Highlighting the thinkers and their ideas driving the evolution of Offsite Construction. 
Be inspired, be informed, be innovative!

How Reframe Systems Is Disrupting the Construction Status Quo

The construction industry often resists change, but one startup is proving that with vision, engineering, and perseverance, the system can be reimagined—quite literally. San Leandro-based Reframe Systems just won the prestigious 2025 House Building Prize from the Centre for Natural Material Innovation at the University of Cambridge, recognizing their groundbreaking robotic and offsite construction platform. The prize isn’t just a trophy—it’s an acknowledgment that the industry’s old ways are under review, and Reframe’s new approach could be the blueprint for what’s next.

all photos -Reframe Systems

So what makes this company different? The name says it all: Reframe. They’re not tweaking the edges of conventional construction—they’re flipping the entire framing process on its head.

Reframe’s approach is built around a modular panelized wall system that’s designed to work seamlessly with both robotic manufacturing and on-site assembly. Unlike traditional prefab systems that rely on lumber-framed panels or heavy volumetric boxes, Reframe’s solution uses robotically produced steel frames that are precise, scalable, and environmentally considerate.

Each panel is a complete building block—pre-fitted with wiring chases, plumbing paths, and insulation compartments. Their innovative connector system makes field installation as easy as snapping components into place. Think IKEA-meets-industrial-engineering—with a focus on high-performance housing.

The result? Buildings that go up faster, with far less labor, tighter tolerances, and improved energy efficiency. And in an industry currently suffering from a global skilled labor shortage, that’s more than innovation—it’s a lifeline.

Founded in 2022 by a team of software engineers, roboticists, and sustainability advocates, Reframe Systems understood early on that automation had to serve more than just profit margins. Their guiding principle was simple: make housing faster, cheaper, and more sustainable—without sacrificing quality or design.

They began by developing a production system that could combine industrial robotics, AI-driven design software, and advanced materials to streamline every phase of the construction process—from design to delivery. Their factories are essentially smart workshops, where robots build walls that are ready to ship, stack, and install within hours of arriving on-site.

But automation is just the tool. The real value comes from how adaptable the Reframe system is. The panel designs can be configured for multifamily housing, townhomes, ADUs, and even disaster-relief shelters. The platform is scalable, and the technology is open enough to be licensed by other builders—making it possible for developers and general contractors to build more, faster, and with less capital investment than a traditional modular factory.

Winning the House Building Prize from a globally respected institution like the University of Cambridge sends a clear message: Reframe is no longer a “what if”—they’re a “what’s next.”

The Centre for Natural Material Innovation praised Reframe’s “holistic” approach, particularly their use of sustainable materials, efficient structural systems, and their dedication to closing the loop between digital design and physical delivery. The award committee also highlighted the potential impact of the Reframe System on underserved housing markets and its compatibility with low-carbon building goals.

For an industry often mired in regulatory red tape, outdated practices, and fragmented supply chains, Reframe Systems represents a breath of fresh air—and a technological leap forward.

What Comes Next

With their first pilot projects completed and several partnerships in the works, Reframe Systems is scaling up production and actively seeking collaborators. Whether you’re a developer, housing nonprofit, modular factory owner, or investor looking for the next big thing in offsite innovation—this is a company to watch.

As we continue to explore the innovators shaping tomorrow’s built environment, Reframe Systems reminds us that the future of construction doesn’t need to be built from the ground up—it can be snapped together, robotically manufactured, and radically reimagined.

Learn more at: www.reframe.systems


Offsite Innovators is dedicated to spotlighting the people, products, and platforms redefining how we build. Want your innovation featured? Contact us.

A Village for Our Heroes: Colorado Springs Builds Tiny Home Community to Honor and House Its Teachers – with video

In the heart of Colorado Springs, a beacon of hope and innovation is rising—one that addresses the pressing challenges faced by educators today. Harrison School District 2, in collaboration with the nonprofit organization We Fortify, is pioneering a transformative initiative: building affordable, dignified housing for teachers right on school grounds.

This visionary project, known as Wendy’s Village, is named in honor of Superintendent Dr. Wendy Birhanzel, whose unwavering commitment to educators has inspired a community-wide movement. Comprising 40 energy-efficient tiny homes, each 352 square feet, the village is set to occupy the former soccer field of Mountain Vista Community School. These homes are thoughtfully designed, featuring full kitchens, bathrooms, living areas, and bedrooms, all powered by electric energy. A central community center will serve as a hub for residents, offering a galley kitchen, event space, and raised garden beds.

