FRAMECAD is one of the worlds leading innovators in automating cold formed steel framing construction. Their claim of being “relentless innovators” caught my eye so I contacted Curtis Edgecombe, who is the Senior Vice President of FRAMECAD Americas. Is it a viable alternative to wood frame offsite construction? Read below, it just may get the proverbial wheels turning.

Curtis Edgecombe, Executive VP, FrameCad

Bill Murray, Offsite Innovators: Can you give us a brief overview of what FRAMECAD does and the role it plays in the offsite construction industry?

Curtis Edgecombe Framecad: For more than 35 years, FRAMECAD has been a leader in steel frame building innovation. We provide end-to-end steel framing systems and the framework to simplify and automate cold-formed steel (CFS) framing construction, from design and engineering to manufacture, build and delivery to the job site. FRAMECAD’s ecosystem of manufacturing equipment and solutions delivers CFS framing faster and more sustainably, with a lower total cost of ownership and the resilience to withstand the test of time.

We see a tremendous opportunity for CFS to impact the future of construction and play a significant role in addressing the need for more sustainable, resilient and affordable structures. As developers, owners and AEC professionals seek ways to overcome market challenges and build faster, affordably and sustainably, FRAMECAD offers a proven path to structures that not only meet the demands of today but are built to last for the next hundred-plus years.

Bill : FRAMECAD is headquartered in Auckland, New Zealand.  What are your major markets currently and how do you serve these markets?

Curtis: FRAMECAD was founded in 1987 with a mission to put a roof over peoples’ heads. From humble beginnings selling roofing products in New Zealand, the company has grown and evolved to offer a full end-to-end solution for residential and commercial construction projects worldwide in over 120 countries and over 1000 FRAMECAD systems. We have a global network of local experts to support our customers. We recently opened a Customer Success Center in Las Vegas, Nevada, to provide live demonstrations and education to customers in the US. 

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Bill: At the heart of the matter is the cost effectiveness of CFS compared to wood frame construction.  Can you speak to the cost effectiveness of CFS, both upfront and over the total cost of a project?

Curtis: The design-led process and precision manufacturing of CFS framing components minimize waste and allow for a more sustainable construction process with lower material costs. Because they are manufactured with precision, CFS panels and components are easy to assemble and come together seamlessly with less labor required on site.

CFS’ durability, strength and ability to withstand extreme climate events reduce risk for contractors. The non-combustible nature of steel significantly lowers the risk of fire-related incidents, a primary concern for insurance providers. By opting for steel framing, developers and builders can benefit from substantially lower builder’s risk insurance premiums. These savings can be considerable, particularly for large-scale projects where insurance costs constitute a significant portion of the budget. The use of steel-framed products can reduce premiums by 25 to 75 percent. 

Unlike wood, which can be subject to variations in standards due to factors such as knots and grain patterns, the strength and durability of CFS are consistent—the reliability and predictability of CFS results in projects with less rework and costly construction delays.

The durability of CFS framing reduces the need for maintenance for a lower total cost of ownership. It leads to fewer claims related to damage from pests, rot and structural failures, which lowers insurance costs. Over time, the cumulative savings from reduced insurance premiums and maintenance costs can substantially affect a building’s overall cost.

The fast, accurate production and assembly of steel framing and the ability to build multiple components simultaneously also result in significant savings. Craning the components into place saves on safety precautions, scaffolding and insurance costs. This accelerated construction cycle reduces the total project cost and allows owners to occupancy buildings more quickly.

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Bill: CFS is often perceived as less sustainable or environmentally friendly than wood.  How does FRAMECAD approach sustainability in its processes and materials?

Curtis: While CFS framing is sometimes seen as less sustainable than wood, FRAMECAD integrates sustainability into every aspect of its construction process. Our precision-driven, offsite manufacturing minimizes waste, and our advanced design software ensures optimal material use.

CFS structures are also highly energy-efficient, reducing environmental impact over their lifespan. Its durability ensures long-term sustainability, as they are adaptable to climate extremes, requiring fewer repairs or replacements. This resilience reduces resource consumption and helps buildings maintain their performance for decades.

Additionally, steel is 100% recyclable. At the end of a building’s life, the material can be recycled and repurposed to create new structures, contributing to a circular economy and reducing the need for virgin raw materials.

At FRAMECAD, sustainability is embedded into our entire process—from design to manufacturing—helping our clients build faster, smarter, and more environmentally responsible structures.

Mobile Factory revolutionises remote and disaster relief construction

Bill: With the rise of modular and prefabricated/offsite construction methods, how does FRAMECAD’s technology enhance efficiency and flexibility in design and construction?

Curtis: FRAMECAD’s end-to-end solution covers the entire CFS process, from design and manufacturing to assembly. Our roll-forming equipment, design and engineering software and production management solution are integrated and open, giving every stakeholder an entry point to take advantage of the benefits of CFS whether they use FRAMECAD’s design software or other design software from providers such as Autodesk, Structsoft, Tekla Structures or Vertex.

