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--Captions by VITAC--
www.vitac.com
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00:00:04,793 --> 00:00:07,758
CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
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00:00:52,827 --> 00:00:55,586
Narrator: MOST EXPERTS
WILL TELL YOU THAT THE KEY
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00:00:55,586 --> 00:00:58,310
TO THE PERFECT PAINT JOB
OR WOOD-REFINISHING JOB
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00:00:58,310 --> 00:01:00,034
IS TO PREP THE SURFACE PROPERLY
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00:01:00,034 --> 00:01:03,000
BEFORE APPLYING THE PAINT
OR WOOD STAIN.
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THAT REQUIRES SANDING
TO REMOVE OLD FINISHES
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00:01:06,034 --> 00:01:08,034
AND TO LEVEL UNEVEN AREAS.
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THE EASIEST WAY TO DO THAT
IS WITH A MOTORIZED SANDER.
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00:01:14,000 --> 00:01:17,482
PROFESSIONAL-CALIBER SANDERS
ARE TYPICALLY PNEUMATIC,
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00:01:17,482 --> 00:01:20,551
MEANING YOU PLUG THEM
INTO AN AIR COMPRESSOR.
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00:01:20,551 --> 00:01:23,413
AIR-DRIVEN TOOLS ARE MORE
POWERFUL THAN TOOLS
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00:01:23,413 --> 00:01:25,034
THAN RUN ON ELECTRICITY.
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THIS TYPE OF SANDER IS CALLED
A STRAIGHT LINE,
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00:01:28,034 --> 00:01:30,793
BECAUSE THE PAD
TO WHICH YOU ATTACH SANDPAPER
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MOVES IN A STRAIGHT LINE
BACK AND FORTH.
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00:01:33,310 --> 00:01:36,689
MANY OF THE TOOL'S COMPONENTS
ARE MADE OF POWDERED METAL,
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THEN MACHINED
TO EXACT DIMENSIONS
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00:01:39,172 --> 00:01:41,103
ON A COMPUTER-GUIDED LATHE.
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POWDERED METAL IS IRON POWDER
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00:01:42,896 --> 00:01:45,172
THAT'S COMPACTED
WITH HIGH PRESSURE
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AND HEATED IN A FURNACE TO BOND
THE PARTICLES INTO A SOLID PART.
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00:01:49,137 --> 00:01:52,413
SOMETIMES THEY FURTHER
STRENGTHEN THE POWDERED METAL
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00:01:52,413 --> 00:01:56,310
BY INFUSING IT WITH COPPER
IN THE FURNACE.
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00:01:56,310 --> 00:01:58,068
USING AN INDUCTION WELDER,
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00:01:58,068 --> 00:02:00,689
WHICH HEATS THE METAL
WITH AN ELECTRIC CURRENT,
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00:02:00,689 --> 00:02:03,965
THEY FUSE A POWDERED-METAL GEAR
TO EACH END OF A STEEL SHAFT
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00:02:03,965 --> 00:02:07,206
BY MELTING ON SILVER.
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00:02:07,206 --> 00:02:10,034
THIS CONSTRUCTS THE SANDER'S
TIMING DRIVESHAFT,
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00:02:10,034 --> 00:02:11,724
THE REGULATING COMPONENT
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THAT MAKES EACH STROKE
OF THE SANDING PAD
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JUST UNDER AN INCH LONG.
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00:02:17,482 --> 00:02:19,931
HEATING THE METAL SOFTENS IT,
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00:02:19,931 --> 00:02:23,862
SO THEY NOW COOL THE TIMING
DRIVESHAFT IN OIL.
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00:02:23,862 --> 00:02:26,655
THIS QUENCHING HARDENS
THE COMPONENT.
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00:02:26,655 --> 00:02:30,310
MEANWHILE, THEY COAT
A SHEET OF ALUMINUM RECTANGLES
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WITH INDUSTRIAL-STRENGTH
CONTACT ADHESIVE.
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EACH RECTANGLE IS A BASE
FOR A RUBBER SANDING PAD.
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00:02:36,965 --> 00:02:41,655
THE RECTANGULAR PAD, WHICH THEY
COAT WITH THE SAME ADHESIVE,
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IS 6 1/2 MILLIMETERS THICK,
THE SAME DIMENSIONS AS THE BASE
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WITH IDENTICAL HOLES
FOR THE MOUNTING SCREWS.
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ONCE THE ADHESIVE BECOMES TACKY,
THEY MATE THE BASE TO THE PAD.
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00:02:54,068 --> 00:02:56,137
USING A SMALL PNEUMATIC PRESS,
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THEY FORCE OUT TRAPPED AIR
TO ENSURE A THOROUGH BOND.
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ELSEWHERE IN THE FACTORY,
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THEY PAINT
THE RECESSED LETTERING
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OF THE POLISHED ALUMINUM PLATES,
TWO PER SANDER,
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WHICH BEAR
THE MANUFACTURER'S NAME.
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00:03:17,379 --> 00:03:19,827
ONCE ALL THE REMAINING
COMPONENTS ARE PREPARED,
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TECHNICIANS BEGIN THE ASSEMBLY.
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FIRST, THE MOTOR'S PISTON.
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THEY PLACE THE PISTON RACK
IN AN ARBOR PRESS
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00:03:28,689 --> 00:03:31,827
AND PUSH A PLASTIC PIECE
ONTO EACH END.