The initiative addresses a critical issue: the affordability crisis that has made it increasingly difficult for teachers to live in the communities they serve. With starting salaries around $47,545, many educators struggle to afford housing in Colorado Springs, where the average rent is approximately $1,720 per month . Wendy’s Village offers these homes at a significantly reduced rent of $800 per month, providing a sustainable solution that allows teachers to focus on their vital work without the burden of financial strain.

Complementing Wendy’s Village is Prospect Village, a neighboring community designed for young adults aged 18-25. This development will offer 18 units at $600 per month and aims to provide long-term transitional housing, educational programming, and job opportunities for young people emerging from poverty .

The collaboration between Harrison School District 2 and We Fortify exemplifies the power of community partnerships in addressing systemic challenges. By leveraging district-owned land and the expertise of a nonprofit developer, the project minimizes costs and maximizes impact. Funding for the $6.5 million initiative is being sourced entirely through private, public, corporate, and foundation donations, ensuring that no taxpayer money is used.

This model of integrating affordable housing within educational environments not only supports teachers but also strengthens the fabric of the community. As Dr. Birhanzel aptly stated, “This project reflects our shared commitment to supporting educators and strengthening the future of our schools and neighborhoods”.

Wendy’s Village stands as a testament to what is possible when innovation, compassion, and collaboration converge. It offers a replicable blueprint for other districts grappling with similar challenges, demonstrating that with bold vision and collective effort, we can create communities where educators are valued, supported, and empowered to thrive.

As we look to the future, initiatives like Wendy’s Village inspire hope and reaffirm our commitment to those who dedicate their lives to educating the next generation.

Hempcrete Rising — The Eco-Friendly Material Paving the Way for Sustainable Construction

Amid the environmental impact of traditional construction, a humble, plant-based material is beginning to make waves—one block at a time. Hempcrete, a biocomposite made from the stalks of the industrial hemp plant, is turning heads not just for its sustainability, but for its strength, insulation value, carbon-storing capabilities, and surprising design flexibility.

Long relegated to the margins of building innovation, hempcrete is now experiencing a renaissance, with forward-thinking architects, builders, and factory operators exploring its potential for everything from residential homes to public infrastructure. Let’s explore how hempcrete is made, where it’s produced, how it’s being used in modern construction, and why its future looks more than promising.

Hempcrete is not a substitute for concrete in structural applications—but it’s not trying to be. Instead, it excels as a natural, breathable, insulating material used in wall assemblies, floors, and roof infills. It’s made from three ingredients:

  • Hemp hurds (the woody core of the hemp stalk),
  • A lime-based binder (often a mixture of lime, clay, and pozzolans), and
  • Water.

When mixed together and packed into forms around a structural frame, hempcrete cures into a firm, yet flexible matrix that insulates, resists fire and pests, regulates indoor humidity, and—most importantly—sequesters carbon throughout its life. Unlike concrete, it doesn’t off-gas harmful chemicals or require energy-intensive production.

For every cubic meter of hempcrete produced, approximately 110 kilograms of CO₂ are absorbed and locked away. It’s one of the few materials that make a building greener the more you build with it.

While many startups and regional manufacturers are entering the hempcrete space, a few major players are helping drive large-scale adoption:

IsoHemp (Belgium)

Founded in 2012, IsoHemp has grown into one of Europe’s largest producers of hempcrete blocks. Its automated factory near Namur, Belgium, produces thousands of units per day, which are used in residential and commercial buildings across Europe. Their standardized blocks are designed for speed and performance in wall construction and are available in multiple thicknesses for varying climate zones.

Hempitecture (United States)

Based in Idaho, Hempitecture is the first U.S.-based company to build a large-scale hemp insulation factory. Partnering with domestic hemp growers, they are scaling up the production of HempWool (loose fiber insulation) and cast-in-place hempcrete materials. Their materials are already being used in schools, wellness centers, and even prefab modular housing.

HempFlax (Netherlands)

One of the pioneers in European hemp processing, HempFlax has diversified its business across industrial applications, including construction. With operations in the Netherlands, Germany, and Romania, they supply hemp fibers and hurd to companies developing insulation panels, hempcrete, and green packaging materials.

As more countries legalize and regulate industrial hemp production, these types of facilities are expected to proliferate—especially in North America, where climate-conscious building codes are being rewritten to allow for low-carbon materials.

Hempcrete’s greatest strength lies in its versatility. Here are a few ways it’s already transforming modern building practices:

Wall Insulation and Infill Panels

Hempcrete is most commonly used to form non-load-bearing walls around timber or steel framing. It can be poured into formwork on-site or used in pre-cast panels for modular builds. In both cases, it provides exceptional thermal resistance (R-values of R-2 to R-3 per inch), reducing the need for additional HVAC equipment.

