 --> 00:09:08,310
SO THAT AFTER EXPANSION
THEN SHRINKAGE,
151
00:09:08,413 --> 00:09:11,344
IT WOULD END UP
AT THIS PRECISE DIAMETER.
152
00:09:13,586 --> 00:09:15,655
THE ROD NOW ENTERS A CUTTER.
153
00:09:15,758 --> 00:09:19,206
THE BLADE IS SO SHARP THAT
A SAFETY COVER IS MANDATORY.
154
00:09:19,310 --> 00:09:22,000
IT'S REMOVED HERE
ONLY FOR THE CAMERA.
155
00:09:27,896 --> 00:09:32,000
THE WINERY PLACING THE ORDER
SPECIFIES THE CORK LENGTH.
156
00:09:32,103 --> 00:09:34,586
AIR JETS AUTOMATICALLY BLOW OFF
ANY CORKS
157
00:09:34,689 --> 00:09:37,379
CUT FROM AREAS
THE MEASURING GAUGES FLAGGED
158
00:09:37,482 --> 00:09:38,758
AS BEING PROBLEMATIC.
159
00:09:41,862 --> 00:09:44,758
THE CUTTER SLICES
ABOUT 10 STANDARD-LENGTH CORKS
160
00:09:44,862 --> 00:09:46,620
PER SECOND.
161
00:09:51,965 --> 00:09:54,448
ALL THE GOOD CORKS
LAND ON THE CONVEYOR BELT
162
00:09:54,551 --> 00:09:56,379
AND TRAVEL
TO THE END OF THE LINE,
163
00:09:56,482 --> 00:09:58,586
WHERE COMPUTER SENSORS
COUNT THEM
164
00:09:58,689 --> 00:10:01,000
AS THEY DROP
INTO A COLLECTION BIN.
165
00:10:03,344 --> 00:10:06,896
ADDITIONAL MACHINES PRINT
ON THE WINERY'S NAME AND LOGO,
166
00:10:07,000 --> 00:10:09,931
AND LUBRICATE THE SURFACE
WITH SILICONE
167
00:10:10,034 --> 00:10:13,482
SO THE CORKS WILL GLIDE IN
AND OUT OF THE BOTTLE WITH EASE.
168
00:10:18,965 --> 00:10:23,068
THE FACTORY'S ON-SITE LAB
TESTS SAMPLES FROM EVERY ORDER.
169
00:10:24,206 --> 00:10:26,965
SENSORY SPECIALISTS
SNIFF EACH CORK
170
00:10:27,068 --> 00:10:30,310
AND COMPARE IT
TO A CONTROL SAMPLE.
171
00:10:30,413 --> 00:10:32,206
THERE MUST BE
NO DISCERNIBLE ODOR
172
00:10:32,310 --> 00:10:36,103
THAT MIGHT AFFECT THE AROMA
OR FLAVOR OF THE WINE.
173
00:10:36,206 --> 00:10:40,551
IF THERE IS, THE ENTIRE ORDER
OF CORKS FAILS INSPECTION.
174
00:10:42,827 --> 00:10:46,103
WHILE NATURAL CORK
IS DESIGNED BY MOTHER NATURE,
175
00:10:46,206 --> 00:10:49,241
A SYNTHETIC CORK MANUFACTURER
CAN ENGINEER THE CLOSURE
176
00:10:49,344 --> 00:10:52,827
TO FIT MORE OR LESS SNUGLY
ACCORDING TO THE AMOUNT OF AIR
177
00:10:52,931 --> 00:10:56,586
THE PARTICULAR WINE NEEDS
TO DEVELOP CORRECTLY.
178
00:11:08,206 --> 00:11:10,862
Narrator:
MULTI-TIERED PARKING GARAGES
179
00:11:10,965 --> 00:11:13,241
HAVE BECOME AN URBAN PHENOMENON.
180
00:11:13,344 --> 00:11:16,000
WITH EACH FLOOR
ADDED TO THE GARAGE
181
00:11:16,103 --> 00:11:19,724
THE NUMBER OF PARKING SPACES
INCREASES.
182
00:11:19,827 --> 00:11:22,068
IN CROWDED CITIES
WHERE LAND IS LIMITED,
183
00:11:22,172 --> 00:11:25,172
GARAGES LIKE THESE
ARE A NECESSITY.
184
00:11:29,724 --> 00:11:33,827
THEY BUILD PARKING GARAGES
ONE CONCRETE SLAB AT A TIME.