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00:03:31,827 --> 00:03:35,620
THEN, ON EACH END PIECE,
THEY MOUNT A PISTON RING
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MADE OF A PROPRIETARY
WEAR-RESISTANT MATERIAL.
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THEY INSERT
THE NOW-ASSEMBLED PISTON
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INTO THE SANDER'S
ALUMINUM MOTOR BLOCK.
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THE RING CREATES A TIGHT SEAL
TO PREVENT AIR LEAKAGE.
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00:03:48,896 --> 00:03:53,034
NEXT, A TECHNICIAN INSTALLS
THE TIMING DRIVESHAFT
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00:03:53,034 --> 00:03:54,758
AND THE IDLER GEAR SHAFT,
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00:03:54,758 --> 00:03:58,448
PRESSING THE GEARS OF BOTH
INTO THE PISTON RACK'S TEETH.
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00:03:58,448 --> 00:04:02,137
THE POWDERED-METAL COUNTERWEIGHT
GOES ON EACH SIDE
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00:04:02,137 --> 00:04:04,103
TO BALANCE THE PISTON RACK,
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00:04:04,103 --> 00:04:07,448
THEN GUIDES MADE OF THAT
PROPRIETARY MATERIAL
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TO ALIGN AND LUBRICATE
THE COUNTERWEIGHTS.
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00:04:13,724 --> 00:04:15,620
A SECOND SET OF ANTI-WEAR GUIDES
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00:04:15,620 --> 00:04:18,241
GOES IN THE LOWER PART
OF THE MOTOR BLOCK.
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00:04:18,241 --> 00:04:21,344
THESE HELP BALANCE
THE SANDING PAD.
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00:04:23,344 --> 00:04:25,724
THEN THE START
OF THE VALVE SYSTEM,
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00:04:25,724 --> 00:04:29,413
WHICH CONTROLS THE ENTRY OF
COMPRESSED AIR INTO THE SANDER.
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00:04:29,413 --> 00:04:31,413
AT THE FRONT OF THE MOTOR BLOCK,
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00:04:31,413 --> 00:04:34,793
THEY INSTALL A PAPER GASKET
TO PREVENT AIR LEAKAGE,
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00:04:34,793 --> 00:04:37,517
THEN SEAL IT
WITH AN ALUMINUM END PLATE.
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00:04:37,517 --> 00:04:40,068
CONTINUING WITH
THE VALVE SYSTEM,
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00:04:40,068 --> 00:04:41,758
THEY INSTALL THE COMPONENTS,
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00:04:41,758 --> 00:04:45,379
WHICH CONTROL THE TIMING OF THE
PISTONS' BACK-AND-FORTH MOTION.
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00:04:45,379 --> 00:04:47,793
AFTER SEALING THE TOP
WITH A CAP,
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00:04:47,793 --> 00:04:51,137
THEY INSTALL THE AIR-VALVE
BLOCK, THEN THE HANDLE,
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00:04:51,137 --> 00:04:52,655
WHICH CONTAINS THE INLET
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00:04:52,655 --> 00:04:55,034
TO WHICH THE AIR COMPRESSOR
CONNECTS.
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00:04:55,034 --> 00:04:56,482
THE HANDLE SQUEEZE TRIGGER
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00:04:56,482 --> 00:04:58,689
IS MOUNTED TO THE CAP
ABOVE THE HANDLE.
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00:05:01,034 --> 00:05:04,137
THEY INSTALL THE COUNTERWEIGHT
FOR THE PAD.
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00:05:07,344 --> 00:05:11,517
HERE, YOU CAN SEE THE TWO SHAFTS
THE PISTON RACK ROTATES.
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00:05:11,517 --> 00:05:15,103
WORKERS CONNECT THEM
TO AN ALUMINUM DRIVE SHOE,
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00:05:15,103 --> 00:05:17,448
WHICH WILL MOVE BACK AND FORTH.
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00:05:17,448 --> 00:05:21,137
A PAIR OF SIDE RAILS HOLDS
THE DRIVE SHOE IN PLACE.
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00:05:21,137 --> 00:05:23,896
WHERE THE AIR EXITS THE TOOL,
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00:05:23,896 --> 00:05:26,344
THEY INSTALL A MUFFLER MADE
OF POROUS PLASTIC.
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00:05:29,000 --> 00:05:30,689
FINALLY, WHEN THE TECHNICIAN
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00:05:30,689 --> 00:05:32,793
SCREWS THE BASE
TO THE DRIVE SHOE,
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THE CHAIN IS COMPLETE.
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COMPRESSED AIR MOVES THE PISTON,
WHICH ROTATES THE SHAFTS,
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WHICH MOVES THE DRIVE SHOE
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00:05:40,827 --> 00:05:43,689
HOLDING THE RUBBER PAD
WITH SANDPAPER.
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00:05:43,689 --> 00:05:46,724
THIS PNEUMATIC SANDER
IS READY TO LEVEL
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00:05:46,724 --> 00:05:49,586
AND SMOOTH A SURFACE
IN SECONDS FLAT.
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00:06:01,827 --> 00:06:04,758
Narrator: A SOLID TERRAIN MODEL,
"STM" FOR SHORT,
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00:06:04,758 --> 00:06:07,586
IS AN EXACT, THREE-DIMENSIONAL,
MINIATURE REPLICA
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00:06:07,586 --> 00:06:09,034
OF A GEOGRAPHIC AREA.