Floor and Roof Insulation

In addition to walls, hempcrete is being used as a subfloor insulation layer and for flat roof insulation, particularly in eco-homes and Passive House designs. Its moisture-buffering properties help prevent mold and mildew—an attractive feature for allergy-sensitive occupants.

Modular and Prefabricated Housing

Prefabricated wall panels filled with hempcrete are gaining traction in the offsite construction world. By combining the sustainability of hemp with the speed of prefab, companies are creating zero-energy and low-impact homes at competitive cost points. Hempitecture and a handful of startups in Canada and Australia are already experimenting with full-panelized hemp-based modular units.

Renovations and Retrofits

Because of its breathability and low weight, hempcrete is ideal for restoring older buildings—especially stone or masonry structures. It allows historic walls to maintain their natural moisture balance while adding insulation and fire resistance.

Hempcrete isn’t a fringe experiment anymore—it’s on track to become a central player in the global push toward sustainable building materials. Here’s why:

Carbon-Negative by Design

In an era of climate urgency, materials that draw down carbon are worth their weight in gold. Hempcrete not only stores carbon from the hemp plant but also benefits from lime’s long-term carbonation process—absorbing more CO₂ over time.

Healthier Indoor Environments

As the world embraces wellness architecture, materials like hempcrete offer a clear advantage. They’re VOC-free, resist mold and pests, and regulate humidity—making them perfect for schools, healthcare facilities, and homes alike.

Regulatory Acceptance Is Growing

In 2022, the U.S. International Code Council accepted a proposal to include hemp-lime construction in the 2024 International Residential Code (IRC). This is a major milestone for builders hoping to use hempcrete without jumping through code interpretation hoops.

A Boon to Rural Economies

Hempcrete encourages local, regenerative agriculture. The hemp plant matures in 90–120 days, requires minimal pesticides, and improves soil health. For rural areas looking to revitalize through green industry, hempcrete manufacturing offers a compelling model.


Despite its promise, hempcrete faces hurdles. Scaling up requires consistent hemp supply chains, better-trained builders, and public awareness. In some markets, cement and synthetic insulation still dominate because of perceived cost advantages. But as hempcrete technologies become more automated—and as climate regulations stiffen—those advantages may quickly reverse.


In the rush to find climate-resilient, low-impact solutions for the built environment, hempcrete checks nearly every box: renewable, breathable, healthy, and beautiful. What was once a niche green building trend is now evolving into a global movement—one bale, block, and panel at a time.

The future of construction won’t just be smarter—it will be greener, lighter, and, quite possibly, full of hemp.

CHECK OUT HempBuild Magazine

Elevation Construction Is Working on Utah’s Housing Crisis in a Unique Way

In the heart of Utah’s housing affordability crisis, Elevation Construction is pioneering a transformative approach to homebuilding. By embracing modular construction and innovative design, the Sandy-based company is delivering high-quality, affordable homes that challenge traditional industry norms.

Building the Future: Modular Innovation

Elevation Construction, led by CEO Brody Lambert, utilizes prefabricated wall panels from Livio, which come equipped with integrated plumbing and wiring. These cold-formed steel structures are both fire-resistant and energy-efficient. Remarkably, a complete home can be assembled in just 12.5 hours, allowing homeowners to walk through their new residence the very next day.

Complementing this rapid construction is an innovative foundation system from Provo-based SimplyBilt. This foam-insulated foundation requires only 12 inches of excavation, significantly reducing labor costs and enhancing energy performance.

Elevation Construction’s Leadership

The Flex Home: Affordable and Adaptable

At the core of Elevation’s offerings is the “Flex Home”—a 1,250 sq. ft., 3-bedroom, 1.5-bath single-family home priced at $299,000. Designed with future growth in mind, these homes feature expandable foundations, allowing for additions such as garages, master suites, or accessory dwelling units (ADUs). This flexibility enables homeowners to adapt their living spaces as their needs evolve.

Moreover, new lending policies permit buyers to include potential ADU rental income when qualifying for a mortgage, making these homes accessible to households earning between $70,000 and $120,000 annually.

Challenging the Status Quo

Elevation Construction’s commitment to affordability has not gone unnoticed. By intentionally leaving $30 to $40 per square foot of equity on the table for buyers, the company diverges from traditional homebuilding models that prioritize higher margins. This approach has led to collaborations with like-minded partners, including landowners willing to defer lot payments and municipalities open to approving smaller lots.

The city of Ephraim was the first to embrace this model, paving the way for additional projects in Grantsville, Nephi, Helper, and Hurricane. Elevation is also in discussions with state officials about utilizing Trust Lands to expand affordable housing developments.

