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--captions by vitac--
Www.Vitac.Com
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Captions paid for by
Discovery communications
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Narrator: most experts
Will tell you that the key
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To the perfect paint job
Or wood-refinishing job
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Is to prep the surface properly
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Before applying the paint
Or wood stain.
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That requires sanding
To remove old finishes
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And to level uneven areas.
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The easiest way to do that
Is with a motorized sander.
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Professional-caliber sanders
Are typically pneumatic,
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Meaning you plug them
Into an air compressor.
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Air-driven tools are more
Powerful than tools
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Than run on electricity.
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This type of sander is called
A straight line,
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Because the pad
To which you attach sandpaper
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Moves in a straight line
Back and forth.
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Many of the tool's components
Are made of powdered metal,
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Then machined
To exact dimensions
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On a computer-guided lathe.
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Powdered metal is iron powder
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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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Sometimes they further
Strengthen the powdered metal
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By infusing it with copper
In the furnace.
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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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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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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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This quenching hardens
The component.
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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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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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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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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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And push a plastic piece
Onto each end.
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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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Next, a technician installs
The timing driveshaft
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And the idler gear shaft,
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Pressing the gears of both
Into the piston rack's teeth.
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The powdered-metal counterweight
Goes on each side
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To balance the piston rack,
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Then guides made of that
Proprietary material
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To align and lubricate
The counterweights.
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A second set of anti-wear guides
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Goes in the lower part
Of the motor block.
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These help balance
The sanding pad.
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Then the start
Of the valve system,
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Which controls the entry of
Compressed air into the sander.
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At the front of the motor block,
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They install a paper gasket
To prevent air leakage,
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Then seal it
With an aluminum end plate.
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Continuing with
The valve system,
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They install the components,
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Which control the timing of the
Pistons' back-and-forth motion.
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After sealing the top
With a cap,
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They install the air-valve
Block, then the handle,
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Which contains the inlet
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To which the air compressor
Connects.
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The handle squeeze trigger
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Is mounted to the cap
Above the handle.
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They install the counterweight
For the pad.
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Here, you can see the two shafts
The piston rack rotates.
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Workers connect them
To an aluminum drive shoe,
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Which will move back and forth.
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A pair of side rails holds
The drive shoe in place.
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Where the air exits the tool,
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They install a muffler made
Of porous plastic.
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Finally, when the technician
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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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Holding the rubber pad
With sandpaper.
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This pneumatic sander
Is ready to level
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And smooth a surface
In seconds flat.
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Narrator: a solid terrain model,
"Stm" for short,
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Is an exact, three-dimensional,
Miniature replica
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Of a geographic area.
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Stms are indispensable tools
For museums, visitor centers,
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And for planning everything
From industrial projects
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To military operations.
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To create a solid terrain model,
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The first step is to gather data
Via satellites and aircraft.
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Two types of data --
Color photographs of the surface
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Showing the precise location
Of vegetation, rock, buildings,
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And so on,
And elevation measurements,
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Taken with lasers
And other equipment.
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A cartographer digitally merges
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The black and white elevation
Diagrams with the color photos
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And adds artwork for roads
And place names.
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He produces a 3-d computer model
Of the area.
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This model will guide
The machines
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That manufacture
The physical model
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Out of a block
Of polyurethane foam.
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Foam is a durable material
And lightweight,
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Making the model easy
To transport.
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A computer-guided cutting
Machine first shapes a ledge
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Around the block's perimeter.
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This is for mounting
The model on a frame.
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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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The machine first does
A rough cut.
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Then --
And this takes much longer --
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It carves the fine details.
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Depending on the complexity
Of the terrain,
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Cutting the elevations
Into the foam
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Can take just a few hours
Or several days.
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When the cutting's finished,
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The technician cleans off
The foam dust
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With compressed air and a brush.
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The foam goes into a spray booth
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Where it first receives
A coat of primer
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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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To make images printed on
The surface sharp and vibrant.
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Once the coating's dry --
That takes about a day --
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Technicians put the model into a
Custom-designed inkjet printer,
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Which reads the computer model's
Photograph file.
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Just like an ordinary printer,
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This printer produces
A multitude of shades
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From just four basic colors --
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Black, yellow, magenta,
And cyan.
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The jets pass just a few
Millimeters above the model,
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Emitting one microscopic drop
Of ink at a time
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At precisely
The correct location.
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The end result
Is a miniature replica
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Of what the surface looks like
In real life.
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Other workers, meanwhile,
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Construct a sturdy frame
For the model
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By gluing, clamping,
And nailing together
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Four lengths of oak.
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This frame will protect
The model from damage
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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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Then they round the edges
With a sander.
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They complete the frame
By protecting the wood
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With a coat
Of clear polyurethane.
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When that dries,
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They spread glue
Onto the frame's inside edge.
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Then they position the model
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So that the ledge
Along its perimeter
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Sits on top of the frame.
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After printing,
They spray the model
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With clear polyurethane
Or lacquer.
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The protective finish
Allows people
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To now touch the model
Without damaging it.
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Sometimes, an area
They're modeling has buildings,
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Bridges, or other structures.
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When that's the case,
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An engineer designs a computer
Model of the object.