185
00:11:33,931 --> 00:11:36,206
THESE SLABS ARE KNOWN
AS DOUBLE-T's
186
00:11:36,310 --> 00:11:40,896
BECAUSE THE TWO SUPPORT BEAMS
ARE IN A DOUBLE-T CONFIGURATION.
187
00:11:41,000 --> 00:11:43,551
DOUBLE-T'S ARE OFTEN
FACTORY MADE
188
00:11:43,655 --> 00:11:46,448
AND TRANSPORTED
TO THE CONSTRUCTION SITE LATER.
189
00:11:46,551 --> 00:11:50,034
THEY ARE DESIGNED TO HOLD UP
UNDER VERY HEAVY LOADS.
190
00:11:51,517 --> 00:11:54,241
THEY MAKE THESE SLABS OUTDOORS.
191
00:11:54,344 --> 00:11:58,344
WIND BLOWS DIRT ONTO THE MOLDS,
SO THEY SWEEP IT CLEAN.
192
00:11:58,448 --> 00:12:01,034
THIS MOLD IS ABOUT 500 FEET LONG
193
00:12:01,137 --> 00:12:05,241
AND WILL BE USED
TO MAKE SEVERAL SLABS.
194
00:12:05,344 --> 00:12:08,448
THEY SPRAY AN OIL-BASED
RELEASE AGENT ONTO IT.
195
00:12:08,551 --> 00:12:11,931
THE RELEASE AGENT WILL ALLOW
THE SLABS TO BE EASILY EXTRACTED
196
00:12:12,034 --> 00:12:14,793
WHEN COMPLETE,
PREVENTING CRACKING.
197
00:12:14,896 --> 00:12:18,551
THEY SPREAD IT MORE EVENLY
USING MOPS.
198
00:12:18,655 --> 00:12:21,758
THIS RELEASE AGENT BONDS
TO THE METAL QUICKLY
199
00:12:21,862 --> 00:12:25,241
AND WON'T WASH OFF EASILY
IF IT HAPPENS TO RAIN.
200
00:12:27,896 --> 00:12:29,206
THEY'RE NOW READY TO ASSEMBLE
201
00:12:29,310 --> 00:12:32,620
THE FLOOR SLAB'S ELABORATE
SUPPORT STRUCTURE.
202
00:12:33,793 --> 00:12:35,862
THEY PROP UP THE ENDS
OF EACH SLAB
203
00:12:35,965 --> 00:12:38,241
WITH GALVANIZED STEEL STIRRUPS.
204
00:12:42,310 --> 00:12:45,344
THEY PLACE L-SHAPED
BEARING PLATES
205
00:12:45,448 --> 00:12:48,448
IN STRATEGIC LOCATIONS
ALONG THE MOLD.
206
00:12:51,931 --> 00:12:55,034
THEN THEY INSERT WOODEN BLOCKS
IN THE MOLD.
207
00:12:55,137 --> 00:12:58,586
THESE BLOCKS WILL FORM NOTCHES
IN THE CAST CONCRETE
208
00:12:58,689 --> 00:13:02,379
THAT WILL BE USED TO JOIN
THE SLABS DURING CONSTRUCTION.
209
00:13:04,827 --> 00:13:07,724
NEXT, WORKERS THREAD
HIGH-STRENGTH STEEL CABLES
210
00:13:07,827 --> 00:13:11,206
CALLED TENDONS THROUGHOUT
THE BEAM SECTIONS OF THE MOLD.
211
00:13:11,310 --> 00:13:15,517
THEY PULL THE ENDS THROUGH HOLES
TO THE OUTSIDE OF THE MOLD
212
00:13:15,620 --> 00:13:17,172
AND CLAMP THEM.
213
00:13:20,724 --> 00:13:24,896
A WORKER TUCKS ANOTHER WOOD
BLOCK BETWEEN TWO TENDONS
214
00:13:25,000 --> 00:13:26,344
TO COMPLETE THE NOTCH PART
OF THE MOLD
215
00:13:26,448 --> 00:13:28,931
AND HOLD THE TENDONS IN PLACE.
216
00:13:30,655 --> 00:13:33,103
THE TEAM THREADS MORE TENDONS
THROUGHOUT THE MOLD,
217
00:13:33,206 --> 00:13:36,620
WEAVING
A STRATEGIC SUPPORT STRUCTURE.
218
00:13:41,551 --> 00:13:45,413
TO SEPARATE EACH CAST SLAB,
THEY INSERT WOODEN DIVIDERS
219
00:13:45,517 --> 00:13:48,172
WITH SLOTS
THAT ACCOMMODATE THE TENDONS.