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00:06:09,034 --> 00:06:13,620
STMs ARE INDISPENSABLE TOOLS
FOR MUSEUMS, VISITOR CENTERS,
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00:06:13,620 --> 00:06:17,275
AND FOR PLANNING EVERYTHING
FROM INDUSTRIAL PROJECTS
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00:06:17,275 --> 00:06:18,931
TO MILITARY OPERATIONS.
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00:06:22,103 --> 00:06:24,310
TO CREATE A SOLID TERRAIN MODEL,
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00:06:24,310 --> 00:06:28,379
THE FIRST STEP IS TO GATHER DATA
VIA SATELLITES AND AIRCRAFT.
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00:06:28,379 --> 00:06:32,137
TWO TYPES OF DATA --
COLOR PHOTOGRAPHS OF THE SURFACE
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00:06:32,137 --> 00:06:36,241
SHOWING THE PRECISE LOCATION
OF VEGETATION, ROCK, BUILDINGS,
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00:06:36,241 --> 00:06:39,068
AND SO ON,
AND ELEVATION MEASUREMENTS,
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00:06:39,068 --> 00:06:41,827
TAKEN WITH LASERS
AND OTHER EQUIPMENT.
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00:06:41,827 --> 00:06:44,137
A CARTOGRAPHER DIGITALLY MERGES
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00:06:44,137 --> 00:06:48,068
THE BLACK AND WHITE ELEVATION
DIAGRAMS WITH THE COLOR PHOTOS
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00:06:48,068 --> 00:06:51,517
AND ADDS ARTWORK FOR ROADS
AND PLACE NAMES.
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00:06:51,517 --> 00:06:55,034
HE PRODUCES A 3-D COMPUTER MODEL
OF THE AREA.
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00:06:55,034 --> 00:06:57,551
THIS MODEL WILL GUIDE
THE MACHINES
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00:06:57,551 --> 00:07:00,103
THAT MANUFACTURE
THE PHYSICAL MODEL
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00:07:00,103 --> 00:07:02,793
OUT OF A BLOCK
OF POLYURETHANE FOAM.
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00:07:02,793 --> 00:07:05,620
FOAM IS A DURABLE MATERIAL
AND LIGHTWEIGHT,
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00:07:05,620 --> 00:07:08,068
MAKING THE MODEL EASY
TO TRANSPORT.
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00:07:08,068 --> 00:07:11,482
A COMPUTER-GUIDED CUTTING
MACHINE FIRST SHAPES A LEDGE
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00:07:11,482 --> 00:07:13,551
AROUND THE BLOCK'S PERIMETER.
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00:07:13,551 --> 00:07:16,620
THIS IS FOR MOUNTING
THE MODEL ON A FRAME.
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00:07:16,620 --> 00:07:20,413
THEN THE MACHINE READS THE
COMPUTER MODEL'S ELEVATION FILES
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00:07:20,413 --> 00:07:24,241
AND CARVES A MINIATURE REPLICA
OF THOSE ELEVATIONS INTO FOAM.
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00:07:24,241 --> 00:07:28,758
THE MACHINE FIRST DOES
A ROUGH CUT.
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00:07:28,758 --> 00:07:32,758
THEN --
AND THIS TAKES MUCH LONGER --
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00:07:32,758 --> 00:07:35,482
IT CARVES THE FINE DETAILS.
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00:07:35,482 --> 00:07:37,896
DEPENDING ON THE COMPLEXITY
OF THE TERRAIN,
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00:07:37,896 --> 00:07:39,965
CUTTING THE ELEVATIONS
INTO THE FOAM
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00:07:39,965 --> 00:07:43,034
CAN TAKE JUST A FEW HOURS
OR SEVERAL DAYS.
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00:07:43,034 --> 00:07:45,034
WHEN THE CUTTING'S FINISHED,
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00:07:45,034 --> 00:07:47,965
THE TECHNICIAN CLEANS OFF
THE FOAM DUST
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00:07:47,965 --> 00:07:50,172
WITH COMPRESSED AIR AND A BRUSH.
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00:07:54,379 --> 00:07:56,344
THE FOAM GOES INTO A SPRAY BOOTH
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00:07:56,344 --> 00:07:58,965
WHERE IT FIRST RECEIVES
A COAT OF PRIMER
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00:07:58,965 --> 00:08:00,827
TO SEAL THE POROUS SURFACE,
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00:08:00,827 --> 00:08:03,724
THEN MULTIPLE LAYERS
OF SPECIAL COATINGS
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00:08:03,724 --> 00:08:07,448
TO MAKE IMAGES PRINTED ON
THE SURFACE SHARP AND VIBRANT.
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00:08:11,241 --> 00:08:14,620
ONCE THE COATING'S DRY --
THAT TAKES ABOUT A DAY --
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00:08:14,620 --> 00:08:19,172
TECHNICIANS PUT THE MODEL INTO A
CUSTOM-DESIGNED INKJET PRINTER,
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00:08:19,172 --> 00:08:23,655
WHICH READS THE COMPUTER MODEL'S
PHOTOGRAPH FILE.