A Vision for Sustainable Growth

Elevation Construction’s innovative approach offers a compelling solution to Utah’s housing challenges. By integrating modular technology, efficient construction methods, and adaptable designs, the company is redefining what affordable housing can look like—without compromising on quality or livability.

As Utah continues to grapple with housing affordability, Elevation Construction’s model presents a scalable and sustainable path forward, demonstrating that innovation and compassion can coexist in the pursuit of the American Dream.


Credit: This blog post is based on the article “Modular, Flexible, Affordable: How Elevation Construction is Quietly Reinventing Housing in Utah” by Mark Tullis, published on May 8, 2025, on TechBuzz News. Read the full article here: TechBuzz News.

2 Ways to Transform Your Business with Thermal Studs

Two Webinars. One Vision for High-Performance Construction.

Join us for two upcoming opportunities to dive into the cutting edge of high-performance construction with Thermal Studs. Whether you’re interested in manufacturing advanced framing products or launching a panelized building system that’s redefining Net Zero Energy Ready construction — we’ve got you covered.

Thermal Studs Ultimate Panel Licensee Webinar

The Net Zero Energy Ready Future of Building Starts Here
Saturday, April 26, 2025 @ 11:00 AM EST

Learn how to license the Thermal Studs Ultimate Panel System (TSUPS™) — the revolutionary building solution delivering all 8 control layers in one flexible, panelized product.

Why You Should Attend:

Learn how TSUPS can cut build times in half and help builders deliver homes in just 28 days

  • Discover how to tailor the system to your market and materials
  • See real-world applications from barndominiums to affordable housing
  • Access our testing library and licensing packages for all 50 states

Who It’s For:
Builders, developers, architects, innovators — anyone who’s ready to transform how we build.

Reserve your spot today

Thermal Studs Manufacturing Webinar

From R19 Tstuds to RhinoStuds: Join the Next Generation of Smart Framing Manufacturing
Tuesday, April 29, 2025 @ 11:00 AM EST

If you’re a manufacturer, mill operator, or component fabricator ready to level up, this manufacturing-focused webinar is your blueprint for success.

What You’ll Learn:

  • How to manufacture a full lineup of smart framing products:
    • R19 Tstud™
    • Un-Insulated Tstud™
    • RhinoStud™
    • WarmStud (built from LSL, LVL, PSL, SPF, SYP, or metal studs)
  • How to meet performance targets for thermal resistance, strength, seismic/fire compliance, and offsite compatibility
  • Real-world production case studies, licensing/tooling requirements, and cost modeling

Who Should Attend:
Wood product mills, metal fabricators, panel manufacturers, truss/component builders — anyone ready to lead the shift toward stronger, smarter, more energy-efficient framing.

Reserve your seat now

You’re invited to attend one or both sessions — because the future of building is multi-material, thermally broken, panelized, and Net Zero Ready.

Blueskin® VPTech™: Innovating Residential Construction for DIY Enthusiasts​

In residential construction, the demand for energy-efficient and easy-to-install building materials is higher than ever. Enter Blueskin® VPTech™, an innovative solution from Henry® Company that combines multiple protective layers into a single, user-friendly panel. This product is particularly beneficial for non-professional builders seeking to enhance their projects with professional-grade materials.​

all photos – Blueskin® VPTech™

This all-in-one panel simplifies the construction process by eliminating the need to install these components separately. The result is a more efficient building process that doesn’t compromise on quality or performance.​

1. Simplified Installation

Traditional methods require multiple steps to install insulation, air barriers, and seam sealing. Blueskin® VPTech™ streamlines this by combining all three into one panel, reducing installation time by up to 30%. Its lightweight design and ease of handling make it ideal for DIY projects.​

Each panel offers an R-value of 5 per inch of Graphite Polystyrene (GPS) insulation, contributing to better thermal performance. This efficiency can lead to lower energy bills and a more comfortable living environment.​

3. Superior Moisture and Air Protection

The integrated WRB and seam sealing provide a continuous air barrier, reducing air leakage and preventing moisture intrusion. This self-sealing feature around nails and fasteners ensures long-term durability and protection against the elements.​

4. Compliance with Energy Standards

Blueskin® VPTech™ helps in achieving a lower Home Energy Rating System (HERS®) score and contributes to ENERGY STAR® and Zero Energy Ready Home (ZERH) program requirements. This compliance is beneficial for homeowners aiming for energy-efficient certifications.​

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  • Preparation: Ensure the substrate is clean and dry.
  • Cutting: Panels can be easily cut to size using standard tools like utility knives.
  • Sealing: Pay attention to sealing all seams and penetrations to maintain the integrity of the air and moisture barrier.
  • Safety: Always follow safety guidelines and wear appropriate protective gear during installation.​

Blueskin® VPTech™ offers a practical and efficient solution for non-professional builders seeking to enhance their construction projects. Its integrated design simplifies installation, improves energy efficiency, and provides superior protection against moisture and air infiltration. By choosing Blueskin® VPTech™, DIY enthusiasts can achieve professional results with greater ease and confidence.​

For more information and detailed installation guides, visit the Henry® Company website.