Our goal is to make it easy for owners, developers and manufacturers to take advantage of CFS steel framing, so we offer files from any design software to feed production-ready data into the FRAMECAD ecosystem.

Our latest innovation, Nexa, is the first end-to-end production management platform designed specifically for cold-formed steel framing. With Nexa, cold-formed steel manufacturers have complete visibility into operations and real-time project data for complete control from the factory to the job site. With a single platform for project management, factory operations and jobsite efficiency, manufacturers can deliver projects faster, with less waste and more predictability. Nexa gives manufacturers the visibility they need for seamless communication and collaboration with contractors and owners, building trust from start to finish.

Bill: What are the major hurdles to overcome in growing the CFS offsite industry?

Curtis: Despite the proven benefits of offsite manufacturing, which include repeatability, less reliance on skilled labor and schedule efficiencies, less than 4 percent of current U.S. housing stock is built using modular techniques. Change is difficult, and for many in the construction industry, doing things as they’ve always been is perceived as easier.

And yet, construction projects are most often over budget and behind schedule. A shortage of skilled labor, the pressure of climate events calling for more resilient structures, tremendous waste in construction processes and practices, and the responsibility for a more sustainable future beg for a solution. We’ve reached a tipping point, and it’s time for a better way to build.

The combination of offsite construction and cold-formed steel offers a solution to owners and developers frustrated by wasteful, delayed and over-budget projects.

The biggest barrier is visibility among developers and owners, as well as educating architects and engineers to consider steel framing as a design alternative.

Bill: What are some notable projects or partnerships that highlight the strengths of FRAMECAD’s systems?  

Curtis: Industrialized Construction Solutions (ICS) engineers, designs, and manufactures prefabricated buildings across the US.

When the company opened its doors 17 years ago, it primarily focused on prefabricated panelized penalized wood buildings. In search of a solution for a shrinking labor force and complicated supply chains, ICS started exploring the applicability of CFS to its design, engineering and delivery and discovered FRAMECAD.

ICS adopted CFS for its stability and resilience benefits over wood. Today, ICS partners with manufacturers who use FRAMECAD equipment to produce CFS designed for seamless manufacturing, assembly and installation in the field. The speed, efficiency, and precision lead to a higher quality product than what general contractors traditionally see arriving at the site.

The FRAMECAD network is critical to the success of ICS. The company works with multiple manufacturers nationwide that use FRAMECAD, allowing it to deliver a standard product with constant quality through multiple vendors. 

Bill: Thanks to Curtis for an introduction to an innovative world leader in CFS offsite construction. The FRAMECAD website is extremely informative and I encourage our readers to visit the site—it just may present a highly sustainable alternative to the way we’ve been building for the last 100+ years!

Having spent over 40 years in the offsite construction industry as a GM and COO, I’m no stranger to the challenges of managing modular manufacturing projects. My team and I constantly navigated a sea of spreadsheets, charts, and verbal communications, trying to keep everything from design approvals to deliveries in sync. Needless to say, when I came across Offsight’s project management software, it immediately caught my attention.

Back in the day, we would have eagerly explored how Offsight’s innovative tool could simplify the planning, tracking, and communication challenges that came with modular projects. From real-time updates to streamlined processes, this software offers solutions that are as close to seamless as I’ve seen for managing everything from pre-production to post-delivery—engaging all key stakeholders, even those on-site.

Panel fabricator Valley Interior Systems leverages Offsight for collaborating and coordinating with stakeholders during offsite projects

But don’t just take my word for it. Offsight has case studies that show real-world applications by industry leaders already using the product. If you’re in the offsite manufacturing space—whether you deal with volumetric builds or components—this is worth a deep dive.

In this interview, I sit down with Andrew Xue, co-founder of Offsight, to learn more about the innovation driving their platform and how it’s transforming the way we manage modular projects. Let’s dig into how Offsight can reshape your operations.

Bill Murray Offsiteinnovators co -founder: Offsight is all about optimizing construction project management. Can you tell us the story behind how Offsight was founded and what specific gap in the industry you aimed to fill?

Andrew Xue,COO & Co-Founder at Offsight

Andrew Xue co-founder of Offsight: Offsight was founded from the consulting work and experience of its founders, Vikas Murali and Andrew Xue with a combined two decades worth of experience in prefabrication. We had worked with many project manufacturers whose process involved designing for manufacturing and assembly (DfMA). They realized that the DfMA industry lacked a project and production management software that could be adapted from project to project to meet their changing project specific manufacturing workflows. Working with their original consulting clients they built a minimum viable product (MVP) that would then become Offsight.

Bill: Offsite construction is booming, but managing projects can still be complex. How does Offsight streamline project management, and what makes your platform stand out from other software solutions?