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00:08:23,655 --> 00:08:25,793
JUST LIKE AN ORDINARY PRINTER,
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00:08:25,793 --> 00:08:28,896
THIS PRINTER PRODUCES
A MULTITUDE OF SHADES
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00:08:28,896 --> 00:08:31,034
FROM JUST FOUR BASIC COLORS --
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00:08:31,034 --> 00:08:34,586
BLACK, YELLOW, MAGENTA,
AND CYAN.
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00:08:34,586 --> 00:08:37,965
THE JETS PASS JUST A FEW
MILLIMETERS ABOVE THE MODEL,
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00:08:37,965 --> 00:08:40,931
EMITTING ONE MICROSCOPIC DROP
OF INK AT A TIME
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00:08:40,931 --> 00:08:43,241
AT PRECISELY
THE CORRECT LOCATION.
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00:08:43,241 --> 00:08:45,758
THE END RESULT
IS A MINIATURE REPLICA
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00:08:45,758 --> 00:08:49,655
OF WHAT THE SURFACE LOOKS LIKE
IN REAL LIFE.
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00:08:49,655 --> 00:08:51,206
OTHER WORKERS, MEANWHILE,
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00:08:51,206 --> 00:08:53,620
CONSTRUCT A STURDY FRAME
FOR THE MODEL
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00:08:53,620 --> 00:08:57,034
BY GLUING, CLAMPING,
AND NAILING TOGETHER
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00:08:57,034 --> 00:08:58,793
FOUR LENGTHS OF OAK.
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00:08:58,793 --> 00:09:02,586
THIS FRAME WILL PROTECT
THE MODEL FROM DAMAGE
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00:09:02,586 --> 00:09:05,724
AND MAKE IT EASIER
TO LIFT AND MOVE.
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00:09:05,724 --> 00:09:10,655
ONCE THE GLUE DRIES, THEY REMOVE
THE CLAMPS, AND WITH A SAW,
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00:09:10,655 --> 00:09:14,000
TRIM EACH CORNER
TO A 45-DEGREE ANGLE.
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00:09:16,517 --> 00:09:19,827
THEN THEY ROUND THE EDGES
WITH A SANDER.
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00:09:31,413 --> 00:09:34,206
THEY COMPLETE THE FRAME
BY PROTECTING THE WOOD
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00:09:34,206 --> 00:09:36,379
WITH A COAT
OF CLEAR POLYURETHANE.
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00:09:38,482 --> 00:09:39,689
WHEN THAT DRIES,
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00:09:39,689 --> 00:09:42,827
THEY SPREAD GLUE
ONTO THE FRAME'S INSIDE EDGE.
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00:09:45,275 --> 00:09:46,896
THEN THEY POSITION THE MODEL
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00:09:46,896 --> 00:09:49,137
SO THAT THE LEDGE
ALONG ITS PERIMETER
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00:09:49,137 --> 00:09:51,068
SITS ON TOP OF THE FRAME.
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00:09:51,068 --> 00:09:53,965
AFTER PRINTING,
THEY SPRAY THE MODEL
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00:09:53,965 --> 00:09:56,241
WITH CLEAR POLYURETHANE
OR LACQUER.
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00:09:56,241 --> 00:09:58,551
THE PROTECTIVE FINISH
ALLOWS PEOPLE
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00:09:58,551 --> 00:10:01,275
TO NOW TOUCH THE MODEL
WITHOUT DAMAGING IT.
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00:10:01,275 --> 00:10:04,758
SOMETIMES, AN AREA
THEY'RE MODELING HAS BUILDINGS,
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00:10:04,758 --> 00:10:06,758
BRIDGES, OR OTHER STRUCTURES.
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00:10:06,758 --> 00:10:08,310
WHEN THAT'S THE CASE,
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00:10:08,310 --> 00:10:12,034
AN ENGINEER DESIGNS A COMPUTER
MODEL OF THE OBJECT.
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00:10:12,034 --> 00:10:14,068
THEN, GUIDED BY THIS MODEL,
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00:10:14,068 --> 00:10:17,586
A 3-D PRINTER PRODUCES
A PHYSICAL MODEL OUT OF PLASTIC,
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00:10:17,586 --> 00:10:19,827
BUILDING THE MINIATURE REPLICA
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00:10:19,827 --> 00:10:23,206
FROM THE BOTTOM UP
ONE THIN LAYER AT A TIME.
178
00:10:23,206 --> 00:10:26,137
THESE MOUNTAINTOP CASTLES
IN PORTUGAL
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00:10:26,137 --> 00:10:28,517
ARE THE FINISHING TOUCH
ON THIS MODEL
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00:10:28,517 --> 00:10:33,655
THAT'S SET TO GO ON DISPLAY
AT THE LOCAL TOURIST CENTER.
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00:10:33,655 --> 00:10:37,965
SOLID TERRAIN MODELS ARE
A CREATIVE AND VALUABLE TOOL
182
00:10:37,965 --> 00:10:41,034
FOR EDUCATING PEOPLE
YOUNG AND OLD.
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00:10:41,034 --> 00:10:43,793
BY TRANSLATING COMPLICATED
TECHNICAL DATA
184
00:10:43,793 --> 00:10:47,068
INTO A UNIQUE AND
SCIENTIFICALLY SOUND VISUAL AID,
185
00:10:47,068 --> 00:10:49,034
A SOLID TERRAIN MODEL DELIVERS
186
00:10:49,034 --> 00:10:52,241
A FASCINATING BIRD'S-EYE VIEW
FROM THE GROUND.