Gary Fleisher

Contact Gary

Gary Fleisher is the Leading Observer of the Offsite Housing Construction Industries. He has been actively involved in researching and writing about the latest trends and developments in the industry for over a decade now.

With his extensive knowledge and experience, Gary has emerged as a go-to expert for businesses looking to stay ahead of the curve in the modular construction industry. In addition to his work as an editor, he is also a sought-after speaker and consultant who has helped numerous companies achieve strategic and operational success.

Meet the AI Brain Behind the Bots: Framebotix’s Game-Changing AI Pack

Imagine a factory where robots don’t just follow orders—they think, adapt, and optimize on the fly. That’s the reality with Framebotix’s Artificial Intelligence Pack, a cutting-edge solution that’s redefining automation in manufacturing.​

At the heart of Framebotix’s innovation is their AI Pack, designed to empower autonomous robotic digital factories. This isn’t just about programming robots to perform tasks; it’s about giving them the intelligence to make decisions, adapt to changes, and optimize processes in real-time.​

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The AI Pack integrates machine learning and computer vision, enabling robots to analyze CAD data and automatically select the appropriate tools and machining parameters. It considers the condition of raw materials and the robot system itself, ensuring precision and efficiency from design to production.

One of the standout features is the system’s ability to adapt to changing conditions. Whether it’s a variation in material quality or an unexpected change in the production environment, the AI algorithms adjust operations on the fly. This level of adaptability minimizes downtime and maintains consistent product quality.​

Beyond immediate production tasks, the AI Pack also plays a crucial role in predictive maintenance. By continuously monitoring machine performance, it can anticipate potential issues before they lead to breakdowns, scheduling maintenance proactively. This not only extends the lifespan of equipment but also ensures uninterrupted production schedules.​

Efficiency isn’t just about speed; it’s also about resource management. The AI Pack optimizes material usage, reducing waste and promoting sustainable manufacturing practices. By ensuring that every cut and movement is calculated for maximum efficiency, it supports both economic and environmental goals.​

Framebotix’s AI Pack is already making waves in various industries. From woodworking and stone processing to metal and carbon fiber manufacturing, the technology is proving its versatility and effectiveness. Companies like Anton Frei, Braun, and Wingcopter are leveraging this AI-driven approach to enhance their production capabilities.

As industries continue to evolve, the integration of intelligent systems like Framebotix’s AI Pack will become increasingly essential. By combining advanced robotics with real-time data analysis and decision-making capabilities, manufacturers can achieve unprecedented levels of efficiency, quality, and adaptability.

In a world where change is constant, having a manufacturing system that can think and adapt is no longer a luxury—it’s a necessity. Framebotix’s Artificial Intelligence Pack is leading the charge, setting new standards for what automated production can achieve.

For more information on Framebotix’s Artificial Intelligence Pack and how it’s transforming manufacturing, visit their official website.

Gary Fleisher

Contact Gary

Gary Fleisher is the Leading Observer of the Offsite Housing Construction Industries. He has been actively involved in researching and writing about the latest trends and developments in the industry for over a decade now.

With his extensive knowledge and experience, Gary has emerged as a go-to expert for businesses looking to stay ahead of the curve in the modular construction industry. In addition to his work as an editor, he is also a sought-after speaker and consultant who has helped numerous companies achieve strategic and operational success.

Pop-Up Offsite Factories: When Fast, Flexible, Innovative and Local Just Makes Sense

Not long ago, the term offsite construction called to mind sprawling modular factories with long-term leases, high capital costs, and rigid logistics pipelines. But that definition is evolving—and fast.

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Enter the pop-up offsite factory, an agile, location-specific production solution that’s gaining attention in North America after proving its value in Europe and Australia. These compact, temporary manufacturing hubs are turning the traditional model on its head—and it’s about time.

What Exactly Is a Pop-Up Offsite Factory?

A pop-up factory is a temporary or mobile offsite manufacturing facility strategically set up near a specific project or development zone. Rather than producing modules or components hundreds of miles away and shipping them cross-country, pop-ups bring production closer to where homes or buildings will actually be placed.