Andrew: Offsight is built specifically for manufacturers and prefabricators who’s DfMA process requires different manufacturing workflows for each product design. Offsight was built as a fully cloud-based solution with both mobile and desktop interfaces to allow for real time collaboration and communication from the floor. We also provide a full suite of solutions to manage a prefab project from planning and forecasting, through production, shipment, delivery, and installation. Our software is built specifically for prefabricators who follow a DfMA process and therefore is a better fit than off the shelf manufacturing operations management or generic project management solutions.

Bill: Data is critical in construction. How does Offsight harness data to improve the efficiency and accuracy of offsite building processes, and what kind of real-time insights can users expect?

All data collected in Offsight is recorded in real-time from the prefab floor and throughout the offsite construction project lifecycle. The time series data we collect includes everything from production progress to material consumption and labor tracking on who worked on specific products and during which process. This data is then consolidated and can be visualized with dynamic charts and dashboards using our Real Time Analytics feature set.

Volumetric steel modular manufacturer Z Modular leverages Offsight to track quality, conformance, and rework.

Bill: What role does Offsight play in improving collaboration between different stakeholders in offsite projects, from modular, panel, and component manufacturers to project managers and contractors?

Andrew: Offsight has an unlimited user model, where customers can add everyone from floor operators and supervisors to project managers, estimators, executive management and even third-party inspectors, general contracting partners, and project owners. Our Reports & Auditing feature set includes daily production progress updates, quality or non-conformance issues and shipment sign-offs can then be tracked and sent within Offsight

to all project stakeholders to ensure everyone has the latest updates and whether the prefab projects are still on track to be completed on time and within budget.

Bill: In what ways does Offsight’s platform contribute to sustainability and waste reduction in offsite construction? Are there any success stories that highlight this impact?

Andrew: Many of Offsight’s customers leverage our Materials and Inventory Management feature set which allows them to track waste in real-time during the materials receiving process or during assembly and installation. Customers can then review the root cause of wasted materials via Offsight’s analytics dashboard to see if process improvements can help reduce assembly errors. Offsight customers can also determine if certain suppliers are shipping defective parts or if parts are damaged on receipt, in which case switching to more reliable vendors may be the solution to improving overall waste reduction.

Luxury modular manufacturer Northstar Systembuilt leverages Offsight to track production progress from the shop floor.

Bill: Looking ahead, how do you see technology like Offsight evolving, and what future innovations in project management are you most excited about for the offsite construction industry?

Andrew: I think technology like Offsight has the real potential to enable the growth of offsite construction by helping prefabricators deliver on the promise. The promise being faster project delivery at lower cost and higher quality than traditional jobsite construction. By leveraging technology like Offsight, prefabricators can actively manage their production progress, materials management and labor to make ensure they are delivering on their goals.

Bill: What do you see as Offsight’s biggest challenge in growing your business?

Andrew: Our biggest challenge is delivering the right features and functionality to support customers at every stage of their offsite construction journey, whether they’re planning their first factory layout or managing multiple production lines across several factory locations. It’s crucial for Offsight to clearly communicate how our tools can address their specific needs. Additionally, we aim to encourage prefabricators to adopt technology early on, as it can be a key differentiator in the success of their projects. When our customers thrive, it not only benefits them but also drives more engagement, interest, and investment in offsite construction, ultimately advancing the entire industry.

Bill: Thanks to Andrew Xue of Offsight for opening the door to an awareness of what’s out there. Whether you are a manufacturer or a vertically integrated developer/manufacturer, I would encourage you to check out their website. At the very least there is much food for thought.

In talking recently with an Offsite modular manufacturer I was impressed with their interest in a relatively new innovative air distribution system that appears to have many distinct advantages not only for modular manufacturers but also for site built multilevel projects. After contacting Rheia and talking with Nigel Watts VP at Rheia, their product does have all the earmarks of an innovative approach that bears further exploration.

 Nigel Watts, Vice President of RHEIA, LLC

Bill Murray, Offsite Innovators: Would you give us a brief history and description of your company?

Nigel Watts,VP Rheia HVAC Stystems: Rheia’s journey began in 2019 after nearly a decade of research, development, and rigorous testing of an innovative HVAC air distribution system designed for optimal efficiency and enhanced comfort. Backed by capital from seven of the nation’s largest homebuilders, leading industry manufacturers, and numerous individual investors, Rheia assembled a team of seasoned manufacturing, supply chain, and software development experts dedicated to redefining comfort and efficiency in homebuilding. In the spring of 2020, Rheia launched our first pilot home, marking the beginning of a new era in HVAC technology. Rheia is currently active in most major homebuilding markets in the US and is installed in over 20,000 homes in the US and Canada.

Bill Murray: Rheia touts an innovative system that revolutionizes the installation of Hvac products in the homebuilding industry.  Would you describe your unique system?