187
00:11:08,931 --> 00:11:10,241
Narrator: STUCCO IS ONE
188
00:11:10,241 --> 00:11:12,000
OF THE OLDEST CONSTRUCTION
MATERIALS ON THE PLANET.
189
00:11:12,000 --> 00:11:14,000
THE EARLIEST FORMULATIONS
190
00:11:14,000 --> 00:11:17,517
DATE BACK TO ANCIENT GREECE
AND MAYAN MEXICO.
191
00:11:17,517 --> 00:11:19,310
STUCCO HAS STUCK AROUND,
192
00:11:19,310 --> 00:11:22,827
AND AS AN EXTERIOR SIDING,
IT'S COME A LONG WAY.
193
00:11:22,827 --> 00:11:26,896
MODERN STUCCO IS MORE ATTRACTIVE
AND OFFERS BETTER PROTECTION.
194
00:11:29,068 --> 00:11:31,689
WHETHER CEMENT-
OR ACRYLIC-BASED,
195
00:11:31,689 --> 00:11:34,896
STUCCO ALWAYS STARTS OUT
AS A STICKY PASTE,
196
00:11:34,896 --> 00:11:37,896
AND THAT'S THE GREAT THING
ABOUT STUCCO.
197
00:11:37,896 --> 00:11:40,586
IN THIS WET AND GOOEY FORM,
IT CAN BE WORKED
198
00:11:40,586 --> 00:11:43,310
AS IT'S APPLIED TO THE EXTERIOR
OF A BUILDING
199
00:11:43,310 --> 00:11:47,068
TO ACHIEVE A VARIETY
OF TEXTURES.
200
00:11:47,068 --> 00:11:49,310
IT HARDENS TO PROVIDE
A TOUGH EXTERIOR
201
00:11:49,310 --> 00:11:51,965
THAT SHIELDS THE BUILDING
AGAINST THE ELEMENTS.
202
00:11:55,931 --> 00:11:58,241
TO MASS-PRODUCE CEMENT STUCCO,
203
00:11:58,241 --> 00:12:02,344
THEY START WITH TONS
OF SILICA SAND.
204
00:12:02,344 --> 00:12:05,758
THEY UNLOAD IT INTO A CONVEYOR
AND ELEVATOR SYSTEM,
205
00:12:05,758 --> 00:12:09,482
WHICH DELIVERS THE SAND TO SILOS
FOR STORAGE UNTIL NEEDED.
206
00:12:12,034 --> 00:12:15,000
THEY SELECT SAND WITH VARIOUS
GRADES OF COARSENESS
207
00:12:15,000 --> 00:12:16,448
FOR DIFFERENT STUCCO FINISHES.
208
00:12:16,448 --> 00:12:21,103
THEY MIX IT WITH CEMENT, LIME,
AND OTHER INGREDIENTS
209
00:12:21,103 --> 00:12:23,448
TO CREATE THE STUCCO BASE.
210
00:12:25,827 --> 00:12:29,827
A TECHNICIAN DEMONSTRATES HOW
THE INGREDIENTS COME TOGETHER
211
00:12:29,827 --> 00:12:31,931
USING THIS RESEARCH LAB MIXER.
212
00:12:31,931 --> 00:12:34,551
SHE BLENDS
ALL THE INGREDIENTS DRY,
213
00:12:34,551 --> 00:12:39,344
ACHIEVING A CONSISTENCY THAT'S
SIMILAR TO CAKE MIX FROM A BOX.
214
00:12:39,344 --> 00:12:42,137
CEMENT STUCCO
IS SOLD IN DRY FORM.
215
00:12:42,137 --> 00:12:46,793
WATER WILL BE ADDED TO LIQUEFY
THE INGREDIENTS ON THE JOB SITE.
216
00:12:46,793 --> 00:12:52,000
IN THIS DEMONSTRATION,
SHE ALSO ADDS PIGMENT.
217
00:12:52,000 --> 00:12:53,689
WITH THE STUCCO PRE-COLORED,
218
00:12:53,689 --> 00:12:56,000
THERE'S NO NEED TO PAINT
THE BUILDING.
219
00:13:01,413 --> 00:13:06,758
TO MASS-PRODUCE CEMENT STUCCO,
THEY USE THIS MEGA-MIXER.
220
00:13:06,758 --> 00:13:10,620
THE OPERATOR ADDS THREE OR FOUR
DIFFERENT PIGMENTS
221
00:13:10,620 --> 00:13:14,448
TO CREATE A CUSTOM COLOR
IN THE DRY STUCCO BATCH.
222
00:13:14,448 --> 00:13:17,206
LARGE PADDLE BLADES
SPIRAL VIGOROUSLY.
223
00:13:17,206 --> 00:13:19,862
USUALLY,
THIS IS A CLOSED OPERATION,
224
00:13:19,862 --> 00:13:23,965
BUT THEY'VE OPENED IT UP
FOR OUR CAMERA.
225
00:13:23,965 --> 00:13:26,310
AFTER THREE MINUTES OF MIXING,
226
00:13:26,310 --> 00:13:29,689
THE DRY STUCCO MIX IS READY
FOR SCRUTINY.
227
00:13:29,689 --> 00:13:33,068
AN EMPLOYEE TAKES A SAMPLE
228
00:13:33,068 --> 00:13:36,310
AND SENDS IT TO THE QUALITY
CONTROL LAB FOR EVALUATION.
