And then, after ten weeks of back-breaking work, dragging permits, unavailable machines, lack of helping hands, and finally COVID lock-down, we finally made it happen: We successfully poured the bond beam to our Earthship inspired structure. This is a MAJOR milestone in our build, if not the most important one. Now the mass of the entire tire wall has been combined to support the mass of the entire roof. Also, at this point we are forced to let it rest for a good two weeks, so the concrete can set to the point of supporting further construction. As it happens, this also coincides with our 15-day quarantine, as it has been announced. Not to mention, the time required for the proper treatment the roof beams.
Preparing for the Most Tiring Day of the Build
The biggest challenge in the entire endeavor was to complete the whole bond beam in one continuous pour. Otherwise we'd be in for so called cold joints, where some of the concrete sets before the next part is poured, unable to join with it properly. So we had to mix an estimated amount of 20 sacks of cement with sand, gravel, and water, in one day. Knowing how exhausted we were after pouring a column of only two sacks, this day seemed to be daunting, to say the least.
We knew, we had to start early in the morning, as soon as it got light, hoping to be finished before it got dark in the evening. Food had to be prepared beforehand, as all six of us were going to be needed at the building site, all day. As for the logistics, we were not exactly sure: having two mixing stations seemed reasonable, but we were debating whether it would make more sense to mix two sacks at one time, or only one-by-one.
Much Appreciated Help
When our neighbors heard that we were going to have a concrete pour, they came to offer their help, maybe by lending a bucket or a shovel, or offering to come over and lend a hand in mixing. We were glad to take up any offer, and when the big day came we had two neighbors show up, each bringing one of their friends, all strong Mexicans, with a lot of concreting experience.
When we told them about our two stations, they just smiled, and said that it's most efficient to have one big mix: of five sacks of cement! We didn't argue, but got going to get the work over with as soon as possible. Their other innovative suggestion was to mix up the sand and cement before adding the gravel and water. In the end it seemed to work like magic: together we were nine guys with buckets, shovels, and blaring cumbia musica, and we managed to complete pouring the first mix in under an hour.
A little water break later we were ready to start with the next one, followed by a coffee break, and after the third mix we only needed to make a small one of a last sack of cement. When we poured out the water after cleaning up all the tools, we looked back at our work with satisfaction: the entire bond beam had been finished before lunch! Talking about accomplishing the impossible.
The Cost of Mexican Help: Mexican Protocol
I've promised some of my followers photos of our hard-core ladies, who don't shy away from mixing concrete. Well, as it turns out, I don't have any cool pics of that sort. The reason: they were not part of the concreting effort, at least this time.
When our neighbor came over with his friend, both eager to help with the pour, the neighbors wife asked Julia: "So what food have you been thinking about making?" Knowing the local tradition of offering your helpers chicken and beer, she set out to buy some chicken (since beer is currently not an option due to the Coronavirus). However, as it turned out, the chicken place was closed, since the vendor is from out of town, who would not be admitted to Mazunte during lock-down. So instead she came back with some beef from the butchers.
"Well, Julia," the neighbor lady shook her head at the sight of the beef, "this will require my wood-burning stove, as there is only one way to prepare this meat." And she went about instructing her how to prepare a delicious beef dish using chiles guajillos and a wood-burner. Though she enjoyed learning from the expert, Julia felt a bit weird being ordered about by a lady half her age, with smiling remarks such as: "Don't worry, there is no way you could know the right way." or "I'm one of the wood-burner, you're better at the stove." Thanks to her guidance, however, we managed to offer our helpers the kind of appreciation they actually enjoyed. The loveliest vegan lasagna would not have had the same result.
Relaxing Afternoon
Once all of us were properly cleaned up, Steph took a spin on his motorcycle to look for beer. He was somewhat successful, coming back with a couple of cans for each person, incidentally clearing out the last remaining stock of one of the little stores. That's COVID prohibition! So in the end even the lunch, beer, and sitting around the table under our kitchen tree was a big success. What better way to enjoy completing the bond-beam pour? Well, that evening we had a little bonfire in the center circle, just the few of us, remembering the Minka Ceremony.
Follow our Construction Adventure in This Series:
The Circle is Complete, We're Pouring Tomorrow
Starting The Long Finish
Concrete Plans and Concrete Actions
Earthship Build in the Time of Hive and Coronavirus
Machines Taking Over Work: The Day Everything Changed
Zome Building Workshop in Mazunte
The Ceremony of a Minka
Hay Pase, Got the Permit!
The Diverse Cars at Itínera
Waiting for the Man
An Impression of Hyperadobe in La Boquilla
Bending Rebar Like a Mexican
Working at Night for the Perfect Level
The Challenge of Scoring Tires
Creating Conditions to Work and Live
Previous series: A Theater on the Beach