Nigel Watts: Rheia is a home-run, small-diameter air distribution system installed within the home’s conditioned space, designed to reduce energy use and improve HERS scores. The system features durable, uninsulated ducts and engineered thermoplastic fittings that quickly assemble to create sealed connections without the need for imprecise, messy duct mastic. Rheia is engineered for easy installation, boosting productivity for HVAC contractors in an industry facing labor shortages. Paired with the industry-first Rheia Verify balancing app, the system enhances thermal comfort and minimizes the costly callbacks commonly seen with conventional duct systems.

Bill Murray: How does the Rheia approach differ from conventional, traditional HVAC applications making it truly innovative?

Nigel Watts: Rheia’s air distribution system changes the game by dramatically simplifying installation. It can reduce installation time by up to 60%, to keep projects on track and maintain high productivity despite workforce shortages. Training for the installation process can be accomplished in mere minutes.

Balancing a traditional HVAC system is another headache—it’s labor-intensive, error-prone, and often leads to uneven temperatures and higher energy bills. Many systems fail to consider the home’s orientation, leading to inefficiencies that require multiple site visits, increasing costs and frustrating customers.

Rheia tackles these problems with its Verify App, a powerful tool that simplifies the complex balancing process into just 10 straightforward steps, taking only 30 to 45 minutes to complete. The app guides technicians through each stage, from verifying equipment settings to adjusting blower speeds and entering room airflows. This ensures that the system operates as intended, reducing the risk of costly errors and ensuring customer satisfaction.

In short, Rheia’s air distribution system and Verify App streamline the installation and balancing of HVAC systems, improving performance, reducing costs, and addressing labor challenges. This innovative approach ensures that HVAC systems work efficiently and effectively, leading to happier customers and more successful projects.

Bill Murray: What are the significant advantages to a builder in using the Rheia system?

Nigel Watts: While solutions like conditioned attics and deeply buried ducts can help reduce heating and cooling costs, Rheia takes a more efficient approach by installing ductwork within the home’s thermal envelope. This method is faster, easier, and more cost-effective. Recent code changes, upgraded tax rebates, and energy incentives are pressuring builders to improve the energy performance of their homes.

The most cost-effective way to meet these new requirements is to move ductwork inside the home’s conditioned space. The challenge they face, however, is that it is costly to make this change. Due to the complexities of rerouting bulky, insulated ducts or creating conditioned attic spaces, Rheia’s compact system is the only cost-effective way to bring ducts into conditioned space. Beyond the financial benefits, builders can also realize improved HERS scores with this approach, improving the marketability of their homes.

Bill Murray: What are the specific advantages of the Rheia products to the Offsite building industry,  particularly to the volumetric modular industry?

Nigel Watts: The Rheia system is a highly engineered solution designed for efficiency and precision. Its high-performance components snap together seamlessly, eliminating the need for time-consuming post-operations such as air sealing after assembly. This approach is perfectly aligned with the volumetric homebuilding approach, which emphasizes a systems-based method of manufacturing that thrives on consistent, repeatable processes.

Rheia’s straightforward design allows installation crews to be trained in just minutes, a significant advantage in an industry facing skilled labor shortages. This combination of simplicity, speed, and reliability makes Rheia an ideal choice for modern homebuilding, where efficiency and consistency are paramount.

Bill Murray: This appears to be a different approach to HVAC installation.  How does Rheia provide training and support for new HVAC contractors?

Nigel Watts: Rheia takes a hands-on approach to guide a contractor through the change management process providing on-site training and easy-access resources. We pride ourselves in our dedication to supporting contractors as they transition to Rheia.

How has your product been accepted in an industry that often resists change?  What are your plans and goals short term as well as long term?

At Rheia, LLC, we’ve observed a wide variety of reactions from builders and contractors as they encounter our system. The homebuilding industry, with its deeply ingrained practices and reliance on traditional methods, can be resistant to change. This resistance is understandable; altering established processes can disrupt workflow retraining, have the potential to impact financial results, and initially seem risky.

However, we’ve found success when partnering with companies that are open to exploring new solutions and willing to embrace the benefits that come with innovation. These forward-thinking builders and contractors recognize that while the transition may pose challenges, the long-term gains—such as improved energy efficiency, reduced installation time, and enhanced system performance—are well worth the effort.

Above all, we’ve learned that patience is essential when introducing new products to the market. Change management in this industry requires time, persistence, and a deep understanding of the challenges builders and contractors face. We are committed to working closely with our partners, providing the necessary tools, training, and support to ensure a smooth transition and, ultimately, a successful integration of Rheia’s advanced air distribution systems into their projects.

The future is bright for Rheia, and for the industry. Gradually, we are having an impact n and refining our business processes and understand of how to make change as painless as possible for our customers. Looking forward, Rheia will be expanding into new segments of the residential homebuilding market, and we have a range of exciting new products already in the works.