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Then, guided by this model,
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A 3-d printer produces
A physical model out of plastic,
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Building the miniature replica
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From the bottom up
One thin layer at a time.
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These mountaintop castles
In portugal
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Are the finishing touch
On this model
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That's set to go on display
At the local tourist center.
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Solid terrain models are
A creative and valuable tool
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For educating people
Young and old.
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By translating complicated
Technical data
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Into a unique and
Scientifically sound visual aid,
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A solid terrain model delivers
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A fascinating bird's-eye view
From the ground.
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Narrator: stucco is one
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Of the oldest construction
Materials on the planet.
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00:11:12,000 --> 00:11:14,000
The earliest formulations
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Date back to ancient greece
And mayan mexico.
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Stucco has stuck around,
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00:11:19,310 --> 00:11:22,827
And as an exterior siding,
It's come a long way.
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00:11:22,827 --> 00:11:26,896
Modern stucco is more attractive
And offers better protection.
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00:11:29,068 --> 00:11:31,689
Whether cement-
Or acrylic-based,
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00:11:31,689 --> 00:11:34,896
Stucco always starts out
As a sticky paste,
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00:11:34,896 --> 00:11:37,896
And that's the great thing
About stucco.
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00:11:37,896 --> 00:11:40,586
In this wet and gooey form,
It can be worked
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00:11:40,586 --> 00:11:43,310
As it's applied to the exterior
Of a building
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To achieve a variety
Of textures.
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00:11:47,068 --> 00:11:49,310
It hardens to provide
A tough exterior
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That shields the building
Against the elements.
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00:11:55,931 --> 00:11:58,241
To mass-produce cement stucco,
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00:11:58,241 --> 00:12:02,344
They start with tons
Of silica sand.
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00:12:02,344 --> 00:12:05,758
They unload it into a conveyor
And elevator system,
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00:12:05,758 --> 00:12:09,482
Which delivers the sand to silos
For storage until needed.
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00:12:12,034 --> 00:12:15,000
They select sand with various
Grades of coarseness
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00:12:15,000 --> 00:12:16,448
For different stucco finishes.
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00:12:16,448 --> 00:12:21,103
They mix it with cement, lime,
And other ingredients
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00:12:21,103 --> 00:12:23,448
To create the stucco base.
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00:12:25,827 --> 00:12:29,827
A technician demonstrates how
The ingredients come together
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00:12:29,827 --> 00:12:31,931
Using this research lab mixer.
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00:12:31,931 --> 00:12:34,551
She blends
All the ingredients dry,
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00:12:34,551 --> 00:12:39,344
Achieving a consistency that's
Similar to cake mix from a box.
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00:12:39,344 --> 00:12:42,137
Cement stucco
Is sold in dry form.
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00:12:42,137 --> 00:12:46,793
Water will be added to liquefy
The ingredients on the job site.
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00:12:46,793 --> 00:12:52,000
In this demonstration,
She also adds pigment.
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00:12:52,000 --> 00:12:53,689
With the stucco pre-colored,
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00:12:53,689 --> 00:12:56,000
There's no need to paint
The building.
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00:13:01,413 --> 00:13:06,758
To mass-produce cement stucco,
They use this mega-mixer.
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The operator adds three or four
Different pigments
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00:13:10,620 --> 00:13:14,448
To create a custom color
In the dry stucco batch.
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00:13:14,448 --> 00:13:17,206
Large paddle blades
Spiral vigorously.
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00:13:17,206 --> 00:13:19,862
Usually,
This is a closed operation,
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00:13:19,862 --> 00:13:23,965
But they've opened it up
For our camera.
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00:13:23,965 --> 00:13:26,310
After three minutes of mixing,
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00:13:26,310 --> 00:13:29,689
The dry stucco mix is ready
For scrutiny.
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00:13:29,689 --> 00:13:33,068
An employee takes a sample
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00:13:33,068 --> 00:13:36,310
And sends it to the quality
Control lab for evaluation.
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00:13:40,068 --> 00:13:43,448
At the lab, the technician
Weighs the stucco mixture
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00:13:43,448 --> 00:13:44,517
And adds water.
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00:13:47,862 --> 00:13:49,517
He keeps an eye on the scale
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00:13:49,517 --> 00:13:52,172
To ensure that the amounts
Are proportionate.
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00:13:56,068 --> 00:13:58,482
He mixes them
And visually checks to confirm
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00:13:58,482 --> 00:14:02,413
That the pigment and raw
Materials are well dispersed.
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00:14:02,413 --> 00:14:05,137
Acrylic stucco,
On the other hand,
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00:14:05,137 --> 00:14:08,241
Calls for
An entirely different recipe.
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00:14:08,241 --> 00:14:11,517
They use calcium carbonate
Instead of silica send
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00:14:11,517 --> 00:14:14,448
And acrylic as a binder
Instead of cement.
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00:14:14,448 --> 00:14:16,172
They mix it with water
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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,
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00:14:22,689 --> 00:14:25,344
Similar to what you find
In a paint store.
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00:14:25,344 --> 00:14:28,034
They load the machine
With liquid pigments
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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.
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00:14:35,931 --> 00:14:39,758
And it releases
The precise amount needed.
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00:14:39,758 --> 00:14:42,551
They blend the color
Into the acrylic stucco,
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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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