220
00:13:53,310 --> 00:13:56,034
THEY ADJUST THE LOCATION
OF EACH OF THE STIRRUPS
221
00:13:56,137 --> 00:14:00,000
SO THAT THEY SIT AT A SPECIFIC
SPOT NEAR THE DIVIDERS.
222
00:14:07,379 --> 00:14:12,172
WITH THE FINAL TENDONS IN PLACE,
THEY BRING IN A HYDRAULIC JACK.
223
00:14:15,379 --> 00:14:19,517
THE WORKER ATTACHES IT TO ONE
OF THE PROTRUDING STEEL TENDONS.
224
00:14:22,586 --> 00:14:25,482
HE ACTIVATES THE JACK,
AND IT PULLS THE TENDON
225
00:14:25,586 --> 00:14:27,827
UNTIL IT'S STRETCHED TIGHT
LIKE A RUBBER BAND.
226
00:14:31,551 --> 00:14:34,793
HE PULLS THE REST OF THE TENDONS
WITH THE JACK
227
00:14:34,896 --> 00:14:36,758
AND CHECKS THE TENSION
TO CONFIRM
228
00:14:36,862 --> 00:14:39,793
THAT IT'S EXACTLY THE SAME
FOR EACH ONE.
229
00:14:42,655 --> 00:14:44,724
PULLED TIGHT AND LATER RELEASED,
230
00:14:44,827 --> 00:14:47,482
THE CABLES WILL HOLD
THE CONCRETE UNDER COMPRESSION,
231
00:14:47,586 --> 00:14:49,379
ADDING STRENGTH TO IT.
232
00:14:53,310 --> 00:14:55,517
WITHOUT IT, THE CONCRETE SLABS
233
00:14:55,620 --> 00:15:00,206
WOULD NEVER BE ABLE TO SUPPORT
THE WEIGHT OF MANY VEHICLES.
234
00:15:00,310 --> 00:15:03,620
THE NEXT WORKER TIES A PLASTIC
BRACKET TO THE STIRRUPS
235
00:15:03,724 --> 00:15:05,724
TO SET THEM AT THE RIGHT HEIGHT.
236
00:15:10,241 --> 00:15:12,931
HE INSERTS METAL MESH
INTO THE MOLD
237
00:15:13,034 --> 00:15:15,137
WHERE EACH SLAB WILL END.
238
00:15:15,241 --> 00:15:16,896
THIS WILL HELP DISPERSE
239
00:15:17,000 --> 00:15:20,310
SOME OF THE CONCENTRATED
BEARING STRESSES.
240
00:15:20,413 --> 00:15:22,310
HE STABILIZES THE MESH,
241
00:15:22,413 --> 00:15:25,137
AND REINFORCES IT
WITH THE SUPPORT STRUCTURE.
242
00:15:30,586 --> 00:15:32,620
THE TEAM PLACES PLASTIC POCKETS
243
00:15:32,724 --> 00:15:35,793
ALONG THE TOPS OF THE BEAM
SECTIONS OF THE MOLD.
244
00:15:38,413 --> 00:15:41,241
THESE POCKETS WILL BE USED
TO CHAIN THE SLAB TO THE TRUCK
245
00:15:41,344 --> 00:15:43,620
DURING TRANSPORT.
246
00:15:43,724 --> 00:15:46,724
THEY'LL ALSO ACT AS ENTRY POINTS
FOR ELECTRICAL WIRING
247
00:15:46,827 --> 00:15:50,448
AND HOLD CONTROLS FOR PARKING
SPACE COUNTING EQUIPMENT.
248
00:15:55,551 --> 00:15:56,931
COMING UP NEXT,
249
00:15:57,034 --> 00:15:59,931
THE DECK SECTION
GETS PLENTY OF EXTRA SUPPORT,
250
00:16:00,034 --> 00:16:02,586
AND THEN IT'S SET IN CONCRETE.
251
00:16:16,310 --> 00:16:18,172
Narrator: THE AVERAGE CAR
WEIGHS WELL OVER 2,000 POUNDS,
252
00:16:18,275 --> 00:16:19,862
SO EACH PARKING GARAGE FLOOR
253
00:16:19,965 --> 00:16:21,862
MUST HOLD UP
MANY TIMES THAT WEIGHT.
254
00:16:21,965 --> 00:16:24,620
DOUBLE-T CONCRETE SLABS
MAKE THIS POSSIBLE.
255
00:16:24,724 --> 00:16:27,379
EACH SLAB
HAS TWO REINFORCING BEAMS,
256
00:16:27,482 --> 00:16:30,000
AND EACH BEAM
HAS A TENSE STEEL SKELETON
257
00:16:30,103 --> 00:16:33,551
THAT COMPRESSES THE CONCRETE,
MAKING IT STRONGER.