Bill Murray: Thanks to Nigel Watts, VP at Rheia for the introduction to an innovative approach to hvac distribution systems. In talking with several modular manufacturers they have expressed a keen interest in this system. Be innovative……check it out.

OFFSITEK is rapidly becoming a leader in automated offsite industrialized construction. Offsitek provides extensive services to support GC’s and owner developers. Their robotic based manufacturing plant produces light gauge steel framing panels, but there is so much more to their vertically integrated approach to offsite construction.

Learn more about this Charlotte, NC based company as Dwight Morgan, Chief Manufacturing Officer & Co-Founder of Offsitek, talks about the role of light gauge steel modular panels coupled with their unique marketing of complete on site support and services.

Co-founders Rick Admani (left) and Dwight Morgan (right)

Dwight thanks for taking the time to share Offsitek’s current efforts as well as your company’s plans for future expansion. Let’s talk not only about light gauge steel products but also your offerings in total support packages to GC’s and owner/developers.

Bill Murray Offsite Innovators: Can you give me a brief overall description of Offsitek as a company?

Dwight Morgan Chief Manufacturing Officer and Co-Founder : OFFSITEK is an automated, offsite, industrialized construction company. We provide light gauge steel framed panelized systems to the commercial and multi-family residential new construction market. We fabricate these lgs panels in our state of the art manufacturing facility just outside Charlotte, NC. Our fully integrated panelized systems are energy efficient, disaster-durable, sustainable, and fire resistant. We offer complete end to end solutions in addition to our manufacturing capabilities. We sell to GC’s who have their own self-perform teams to erect the panels. Our concentration is on providing wall systems, floor cassettes, stairwells, elevator shafts, bathroom, kitchen, and laundry mechanical pods. Our focus is on supporting GC’s and owners.

Bill: What inspired the formation of Offsitek?

Dwight: The inspiration behind the formation of Offsitek was driven by two key issues: 1) the fact that the construction industry is one of the largest industries in the U.S., representing over 13% of our GDP, and 2) that the industry has a historic record of very poor productivity.

Offsitek was inspired by the stark reality that the US construction industry was underperforming and unable to meet the needs of a growing market. We were inspired by the fact that over 500,000 US citizens are homeless every night due to lack of supply of shelters and affordable housing solutions. Our challenge was to introduce prefabrication elements to make construction resemble that of modern day, industry 4.0 manufacturing.

Bill: What led you to focus on offsite construction and pre-fabrication?

Dwight: Our extensive research indicates that the construction industry will need almost 1 million additional workers to meet the demand for labor through 2025. Offsite construction reduces the need for skilled labor that traditional on site construction demands. Offsite construction appeals to a workforce that does not wish to move from one construction site to another, but that takes place in a controlled setting not subject to weather extremes and other variables. Other advantages include condensed predictable schedules, curtails rework and waste, dramatically increases productivity and reduces costs.

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Bill: What are the core innovations that Offsitek has introduced to the offsite construction industry?

Dwight: Offsitek has pioneered many industry-first innovations in its pilot factory in Charlotte NC. 1) We have developed a “kit of parts’ featuring Design-Lead Architecture, 2) Digitalization of Design for Error Proofing of MEP Integration, 3) Building Science for Passive Energy Buildings 4) Automation of construction–lgs panelization of walls, floors, and roofs. 5) Prefabricated lgs volumetric bathroom and kitchen pods, 6) collaboration of workers alongside automation, 7) Adoption of steel vs wood panels and pods in multifamily, multi-level residential projects.

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Bill: How does Offsitek integrate technology such as BIM and 3d modeling in its construction process?

Dwight: Offsitek integrates four key computer technologies in its construction process, We combine VDC, BIM, Cad to Steel CNC machine file production and Cad to Steel Robotic Motion creation. All four systems comprise our unique “Cad-to-part prefabrication processes.

All construction projects are fully digitalized using 3D modeling. We rely upon certain systems from our technology partner, Autodesk, and upon their plug in developer partner Graitec/Stucsoft. We rely on Autodesk as well as MWF, Onyx, and ABB Robot Studio to create all digital workflows.

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Bill: To what extent is Offsitek focused on affordability and sustainability?

Dwight: Offsitek’s reliance upon steel framing plays a critical role in our focus on sustainability. Besides water, steel is the most recycled material on the planet. As such, our steel based framing solutions are based upon using steel, which is 98% recyclable, and in itself consists of approximately 75% recycled content in all new steel that we use in our process. Our focus on supply chain management results in decreased materials costs which contribute to making our products increasingly affordable.

Bill: What are Offsitek’s goals for growth?

Dwight: Our forward-looking 5 year outlook, known as our Next Level Strategy, is to expand the reach of our innovative process to other markets in the US. We are also in the planning phase of expanding within NC.