229
00:13:40,068 --> 00:13:43,448
AT THE LAB, THE TECHNICIAN
WEIGHS THE STUCCO MIXTURE
230
00:13:43,448 --> 00:13:44,517
AND ADDS WATER.
231
00:13:47,862 --> 00:13:49,517
HE KEEPS AN EYE ON THE SCALE
232
00:13:49,517 --> 00:13:52,172
TO ENSURE THAT THE AMOUNTS
ARE PROPORTIONATE.
233
00:13:56,068 --> 00:13:58,482
HE MIXES THEM
AND VISUALLY CHECKS TO CONFIRM
234
00:13:58,482 --> 00:14:02,413
THAT THE PIGMENT AND RAW
MATERIALS ARE WELL DISPERSED.
235
00:14:02,413 --> 00:14:05,137
ACRYLIC STUCCO,
ON THE OTHER HAND,
236
00:14:05,137 --> 00:14:08,241
CALLS FOR
AN ENTIRELY DIFFERENT RECIPE.
237
00:14:08,241 --> 00:14:11,517
THEY USE CALCIUM CARBONATE
INSTEAD OF SILICA SEND
238
00:14:11,517 --> 00:14:14,448
AND ACRYLIC AS A BINDER
INSTEAD OF CEMENT.
239
00:14:14,448 --> 00:14:16,172
THEY MIX IT WITH WATER
240
00:14:16,172 --> 00:14:19,551
AND SELL IT WET IN A BUCKET
INSTEAD OF DRY.
241
00:14:19,551 --> 00:14:22,689
TO COLOR IT, THEY USE
A COMPUTERIZED TINT MACHINE,
242
00:14:22,689 --> 00:14:25,344
SIMILAR TO WHAT YOU FIND
IN A PAINT STORE.
243
00:14:25,344 --> 00:14:28,034
THEY LOAD THE MACHINE
WITH LIQUID PIGMENTS
244
00:14:28,034 --> 00:14:30,896
AND ENTER A COLOR FORMULA
INTO THE COMPUTER.
245
00:14:30,896 --> 00:14:34,000
IT MIXES THE PIGMENTS
TO PRODUCE THE EXACT COLOR.
246
00:14:35,931 --> 00:14:39,758
AND IT RELEASES
THE PRECISE AMOUNT NEEDED.
247
00:14:39,758 --> 00:14:42,551
THEY BLEND THE COLOR
INTO THE ACRYLIC STUCCO,
248
00:14:42,551 --> 00:14:46,517
AND THE BATCH ENDS UP
LOOKING LIKE BLUE MUD.
249
00:14:46,517 --> 00:14:49,275
IT'S NOW READY TO APPLY
TO A HOME.
250
00:14:49,275 --> 00:14:50,689
NO PREP REQUIRED.
251
00:14:52,758 --> 00:14:56,379
THEY ALSO SELL ACRYLIC STUCCO
WITH NO COLOR AT ALL.
252
00:14:56,379 --> 00:14:58,034
IT'S CALLED TINT BASE.
253
00:14:58,034 --> 00:15:00,724
THE PIGMENTS WILL BE ADDED
ON THE JOB SITE,
254
00:15:00,724 --> 00:15:03,206
WHERE THEY CAN BE ADJUSTED
IF NEEDED.
255
00:15:03,206 --> 00:15:07,931
AN AIRTIGHT SEAL KEEPS
THE STUCCO IN ITS VISCOUS STATE.
256
00:15:07,931 --> 00:15:11,103
ACRYLIC STUCCO DRIES QUICKLY,
LIKE PAINT,
257
00:15:11,103 --> 00:15:14,758
WHILE CEMENT STUCCO
TAKES 28 DAYS TO TOTALLY CURE
258
00:15:14,758 --> 00:15:18,068
INTO A MORE DURABLE FINISH.
259
00:15:18,068 --> 00:15:19,965
OVER ON THE CEMENT STUCCO LINE,
260
00:15:19,965 --> 00:15:22,724
A ROTATING MACHINE
HANDLES ALL THE PACKAGING.
261
00:15:22,724 --> 00:15:26,068
A SUCTIONING DEVICE PULLS
A PAPER BAG INTO POSITION
262
00:15:26,068 --> 00:15:30,172
UNDER A SPOUT,
WHICH THEN FILLS IT UP.
263
00:15:30,172 --> 00:15:33,965
IT TAKES JUST 8 SECONDS
TO FILL A 90-POUND BAG.
264
00:15:33,965 --> 00:15:37,448
THAT WORKS OUT
TO OVER 1,300 BAGS PER HOUR,
265
00:15:37,448 --> 00:15:42,275
ENOUGH MATERIAL FOR 30 HOUSES.
266
00:15:42,275 --> 00:15:47,965
THE MACHINE TRANSFERS THE BAG
TO THE CONVEYOR BELT.
267
00:15:47,965 --> 00:15:51,137
THIS STUCCO IS NOW READY
TO PROVIDE A STRONG FINISH
268
00:15:51,137 --> 00:15:52,551
TO BUILDING PROJECTS.