Think of it as setting up a jobsite-adjacent mini factory that can produce panels, volumetric modules, components—or a hybrid of all three—based on the project’s needs. Once the project is complete, the factory can be disassembled, moved, or even repurposed.

These facilities aren’t just about novelty; they’re about speed, reduced transportation costs, minimal site disruption, and better oversight.

Why Are They Gaining Traction Now?

Pop-up factories aren’t a brand-new concept—but they’re certainly having a moment.

Several factors are converging to make them more attractive than ever:

  • Rising transportation and fuel costs are eating into profit margins and delivery timelines.
  • Workforce shortages make it hard to staff permanent facilities in remote areas.
  • Large-scale affordable housing developments are increasingly being planned in areas without nearby modular production capacity.
  • Communities want localized economic impact—and pop-ups bring jobs and innovation right to them.

For some developers and builders, the old model—hauling volumetric boxes from a regional factory—is simply not feasible anymore. It’s too slow, too expensive, and sometimes just too far away. Pop-up factories provide a smarter, leaner alternative.

Real-World Use Cases: It’s Already Happening

Pop-up factory models are already being tested and refined in places like:

  • The UK, where several modular housing developers have established temporary production lines next to urban infill projects.
  • Australia, where pop-ups are used in remote regions to address indigenous housing and mining workforce needs.
  • Rural North America, where permanent factories often won’t pencil out, but a pop-up could meet demand for one large project.

An Amazing In-Depth Interview with Thunderhaus Innovator – Paul Richards

Even FEMA and disaster response organizations are looking into pop-up manufacturing as a way to rapidly respond to housing needs after wildfires, hurricanes, or other emergencies—bringing both construction and hope closer to where it’s needed most.

Not a One-Size-Fits-All Solution

While pop-ups are exciting, they’re not a silver bullet. These operations require:

  • Fast permitting and code compliance,
  • Mobile or modular production equipment,
  • Reliable local subcontractor integration,
  • And logistical mastery to avoid bottlenecks.

They also need modular thinkers—those who aren’t tied to traditional definitions of a factory and are willing to reinvent the process based on location, labor availability, and community needs.

What Could Pop-Up Factories Look Like in the U.S.?

Imagine a developer planning a 500-home project in a state with limited offsite infrastructure. Instead of battling for production slots at a distant factory, they build a pop-up plant 10 minutes from the site. Panels or modules are built under controlled conditions and delivered across the street, rather than across the state.

That’s not fantasy—it’s already in the planning stages in several states, particularly in underserved rural areas and tribal communities.

Some manufacturers are even exploring Factory-as-a-Service (FaaS) business models, where they lease mobile production capabilities to developers or general contractors, complete with on-site training and startup consulting.

When Will They Start “Popping Up”?

They already are—just quietly, and often under different names like “micro-factories” or “temporary satellite facilities.” But over the next few years, expect to see more builders and developers waking up to the potential of portable, local, and adaptable manufacturing.

Pop-up offsite factories might not replace the mega-factories—but they will absolutely complement them, especially in places where conventional approaches just can’t get the job done on time or on budget.

In a world of housing shortages, strained logistics, and community pushback, the pop-up factory just might be the offsite solution we didn’t know we needed—until now.


From Field to Foundation: How Bio-Based Materials Are Growing the Future of Housing

In a quiet field somewhere in North Dakota, rows of tall, leafy hemp plants sway in the wind. A few states away, in Georgia, acres of bamboo stretch to the sky. And in countless corners of the world, crops once used for textiles, food, or insulation are now being reimagined as walls, roofs, and even entire homes.

Welcome to the world of bio-based building materials—a movement where the future of housing starts in the soil and ends in a structure. For modular and offsite construction innovators, the journey from field to foundation isn’t just about sustainability. It’s about opportunity.

Let’s dig into how these materials are grown, processed, and now woven into the very framework of tomorrow’s buildings—and why offsite construction might be the best place for this revolution to take root.

The term “bio-based” refers to materials derived from living or once-living organisms—typically plants. These include hempcrete, bamboo panels, flax-based insulation, straw bales, and mycelium bricks (yes, mushrooms). Unlike traditional materials that require mining, smelting, or high-carbon production processes, bio-based products often regenerate yearly, absorb CO₂ during growth, and can break down harmlessly at end of life.

But these aren’t backyard garden materials—they’re becoming serious contenders for structural and thermal performance. Hempcrete, for example, offers excellent insulation and vapor permeability while being fire-resistant and carbon-negative. Bamboo is stronger than steel in tension and can be processed into sleek laminated panels rivaling engineered wood.

