After doing a lot of research on various types of construction materials and the problems of getting them across the border, I decided that the best way to build a house or an office in Puerto Peñasco was to use Tridipanels, made in Mexicali by Insteel PanelMex. These are made of foam, with a steel mesh reinforcement. After they are put together, they are coated with 1.5" of concrete, inside and out, and finished in any way desired. In a past issue I described these panels in some detail. I'll just summarize here some of their advantages:
The next step was for me to go to Mexicali and see the factory and talk to the manager. He was very cordial on the phone and even more so when I met him personally. I was given a tour of the factory and was thoroughly impressed. Acres of panels in lengths of 8' to 40' were inside in stacks and outside being loaded onto trucks. Loud clanking and banging of welding machines accompanied the fabrication of the panels, which took place before my eyes. A 40' foam panel slipped between the jaws of this monstrous machine, and large spools of wire fed into it. At the other end the Tridipanels came out, with foam embedded between wire mesh sheets welded together through the foam.
I was shown a house built of the panels located inside the plant. No concrete--just the panels. I went up Tridipanel stairs, walked across Tridipanel floors, and stepped out onto a Tridi panel balcony overlooking the factory. The foam and metal alone were strong enough to hold the weight of 3 or 4 people. With 1.5" to 2" of concrete on both sides of each panel, the house would becomes what builders call a monolithic structure--all one piece--floors, walls, roof, and stairs. This makes it earthquake resistant.
This material is used throughout the United States, Canada, and Mexico for both commercial and residential buildings. Former U.S. President Jimmy Carter is using Tridipanels to build homes in the Habitat for Humanity program. 14 houses were built in a week, using it.
I was sold. I decided to put up a model in Puerto Peñasco and to sell homes built with this material to others. I was given a number of plans and offered as much help as I needed . I used some ideas from the plans they gave me and handed them a finished copies. They told me that they would have an estimate for the shell in less than a week. I had my estimate in a few days and I decided to go ahead. This was about January of 1997.
Day One
It all started at 8:00 Monday morning. The Tridipanel material and all the necessary tools, equipment, and parts, were sitting on our lot. The wind was blowing dust into our teeth and ears. All 3 of the Tridipanel architects, Juan, Sergio, and Leopoldo, were there. Sergio's lips were bluish. He kept asking me, "When will the wind stop?"
The workers began arriving. One was wearing two sweaters and a coat. Another wore two coats and a sweater. Another wore a skier's face mask.
Adela and Victor, our chief architects, arrived. Victor was wearing red gloves and slapping his hands together. She was bundled up, with a thick scarf around her neck and a baseball cap.
All of a sudden everybody started to move. 4' x 8' panels were being picked up and their ends placed on the slab vertically over the protruding rebar. Each panel consisted of a polystyrene foam core with outer layers of welded wire mesh. One panel went up; it was supported by bracing wires. Another panel went up and was braced with wires. This continued until all the outer and inner walls were up. The house blossomed on top of the slab--white panels waving in the wind, no windows yet, just a square box sitting there. The wind was getting stronger. I asked Sergio, "Have you ever had a house blow away?" He laughed and said no.
By now the site was getting hot with rushing bodies and activity. Our small 600-sq. ft. house was surrounded by 5 architects and 10 workers, plus several bystanders taking note of what was going on. My friend Bud and I were photographing the activity. Everything occurred rapidly. People were moving fast. There were chunks of wood and foam scattered around, piles of sand, boards, boulders, boxes, and stabilizing wire fastening the house to the ground. But nobody tripped or stumbled. They moved deftly, with grace and speed. The air was electric with excitement. I heard somebody say, "Es la casita del Futuro."
Now the workers started to join the panels together, using an air-compressed staple gun and reinforcing the joints with braces. The walls immediately became solid and rigid. My fears of its blowing away blew away.
The worker with the mask walked from place to place, his piercing eyes peeking out from the ski mask, observing everything. Once in a while he'd say a few words. Although I never saw his face, I could tell he was the moving force behind the muscle machine. Later I found out he was the foreman of the crew, Pedro Castro.
Sergio and Leopoldo, the industrial advisers from Mexicali, were hands-on people, showing us how to cut the panels, how to mark them, how to lay them. They worked as hard as anybody else on the site. They too were pace-setters. Victor was at one end of the building, working with the others, putting panels up, overseeing and participating in the construction. Adela went from one place to another with a clipboard, writing notes and comments, making sure no detail was overlooked. Nobody stood around with their hands in their pockets--except me.
By the end of Day One all the walls were up and reinforced.
On Tuesday, the wind was still blowing. There was talk of frost on the roofs of nearby properties. Sergio asked me again, "When will the wind stop?" I told him I didn't know.
Most of the morning was spent doing additional reinforcing and tightening of the panels. By afternoon some of the men were inside using hacksaw blades to cut windows and doors out of the metal and foam panels. Little pieces of foam flew about in the wind, sticking to people's clothing and hair. It looked like the beginning of a snowstorm.
Once the windows were cut, light entered, and the edifice became a house, not a box. I suddenly realized that there was no facade for the rear of the house. We needed something to hide the roof lines and the air conditioner. I asked Sergio if they could make one like the one on the front, and he said yes. He told the workers to make one. They wired a panel into position and marked the cutting line with blue spray paint, to be cut with a hacksaw. When I saw that blue line on the white panel, the house started to live.
By the end of Day Two the walls were tightened and reinforced, and the roof was in place. It too was made of Tridipanel.
In the morning the electricians and plumbers came in. They used torches to shrink the foam and make recesses for the plumbing pipes and electrical conduits. The conduits, made of black plastic tubing, were snaked between the foam and the metal of the panels, leading to each of the electrical boxes already in place. The wire would be fed through the the conduits later.
By afternoon the team was getting the structure ready to spray concrete. The process uses a 5 horsepower compressor and a specially-designed gun to blast concrete, called shotcrete, onto the walls, bonding wire, foam, and concrete into a monolithic unit. Some hand troweling is also necessary. The first coat brings concrete up to the level of the mesh. A second coat extends the concrete 1/4" above the surface of the mesh. A final coat of plaster is applied and then the wall is painted. Once the wall is complete and the concrete is dry, the roof is supported with temporary beams to hold it in place while 2" of concrete is applied to its surface.
Juan Martinez at Tridipanel tells me that they have been able to put up 1200 and 1300 sq. ft. homes in less than 20 days. That's tile, paint, stucco, utilities, everything--ready to move in. Ours, of course, may take a little longer until we get enough practice to do it that fast.
These are the friends who are participating in this effort:
Tridipanel Advisors/Consejeros
- Arq. Juan Martinez Garciamoreno
- Arq. Sergio Peterson Almada
- Arq. Leopoldo Reyes Gonzalez
Builders/Construcción
- Arq. Adela Romero Ortiz
- Arq. Victor Lagunes Valdes
Building Crew/Albañileria
- Pedro Castro
- Jose Luis Rosas Romero
- Remigio Moreno Castro
- Cayetano Ballarena Angel
- Bonifacio Sanchez Flores
- Roman Salgado Ramos
- Floriano Vazquez Vazquez
- Eleno Vazquez Vazquez
- Maurino Vazquez Vazquez
- Modesto Castro Castro
Installations/Instalaciones
- Ing. Cesar Angel Valle Alarcón
- Rafael Mesa Mendez, electrician/electricista
- Rogelio Rodriguez Amaral, plumber/plomero
- Salvador Olmedo Lopez, plumber/plomero