258
00:16:36,793 --> 00:16:37,931
WITH THE STEEL TENDONS
259
00:16:38,034 --> 00:16:40,137
STRETCHED THROUGH THE BEAM PARTS
OF THE MOLD,
260
00:16:40,241 --> 00:16:43,862
WORKERS NOW LAY METAL MESH
ACROSS THE DECK.
261
00:16:43,965 --> 00:16:47,241
THIS MESH IS KNOWN
AS WELDED WIRE FABRIC,
262
00:16:47,344 --> 00:16:50,896
AND IT WILL REINFORCE
THE SURFACE OF THE PARKING SLAB.
263
00:16:53,241 --> 00:16:56,103
THEY TIE THE WELDED WIRE
TOGETHER
264
00:16:56,206 --> 00:16:58,758
FOR FULL COVERAGE
ACROSS THE DECK.
265
00:17:01,000 --> 00:17:04,206
THEY USE PLASTIC CLIPS
TO PROP UP THE WIRE
266
00:17:04,310 --> 00:17:05,620
SO THAT WHEN THEY
POUR THE CONCRETE,
267
00:17:05,724 --> 00:17:08,068
IT WILL ENVELOP BOTH SIDES.
268
00:17:09,931 --> 00:17:11,724
THEY INSERT HANDLES
269
00:17:11,827 --> 00:17:14,379
THAT WILL PROTRUDE FROM THE ENDS
OF THE COMPLETED SLAB
270
00:17:14,482 --> 00:17:18,068
TO ALLOW IT TO BE LIFTED
FOR TRANSPORT AND INSTALLATION.
271
00:17:18,172 --> 00:17:23,000
THERE ARE FOUR DOUBLE HANDLES
IN EACH PARKING FLOOR SLAB.
272
00:17:25,448 --> 00:17:30,517
THEY ENMESH THE PRONGS OF WELD
PLATES IN THE STEEL GRID.
273
00:17:30,620 --> 00:17:32,862
THE PLATES
ARE STRATEGICALLY POSITIONED
274
00:17:32,965 --> 00:17:36,689
FOR THE WELDING OF THE SLAB
TO OTHER PIECES OF CONCRETE.
275
00:17:38,620 --> 00:17:41,551
ALL THE PREP WORK
IS FINALLY DONE,
276
00:17:41,655 --> 00:17:43,758
AND THEY POUR THE CONCRETE.
277
00:17:45,896 --> 00:17:49,620
THE CONCRETE FLOWS INTO THE BEAM
SECTIONS OF THE MOLD FIRST,
278
00:17:49,724 --> 00:17:53,379
AND THEN WORKERS SPREAD
THE OVERFLOW ACROSS THE DECK.
279
00:17:53,482 --> 00:17:55,517
THIS IS A HIGH-PERFORMANCE
FORMULA
280
00:17:55,620 --> 00:17:59,724
THAT'S KNOWN IN THE INDUSTRY
AS SELF-CONSOLIDATING CONCRETE.
281
00:17:59,827 --> 00:18:02,482
IT FLOWS EVENLY
INTO TIGHT SPACES
282
00:18:02,586 --> 00:18:06,965
AND COMPACTS BETTER WITHOUT
THE NEED FOR MUCH VIBRATING.
283
00:18:07,068 --> 00:18:09,827
THIS LEVELER VIBRATES
THE SURFACE OF THE CONCRETE
284
00:18:09,931 --> 00:18:12,758
ONLY SLIGHTLY
AS IT EVENS IT OUT.
285
00:18:15,931 --> 00:18:18,172
THEY THEN RAKE THE SURFACE
OF THE SLAB
286
00:18:18,275 --> 00:18:21,034
TO ALLOW ANOTHER LAYER
OF CONCRETE TO ADHERE TO IT
287
00:18:21,137 --> 00:18:23,068
LATER DURING CONSTRUCTION.
288
00:18:28,103 --> 00:18:30,000
THEY NOW INSERT ARCED METAL BARS
289
00:18:30,103 --> 00:18:32,448
INTO SLOTS
ON THE SIDES OF THE MOLD
290
00:18:32,551 --> 00:18:35,655
TO FORM A RIBBED FRAMEWORK
DOWN THE LENGTH OF IT.
291
00:18:37,620 --> 00:18:40,586
THIS SERVES AS A SUPPORT
STRUCTURE FOR A TENT.
292
00:18:40,689 --> 00:18:42,793
THEY UNROLL THE TARP
FROM A HUGE SPOOL
293
00:18:42,896 --> 00:18:44,827
AND DRAPE IT OVER THE RIBBING.