As demand grows for homes that are healthier to live in and lighter on the planet, the raw materials are literally sprouting beneath our feet.

One reason bio-based materials are catching on now is timing. Climate anxiety is high. Government incentives are shifting. Builders are seeking greener materials that don’t cost double. And modular construction is poised to take full advantage.

Why? Because offsite builders operate in controlled environments where new materials can be tested, refined, and scaled. You’re not battling weather delays or inconsistent labor on-site. You can prototype a wall panel made from hemp-lime composite on Monday and tweak the process by Wednesday. That’s a level of agility that site-built contractors can only dream of.

Factories that partner directly with growers or regional suppliers also stand to benefit from material consistency and price stability. As global supply chains wobble, building local may not just be eco-friendly—it might be necessary.

Let’s say you’re building a small-footprint modular home with high thermal requirements and an eco-conscious client base. Traditionally, you might use fiberglass insulation and standard gypsum board. But imagine this:

  • Walls framed with laminated bamboo
  • Insulated with flax or straw panels
  • Sealed with lime plaster
  • Wrapped in mycelium board for breathability and fire resistance

Every one of those materials is plant-based, and every one of them can be pre-assembled in an offsite production facility. The result? A modular home with significantly lower embodied carbon, better indoor air quality, and a compelling story that resonates with next-gen buyers.

That’s not fiction. That’s what a growing number of European factories—and a few bold U.S. operations—are doing right now.

Of course, not everything’s rosy in the bio-based world. There are real challenges that make some factory owners raise an eyebrow:

  • Code compliance: Many building officials still don’t know what to do with hempcrete or straw walls. Testing and certifications lag behind.
  • Supply chain limitations: Consistent sources of plant-based materials aren’t available nationwide. This makes regional adoption more feasible than national rollout (for now).
  • Processing complexity: Turning raw plant material into construction-grade components isn’t easy. It requires drying, treatment, forming, and quality control that not all startups are ready to handle.

But none of those are deal-breakers. They’re infrastructure problems, not product problems. And infrastructure can be built.

Offsite construction has always been about optimization—doing more with less, faster, cleaner, and more consistently. Bio-based materials offer the same logic: more performance from less input, faster renewability, cleaner lifecycle, and consistent thermal or structural behavior once scaled.

They also offer a marketing advantage. People want to live in homes that feel like they belong to the earth, not ones built like a machine. If a modular factory can tell a client, “This home was grown before it was built,” that’s a story that sticks.

We’re entering a time where materials need to do more than just meet spec sheets. They have to meet expectations, values, and climate goals. And if you’re in offsite construction, you’re already ahead of the curve. Why not stay ahead by planting something new?

The rise of bio-based building isn’t a flash in the pan—it’s a seedling industry, still growing but deeply rooted in both innovation and common sense. As more offsite factories explore ways to differentiate themselves, solve climate challenges, and meet shifting market demands, the field-to-foundation model is going to bloom.

So the next time someone tells you modular homes are just “boxes,” you can smile and say, “Yes—and some of us grow the box before we build it.”

Want to see which plant-based building startups are making waves in offsite? Stay tuned for our next piece where we spotlight 5 innovators quietly changing the way homes are grown.

Gary Fleisher

Contact Gary

Gary Fleisher is the Leading Observer of the Offsite Housing Construction Industries. He has been actively involved in researching and writing about the latest trends and developments in the industry for over a decade now.

With his extensive knowledge and experience, Gary has emerged as a go-to expert for businesses looking to stay ahead of the curve in the modular construction industry. In addition to his work as an editor, he is also a sought-after speaker and consultant who has helped numerous companies achieve strategic and operational success.

Building Smarter, Faster, Greener: How CertainTeed’s ONE PRECISION ASSEMBLIES™ Is Transforming Home Construction

CertainTeed stands out as a pioneer, especially with its innovative ONE PRECISION ASSEMBLIES™ (OPA™) system. This cutting-edge approach to building is redefining efficiency, quality, and sustainability in residential construction.​

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Understanding ONE PRECISION ASSEMBLIES™

Introduced in March 2023, the OPA™ system offers fully constructed wall, floor, ceiling, and roof panels that are prefabricated in a controlled environment. These panels are tailored to meet specific design requirements and local building codes, ensuring a seamless fit and compliance with regulations.