We have already begun in this Next Level Strategy through our recent joint venture with Visions Manufacturing of Canton, MS where our second state of the art automated prefabrication facility will open in late 2025.

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Offsitek will be focusing on manufacturing critical building components and systems especially applicable to the volumetric manufacturers. Modular elevator shafts, modular stairwells, kitchen and bath pods, will be manufactured for delivery and integration into onsite construction processes.

Again thanks to Dwight Morgan for sharing the innovative approach to using light gauge steel manufacturing of modular panels and extensive support systems available to GC’s and owner/developers. Innovation is the key to the growth of the offsite construction industry and Offsitek exemplifies the possibilities.

Offsite Innovators is launching our website with a truly innovative topic and a leading innovator. Merrick Macomber, wears many hats one of which of which is Chief Culture Officer at Autovol Volumetric Modular in Nampa, ID. Her innovative approaches however transcend her work at offsite innovator Autovol.

Learn more about this Innovator as I interview Merrick Macomber. Thank you Merrick for taking the time to share.

Merrick is Chief Culture Officer, an innovative title to say the least, at Autovol Volumetric Modular in Nampa, ID.

Bill Murray: Can you share your background and how it inspired you to work in the offsite construction industry, particularly with Autovol?

Merrick Macomber: I started my modular career at another local off-site builder over a decade ago. I always knew the construction sector was a good industry where a person could put in hard work and effort and make a decent income with or without a pedigree. At the time, this innovative company was building the Yellowstone Lodges using volumetric modular methods. I found this work fascinating. During my time there, I had the opportunity to take on many different roles, from the front desk to accounting, HR, and Safety Manager. I was also their self-appointed Director of Employee Happiness. One of the Founders and COO of that company was Rick Murdock, Autovol’s Co-Founder & CEO, and Prefab Logic’s Co-Founder and Chairman. In 2015, he sold his portion of that company and moved on to what we’re doing today. On his last day, he tapped on my desk as he walked out the door and said: “Hey, Sunshine, you’re coming with me.” And the rest is history. I was there at Prefab Logic’s beginning days, helping create the brand, values, and culture they have today, and I was there at Autovol’s conception, too. I was honored to give Autovol its name, design our logo, and drive culture. I am Solutioneer number two, after Rick. I collaborated with the first eight Solutioneers to determine what we stood for, how we appeared, and what we wanted to become through our vision, mission and values. Today, we are known for being a destination employer full of proud Americans innovating in construction in ways that haven’t been seen before. It’s been an incredible journey in this space.

Bill: How would you characterize your overall philosophy with respect to a company’s culture?

Merrick: The way you feel at work can ripple out into society in a positive way. A workplace culture can actually spread more light and love to the world, helping the battle against good and evil. That might seem like a lofty philosophy on culture, but we should aim high. A good or bad culture genuinely impacts people’s lives. We spend so much time in the workplace. People should be happy and fulfilled at work and feel like they fit in as the individuals they are.

Bill: In your opinion what makes an employee (or Solutioneer) as you have named them, want to go to work every day and sometimes even Saturday and Sunday?

Merrick: The people who surround us and the purpose of their work are significant factors in a person’s desire to work. Work-life balance matters, too. At Autovol, we intentionally designed the workweek to support family life, even providing Fridays off and three-day weekends as the norm. You might be more excited to go to work knowing you will have plenty of free time to recharge. There’s “light at the end of the tunnel every week.”

Bill: What has happened innovatively at Autovol, in the realm of employee engagement, because of your focus on the crucial role of building the proper culture?

Merrick: We have a “Solutioneer Intel Form” that tells us much about each Solutioneer. That helps us get to know them and celebrate who they are from day one. Another innovation I thought turned out pretty cool was the term “Solutioneer” I came up with. It allowed everyone to have freedom of thought, expecting them to innovate as Solutioneers. It’s a term of endearment and a name that lets everyone know they are part of a pioneering, innovating, and problem-solving team. I am proud to be a Solutioneer. It’s an innovation and movement that has a high level of belonging. It also empowers everyone at the point of use to bring forward ideas that will improve the things they know better than anyone else.

Bill: What was your biggest challenge at Autovol in terms of building a culture?

Merrick: Unwinding the ingrained habits that people previously experienced in other cultures. People get trained to stay in their lane and believe in limitations or “the way it’s always been done.” We must help them not fall into their old ways and take for granted that the old ways will work at Autovol. This can include the way we do work, as well as the way we treat and talk to each other. Also, our philosophy is to help people be leaders in every role…not just management roles.

Bill: What do you think the biggest mistake(s) offsite manufacturers make in terms of their company culture?