294
00:18:49,965 --> 00:18:52,551
THEY SECURE THE CANVAS
TO THE SIDES OF THE MOLD
295
00:18:52,655 --> 00:18:54,413
WITH HOOKS.
296
00:18:56,206 --> 00:18:58,241
THE TENT WILL SHELTER
THE CONCRETE
297
00:18:58,344 --> 00:19:00,827
FROM THE WIND AND RAIN
AS IT CURES.
298
00:19:03,413 --> 00:19:05,655
ALONG WITH AN ADDITIONAL
PLASTIC LAYER,
299
00:19:05,758 --> 00:19:09,620
IT WILL CONTAIN THE HOT AND
HUMID CONDITIONS CREATED INSIDE.
300
00:19:09,724 --> 00:19:12,482
THE HEAT ACCELERATES THE CURING
OF THE CONCRETE,
301
00:19:12,586 --> 00:19:16,310
AND THE HUMIDITY
PREVENTS CRACKING.
302
00:19:16,413 --> 00:19:20,896
THE CURE TAKES 16 HOURS,
AND THEN THEY ROLL UP THE TARP.
303
00:19:24,482 --> 00:19:27,310
USING A TORCH,
THEY CUT THE STEEL TENDONS
304
00:19:27,413 --> 00:19:30,793
AND PLACE THE CONCRETE
UNDER COMPRESSION.
305
00:19:30,896 --> 00:19:34,068
THE CUTS
ALSO SEPARATE THE SLABS.
306
00:19:35,758 --> 00:19:39,482
A DRIVER NOW PARKS HIS CRANE
OVER ONE OF THE SLABS.
307
00:19:42,241 --> 00:19:44,275
WORKERS ATTACH THE HOOKS
OF THE CRANE
308
00:19:44,379 --> 00:19:47,689
TO THE PROTRUDING HANDLES
AT THE ENDS OF THE SLAB.
309
00:19:50,241 --> 00:19:54,482
THEY SIGNAL THE CRANE OPERATOR,
AND HE ACTIVATES THE LIFT.
310
00:19:54,586 --> 00:19:56,862
THANKS TO THE RELEASE AGENT
APPLIED EARLIER,
311
00:19:56,965 --> 00:20:00,310
THE CONCRETE SLAB
EASILY DISLODGES FROM THE MOLD.
312
00:20:00,413 --> 00:20:01,827
IT'S A HEAVY LOAD.
313
00:20:01,931 --> 00:20:04,517
EACH SLAB WEIGHS 40,000 POUNDS.
314
00:20:07,034 --> 00:20:09,275
THE CRANE SETS IT DOWN
315
00:20:09,379 --> 00:20:12,551
AND THE TEAM INSPECTS THE SLAB
FOR DEFECTS.
316
00:20:15,310 --> 00:20:18,172
SATISFIED THAT THE SLAB
IS FREE OF FLAWS,
317
00:20:18,275 --> 00:20:20,620
A WORKER TRIMS
THE PROTRUDING STEEL TENDONS
318
00:20:20,724 --> 00:20:22,689
FLUSH TO THE CONCRETE.
319
00:20:25,689 --> 00:20:28,448
ANOTHER WORKER
SPREADS A CONCRETE-LIKE PASTE
320
00:20:28,551 --> 00:20:31,034
ON THE EXPOSED ENDS
OF THE SEVERED STEEL
321
00:20:31,137 --> 00:20:33,206
TO SEAL IT FROM THE ELEMENTS.
322
00:20:38,689 --> 00:20:43,172
THEN A WORKER GLUES RUBBER PADS
TO THE BEARING PLATES.
323
00:20:43,275 --> 00:20:44,448
THEY'LL ACT AS CUSHIONS
324
00:20:44,551 --> 00:20:47,000
WHEN THE SLAB SITS
ON ANOTHER CONCRETE BEAM.
325
00:20:47,103 --> 00:20:51,689
HE WRAPS SOME TAPE AROUND THEM
WHILE THE ADHESIVE SETS.
326
00:20:54,758 --> 00:20:59,620
THIS PARKING GARAGE FLOOR SLAB
IS NOW READY TO JOIN THE REST.
327
00:20:59,724 --> 00:21:00,931
SIDE-BY-SIDE,
328
00:21:01,034 --> 00:21:04,103
THE SLABS WILL FORM
ONE LARGE PARKING SURFACE
329
00:21:04,206 --> 00:21:06,827
TO CREATE EVEN MORE SPACES.
26788
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