Simulated return

Bottom left Simulated return, second right, third left etc...

BPDL Plant visit May 20, 2009 Alma, Quebec Canada

Panoramic view of storage yard at BPDL

Completed assemblies in storage

Panoramic view of BPDL Plant.

Plywood forms in various stages of completion

The first of the forms for arch assemblies being readied.

This panel was cast with the shot running vertical rather than horizontal. The misplaced panel had to be broken out damaging the panels on either side.

Note the plastic sheeting being used for a bond breaker rather than foam.

Completed assembly

Area of concern. The shot sawn finish has a tolerance of plus/minus 1/2" causing some heads to be out of alignment.

The head tolerance will be controlled by increasing slab thickness and back checking the heads to maintain proper alignment.

BPDL Dutchman repair in upper right comer. It is not uncommon for some damage to occur when lifting the panels from thier casting tables.

Precast beam assembly being  readied for outdoor storage.

Raw material storage area.

Each home will fit into a single shipping container with a weight of 20,000 pounds or less.

Everything is concrete except for the door and windows.

Mockup of the concrete roof panels.

Each piece of the home can be lifted and set in place by hand, no equipment required.

Roof truss system.

Completed arch, both inner and outer walls in a single assembly, total weight 55,000 pounds.

Transportation

Trucks frequently arrive without enough nylon straps so they place a single strap across the weakest portion of the pallet.

Straps should always be placed directly over the homasote skids.

Oddly configured trailers that don't have continuous strapping rails mean the straps can't be properly located.

Steel chains that are very unforgiving and conduct vibration are frequently used in lew of nylon straps.