269
00:15:52,551 --> 00:15:54,793
APPLIED TO
A BUILDING'S EXTERIOR,
270
00:15:54,793 --> 00:15:58,517
STUCCO CAN BE TEXTURED TO SUIT
THE HOMEOWNER'S TASTE,
271
00:15:58,517 --> 00:16:02,172
AND IT WILL HARDEN TO PROVIDE
THE BUILDING WITH A TOUGH SKIN.
272
00:16:02,172 --> 00:16:06,448
THAT'S WHY STUCCO CONTINUES TO
BE PART OF THE URBAN LANDSCAPE.
273
00:16:17,551 --> 00:16:20,068
Narrator: AN INDUSTRIAL
ROLL-UP DOOR OPENS AND CLOSES
274
00:16:20,068 --> 00:16:21,448
AT LEAST THREE TIMES AS FAST
275
00:16:21,448 --> 00:16:24,068
AS YOUR AVERAGE
RESIDENTIAL GARAGE DOOR.
276
00:16:24,068 --> 00:16:28,758
THAT MEANS MACHINES AND PRODUCTS
CAN BE MOVED IN AND OUT QUICKLY.
277
00:16:28,758 --> 00:16:30,551
THESE HEAVY-DUTY RUBBER DOORS
278
00:16:30,551 --> 00:16:34,206
ARE ALSO ENGINEERED FOR A GOOD
SEAL, SO THEY'RE WEATHERTIGHT.
279
00:16:38,758 --> 00:16:42,862
IN MANY WORKPLACES, DOORS
ARE ALWAYS OPENING AND CLOSING.
280
00:16:42,862 --> 00:16:46,379
A HIGH-SPEED ROLL-UP DOOR
IS DESIGNED FOR HEAVY TRAFFIC.
281
00:16:46,379 --> 00:16:50,965
COAL MINES, PARKING GARAGES,
AND LARGE FOOD FREEZER ROOMS
282
00:16:50,965 --> 00:16:53,965
ARE JUST A FEW OF THE PLACES
YOU WILL FIND THEM IN ACTION.
283
00:16:56,655 --> 00:16:58,620
THEY START WITH RUBBER PANELS.
284
00:16:58,620 --> 00:17:02,206
THEIR NUMBER AND SIZE DEPENDS
ON THE WIDTH OF THE DOOR
285
00:17:02,206 --> 00:17:03,551
BEING MANUFACTURED.
286
00:17:03,551 --> 00:17:07,620
WORKERS BRUSH HIGH-STRENGTH
EPOXY ONTO THE EDGES
287
00:17:07,620 --> 00:17:10,000
TO BIND THE PANELS TOGETHER.
288
00:17:10,000 --> 00:17:12,620
THE EPOXY WILL TAKE
A COUPLE OF HOURS TO CURE,
289
00:17:12,620 --> 00:17:15,206
SO THERE'S TIME TO SMOOTH OUT
THE AIR BUBBLES
290
00:17:15,206 --> 00:17:19,344
BY APPLYING PRESSURE TO
THE SEAMS WITH A HEAVY ROLLER.
291
00:17:19,344 --> 00:17:23,551
AFTER THE EPOXY CURES, THEY MAP
OUT AREAS WITH MASKING TAPE
292
00:17:23,551 --> 00:17:24,862
TO CONTAIN GLUE
293
00:17:24,862 --> 00:17:28,379
FOR THE APPLICATION
OF EXTRUDED RUBBER STRIPS.
294
00:17:28,379 --> 00:17:30,827
THE HORIZONTAL ONE
IS A STIFFENER,
295
00:17:30,827 --> 00:17:34,310
AND THE VERTICAL STRIPS
AT THE SIDES ARE WIND BLOCKS.
296
00:17:34,310 --> 00:17:37,206
THEY'LL SECURE THE CURTAIN
TO THE BUILDING
297
00:17:37,206 --> 00:17:38,620
EVEN IN BAD WEATHER.
298
00:17:38,620 --> 00:17:42,551
THE EMPLOYEE ALSO APPLIES
SYNTHETIC FABRIC TO BOTH SIDES
299
00:17:42,551 --> 00:17:44,103
TO PREVENT WEAR.
300
00:17:47,000 --> 00:17:50,517
HE ADDS REFLECTIVE YELLOW STRIPS
TO THE FRONT AND BACK
301
00:17:50,517 --> 00:17:53,620
TO MAKE THE BLACK RUBBER DOOR
VISIBLE AT NIGHT.
302
00:17:55,655 --> 00:17:58,551
A MACHINE NOW DRILLS HOLES
IN A STEEL TUBE.
303
00:17:58,551 --> 00:17:59,965
THIS TUBE IS THE HEADER
304
00:17:59,965 --> 00:18:02,862
THAT THE RUBBER CURTAIN
WILL BE ROLLED UP ON TO.
305
00:18:02,862 --> 00:18:07,379
THE HOLES WILL BE USED
TO ATTACH THE CURTAIN TO IT.
306
00:18:11,724 --> 00:18:15,620
HE TACK-WELDS AXLES
ONTO BOTH ENDS OF THE TUBE.
307
00:18:15,620 --> 00:18:18,758
THE AXLES WILL BE ATTACHED
TO MOUNTING PLATES,
308
00:18:18,758 --> 00:18:20,620
SO THESE ARE CRITICAL WELDS.