Merrick: Most manufacturers are looking for workers. We’re looking for a family member. That means they need to meet our existing family, and our family needs to meet them. That’s why our hiring process includes three phases to give everyone a chance to ensure it’s a comfortable, enjoyable fit. Culture is not a thing you do. It’s the way all of us behave and the company’s character. You can’t just grill some hotdogs and hamburgers and call it culture. It must be nourished by being genuine and appreciating the people you work with for who they are, minute by minute and day by day. Although having a cultural leader is beneficial, maintaining the culture is not one person’s job. It’s a team sport.

Bill: What is your approach to building a company culture that is true to the company’s mission?

Merrick: Everyone must align on the mission and the values we share. There needs to be a clear and inspiring vision that will make people want to band together and be passionate and proud about their work daily.

Bill: Tell us about your other interests and efforts currently outside your role as Chief Culture Officer at Autovol.

Merrick: I’m a full-time working Mom of a sweet and smart 13-year-old girl, and we have two adorable puppies. I enjoy traveling, extreme sports, and live music. I’m engaged in the community in many ways to evangelize our industry—locally in our community and nationwide at industry events. Besides Autovol, I lead culture efforts at Prefab Logic, Waypaver International, and my culture consulting company, Modular Maven.

I spend significant time working with youth throughout our valley, with a focus on building programs for off-site construction. Throughout the school year, I give many Autovol and Prefab Logic tours to 5th -12th grade students. Doing these things to help youth and grow our industry is something I’m proud to be part of. In 2015, I founded a non-profit, Dragonflybrary, that supports mental health awareness and suicide prevention, which I’m also very passionate about. Thanks for asking! 😊

Bill: What gives you the most satisfaction as you build a company culture?

Merrick: Knowing that we can positively impact someone’s life. By doing that, we often see that making a difference can ripple through our company, but just as important, it can spread far beyond our walls. We see it every day as people visit our company and leave inspired. I genuinely believe that the only way to build our industry is to remove the stigma many people have about working in a factory environment. We do this by giving people a mission, purpose, and career path. But more than that, we are creating a repeatable climate that is so attractive that it is a model for how to be a “destination employer.” A place that people want to work in and a place where people want to stay. By doing so, I believe our growing construction sector will appeal to younger generations, who will be enticed to want to be part of the movement. It’s satisfying to be helping drive the off-site industry mainstream. It’s also satisfying to have a hand in bringing people and robots together as a team in the construction industry, and see how exciting and empowering that is for our Solutioneers.

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Bill: In a few sentences, what advice would you give to any offsite manufacturing company or even other companies in other industries?

Merrick: Open your heart and genuinely care about the people building your company. Get to know them—their hopes, dreams, desires, and struggles. Do your best to support the whole human you’ve employed. It will affect you if you’re not taking action to ensure employees are engaged and satisfied. You’ll gain a reputation for being an excellent workplace by showing genuine care for those you employ. It’s hard to put a dollar amount into that type of recruiting.

Innovation isn’t restricted to manufacturing methods and materials. As Merrick exemplifies, innovation can and must be integrated into a company’s approach to establishing their organizational health. A final thank you to Merrick for helping spread the word.

Bill Murray, co-founder of Offsite Innovators, is a 40-year veteran in the Offsite industry. His goal is to assist in the growth of the industry by presenting and sharing innovation.

CLICK HERE if you would like to be interviewed about something innovative you have designed or are currently using.

Several weeks ago I had an opportunity to learn about a panelized start-up in Durango, CO. I was immediately struck by their innovative approach to maximizing sustainability through the use of readily available underharvested Ponderosa Pine. Timber Age and their use of cross-laminated timber (CLT) which is composed of sustainable Ponderosa Pine, epitomize true sustainability.

I talked with Kyle Hanson, co-founder of Timber Age Systems about his team’s approach and work at this innovative panel manufacturer in the heart of sustainable timber country. Thank you Kyle for leading the charge on providing innovation through sustainability in Offsite manufacturing.

Kyle and Charlie. Kyle is the one on the left!

Timber Age Systems Interview Questions

Bill Murray, Offsite Innovators: Would you summarize your current business model?

Kyle Hanson, Cofounder of Timber Age : First and foremost, Timber Age™ makes durable, attainable, high-performance homes in an off-site modular factory. The homes are produced from locally and sustainably harvested Ponderosa Pine.

Our business model leverages a local value chain and community partnerships supplying design, engineering and installation support. This focus on circular economics allows Timber Age™ the chance to address forest health, housing constraints and job creation while significantly improving the built environment in terms of embodied and operational carbon content.

Secondly, Timber Age™ is continually refining a replicable production model in preparation for widespread expansion over the coming decade. This production model prioritizes shared ownership, a short amortization of investment capital and a flexible and adaptive learning environment supplied through the Timber Age Operating System (TAOS).

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Bill: What inspired you to found Timber Age Systems?

Kyle: After spending four years as the Business Unit Leader for a local wood products manufacturer working closely with the US Forest Service, I developed a curiosity to better understand how to create a use for the overabundance of Ponderosa Pine in our region.

In addition to unhealthy forests, many teachers of my two daughters struggled to establish stable local housing. An inability to establish an “anchored” existence in our community frequently ended in job openings. This damaging pattern of churn repeats across public servant roles resulting in instability for schools and local government.

Last, but not least, many in our community maintain seasonal and overlapping jobs in an attempt to achieve sustainable adjusted median income (AMI) levels. My background studying and implementing Lean Operating Systems to achieve world-class manufacturing operations illustrates how the creation of predictable, safe and rewarding skilled labor jobs could help create more anchored community members.

A 2018 USFS Wood Innovation Grant award catalyzed an amazing group of individuals collaborating around the key market definition and challenges. This group problem solving process eventually allowed our co-founder Andy Hawk to enter the fray as team member number two.

Most of the idea development has followed the ideas inherent in the world of Lean (Operational Excellence, TPS, etc). These themes surrounding rapid experimentation and improvement have been codified in the excellent book “The Lean Startup” by Eric Ries. Our team is continually working to clearly identify a problem and its causes and then establish an experiment where we can test a hypothesis to address the problem. When we do this in a disciplined and continuous manner, Timber Age™ gets better and we all get smarter and more connected as a team.

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Bill: How would you describe some of the most innovative solutions Timber Age Systems has developed for offsite construction?

Kyle: Our approach to vertical integration and small scale manufacturing of Cross-Laminated Timber (CLT) seems to be a differentiating factor in the worlds of mass timber and off-site manufacturing. We don’t have a huge factory with giant cranes, and yet we create beautiful enclosures which are easily installed.

In the long-term, we believe our integrated approach to helping create housing, fulfilling jobs and healthy forests will provide a powerful model for sustainable community development around the world.

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Bill: In what way does Timber Age prioritize sustainability in its innovative approaches to construction?

Kyle: Timber Age™ is intensely focused on both the embodied carbon and operational carbon of buildings. A key mission metric for our team is miles traveled/ pound. In this way, we can look at the many components in one of our assemblies and create a weighted average of the total waste associated with transportation. In addition, our assemblies are almost completely foam-free.

Our CLT is constructed from trees which would have otherwise released carbon dioxide into the air due to overcrowding, fire and disease.

This approach to using a carbon-sequestering structural material (CLT) combined with recycled cellulose insulation (also carbon-sequestering) means an enclosure with net-zero embodied carbon and a home with super low operational carbon emissions due to the passive house building science behind our system design.

The Timber Age™ Modular Building System (TAMBS) incorporates low-carbon materials and is designed to meet the Passive House building standard.

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Bill: What are some of the biggest challenges you have faced in gaining an acceptance of your innovative approach both locally and regionally?

Kyle: Since the Timber Age Modular Building System (TAMBS) contains many unique innovations, our biggest challenge was proving out the ability to manufacture the system at a hyper-local scale. After proving out the system, our biggest challenge has been builder uptake of our approach. Introducing an innovative building system into a marketplace where demand for the status quo is still outstripping the capacity of local builders doesn’t incentivize builders to seek out or make time for learning a new system even if many of the builders understand and appreciate the inherent value proposition.

Matt Betts, Value Stream Manager

The world of building, much like the world of healthcare, encompasses multiple customers with varying definitions of value. We are working hard to collaborate with as many stakeholders as possible to ensure the highest level of value is created for each step off the value chain. We believe our system is easy for designers to implement, very quick and effective to install for the builders and beautiful, durable and very energy efficient to help enforce the inherent value for the end users.

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Bill: How important are collaborations and partnerships as you seek to grow your business?

Kyle: Timber Age™ would not exist without the help of our local forest collaboratives, fellow building scientists, collaborating designers and contractors and especially the funding and support of the US Forest Service and our incredible mission-driven shareholders.

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Bill: What are you short- and long-term goals for Timber Age Systems and what philosophy did you use in developing these?

Kyle: Short-term: Get our new interim factory running to produce our current backlog of projects and hire another ten great team members.

Long-term: Construct our new prototype factory and housing models in Mancos and then replicate this model across all viable markets to help create 1000+ fulfilling jobs and hundreds of thousands of durable, beautiful high-performance housing units around the world.

Our philosophy around planning, Hoshin Kanri, follows the teaching and examples of Toyota and other world-class companies.

Tens of thousands of acres of sustainable pine being put to use by this innovative panelizer in Durango, CO. Sustainability is more than a buzzword at Timber Age Systems, its a way of doing business and a way of life.

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Bill: I want to thank you , Kyle, for a very insightful, behind the scenes look at what you and Timber Age Systems are currently doing and what you have planned for the future.

Bill Murray, co-founder of Offsite Innovators, is a 40-year veteran in the Offsite industry. His goal is to assist in the growth of the industry by presenting and sharing innovation.

CLICK HERE if you would like to be interviewed about something innovative you have designed or are currently using.