309
00:18:20,620 --> 00:18:22,724
HE MEASURES THE AXLES TO CONFIRM
310
00:18:22,724 --> 00:18:25,724
THAT THE ASSEMBLY IS LEVEL
AND WON'T WOBBLE.
311
00:18:25,724 --> 00:18:29,310
SATISFIED, HE WELDS THEM
PERMANENTLY TO THE STEEL TUBE.
312
00:18:32,586 --> 00:18:35,689
NEXT, HE ASSEMBLES
AND WELDS THE SIDE FRAME
313
00:18:35,689 --> 00:18:37,344
FOR THE RUBBER CURTAIN.
314
00:18:42,689 --> 00:18:45,517
HE ASSEMBLES A HINGE COVER
TO THE FRONT OF THE FRAME,
315
00:18:45,517 --> 00:18:47,689
CREATING A COMPARTMENT
FOR THE CURTAIN
316
00:18:47,689 --> 00:18:51,482
THAT CAN BE OPENED WHEN NEEDED.
317
00:18:51,482 --> 00:18:54,551
THEN IT'S ON TO THE PAINT BOOTH.
318
00:18:54,551 --> 00:18:57,310
HERE, AN EMPLOYEE PRIMES
THE FRAME COMPONENTS
319
00:18:57,310 --> 00:19:00,896
TO PROTECT THEM FROM RUST AND
THEN GIVES THEM A COAT OF PAINT.
320
00:19:04,724 --> 00:19:07,310
A WORKER ASSEMBLES
THE BOTTOM BEAM NOW.
321
00:19:07,310 --> 00:19:10,379
HE BOLTS AN ALUMINUM TRACK
FOR THE RUBBER EDGING
322
00:19:10,379 --> 00:19:11,862
TO A HEAVY STEEL FRAME.
323
00:19:18,931 --> 00:19:21,758
HE SCREWS THE BOX
FOR THE WIRELESS TRANSMITTER
324
00:19:21,758 --> 00:19:24,379
THAT OPENS AND CLOSES THE DOOR
TO THE BEAM.
325
00:19:27,620 --> 00:19:30,000
TWO WORKERS NOW PULL
THE RUBBER EDGING
326
00:19:30,000 --> 00:19:31,655
THROUGH THE ALUMINUM TRACK.
327
00:19:31,655 --> 00:19:34,620
THE EDGING IS EQUIPPED
WITH AN ELECTRIC SAFETY WIRE
328
00:19:34,620 --> 00:19:37,206
TO DETECT MOVEMENT
AND ABORT A DOOR CLOSING.
329
00:19:37,206 --> 00:19:40,862
THIS WILL KEEP THE DOOR
FROM HITTING ANYONE
330
00:19:40,862 --> 00:19:42,586
WHO WALKS UNDER IT.
331
00:19:42,586 --> 00:19:47,586
IT'S NOW TIME TO PULL
EVERYTHING TOGETHER.
332
00:19:47,586 --> 00:19:50,965
THE TEAM SCREWS THE RUBBER
CURTAIN TO THE STEEL TUBE,
333
00:19:50,965 --> 00:19:53,448
MAKING USE
OF THOSE PRE-DRILLED HOLES.
334
00:19:58,655 --> 00:20:02,931
THEY MOVE DOWN AND POSITION
THE BOTTOM BEAM ON THE CURTAIN.
335
00:20:08,517 --> 00:20:11,862
THEY ATTACH IT TO THE CURTAIN
WITH NUMEROUS NUTS AND BOLTS.
336
00:20:19,758 --> 00:20:21,448
THEY ROLL UP THE RUBBER CURTAIN
337
00:20:21,448 --> 00:20:24,172
TO PREPARE FOR ASSEMBLY
TO THE MOUNTING BRACKETS.
338
00:20:33,551 --> 00:20:35,275
WITH THE ATTACHMENTS,
339
00:20:35,275 --> 00:20:38,620
THE CURTAIN NOW WEIGHS
OVER 1,100 POUNDS.
340
00:20:38,620 --> 00:20:42,206
A CRANE TRANSFERS IT
TO THE END MOUNTING PLATES
341
00:20:42,206 --> 00:20:43,517
AND HOLDS IT STEADY
342
00:20:43,517 --> 00:20:46,862
WHILE WORKERS SLIDE
THE END BRACKETS ONTO THE AXLES.
343
00:20:46,862 --> 00:20:50,413
THEY BUILD A STEEL SUPPORT
STRUCTURE AROUND THE BRACKETS
344
00:20:50,413 --> 00:20:51,965
AND THE ROLLED-UP CURTAIN.
345
00:20:54,413 --> 00:20:59,379
THEY ATTACH THE MOTOR
TO ONE OF THE AXLES.
346
00:20:59,379 --> 00:21:03,620
THIS ROLL-UP DOOR IS NOW READY
FOR DELIVERY.
347
00:21:03,620 --> 00:21:06,344
TWO DAYS IN THE MAKING,
348
00:21:06,344 --> 00:21:09,068
IT'S READY
FOR WHATEVER COMES ITS WAY.
349
00:21:21,758 --> 00:21:24,275
IF YOU HAVE ANY COMMENTS
ABOUT THE SHOW,
350
00:21:24,275 --> 00:21:26,965
OR IF YOU'D LIKE TO SUGGEST
TOPICS FOR FUTURE SHOWS,
351
00:21:26,965 --> 00:21:28,931
DROP US A LINE AT...
28586
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