Key Features and Benefits of ONE PRECISION ASSEMBLIES™

1. Speed and Efficiency: Build Faster, Smarter

Traditional construction is often a game of waiting—waiting for subcontractors, waiting for materials, waiting for good weather. ONE PRECISION ASSEMBLIES™ flips the script. Because the components are built in a factory-controlled environment, multiple stages of construction happen simultaneously instead of sequentially. While a builder is preparing the site or pouring a foundation, the wall, roof, floor, and ceiling panels are being manufactured with precision.

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Once delivered to the site, the real magic happens: panels are craned into place and connected, allowing a home to be dried in within just 1–3 days. This rapid assembly process drastically reduces construction schedules, slashes labor costs, and gets homes to market faster—a big win in today’s competitive housing environment.

2. Quality and Precision: Built in a Factory, Not in the Mud

Building on-site always comes with a margin of error. Weather can affect material quality, subcontractor turnover can lead to inconsistent workmanship, and site conditions are rarely perfect. With OPA™, every component is built indoors using digital plans, automated tools, and trained technicians. That means tighter tolerances, better quality control, and fewer on-site surprises.

Each panel arrives straight, dry, and ready to install—no warped studs, no waiting for inspections before you can move to the next phase. This also helps eliminate time-consuming rework, which is one of the most expensive and frustrating aspects of traditional construction.

3. Energy Efficiency and Sustainability: Designed for Performance

One of the standout features of ONE PRECISION ASSEMBLIES™ is its built-in energy performance. Each panel comes with a “Performance Core” designed to meet or exceed energy codes in your region. This includes advanced insulation, moisture barriers, and air sealing—components that are difficult to install correctly on-site but easy to control in a factory.

For homeowners, this means lower energy bills, improved indoor air quality, and reduced maintenance from moisture-related damage. For builders, it simplifies the path to energy-efficient certifications such as ENERGY STAR, LEED, or local green building codes. It also aligns with broader sustainability goals, cutting job site waste and reducing the carbon footprint of each project.

4. Design Flexibility: Not One-Size-Fits-All

One of the misconceptions about panelized construction is that it limits architectural creativity. Not so with CertainTeed’s OPA™. These panels can be customized to fit a wide range of designs—from single-family homes to multifamily buildings and everything in between.

The exterior finishes are also flexible. Builders can choose from CertainTeed’s extensive catalog of siding and roofing products, including Monogram® vinyl siding for a classic look or Landmark® shingles for durability and curb appeal. This allows builders to maintain their brand identity and deliver on customer expectations—while still reaping the benefits of prefabrication.

5. Risk Mitigation: Fewer Surprises, More Control

Construction risk often comes from two places: unpredictable weather and unpredictable people. When you build outdoors with dozens of moving parts, it’s easy for timelines to stretch and budgets to swell. With OPA™, risk is significantly reduced.

Factory-made assemblies mean consistent timelines and reliable quality. Fewer trades are needed on-site, which reduces coordination challenges and liability exposure. Plus, since much of the building envelope is constructed in advance, there’s less opportunity for design drift, miscommunication, or scope creep. Developers and general contractors appreciate the predictability, and lenders and investors love the reduced financial uncertainty.

A Holistic Solution for Modern Builders

What makes CertainTeed’s ONE PRECISION ASSEMBLIES™ truly stand out is that it isn’t just a product—it’s a complete building solution. From the design phase to delivery and installation, the OPA™ system is engineered to bring together speed, accuracy, performance, and style in a single streamlined process. It takes the best of offsite construction—efficiency, precision, and innovation—and applies it to real-world building challenges without asking the builder to compromise on design or function.

In a time when skilled labor is scarce, housing demand is high, and environmental performance is more important than ever, solutions like OPA™ offer a path forward that makes sense for the industry—and for the planet.

Industry Recognition

The National Association of Home Builders (NAHB) recognized the innovative nature of OPA™ by awarding it the Offsite Construction Award for Innovative Product or Service in 2023. This accolade underscores CertainTeed’s commitment to advancing construction methodologies and delivering value to builders and homeowners alike. ​CertainTeed+2CertainTeed+2National Association of Home Builders+2

CertainTeed’s ONE PRECISION ASSEMBLIES™ system represents a significant advancement in residential construction. By integrating speed, precision, energy efficiency, and design flexibility, OPA™ offers a comprehensive solution that addresses many of the challenges faced by builders today. As the industry continues to evolve, innovations like OPA™ pave the way for more efficient, sustainable, and high-quality homebuilding practices.​

About CertainTeed

Founded in 1904, CertainTeed is a leading North American manufacturer of building materials for both residential and commercial construction. With a commitment to innovation, sustainability, and performance, CertainTeed offers a comprehensive portfolio of products including roofing, siding, insulation, ceilings, and drywall. As a subsidiary of Saint-Gobain—one of the world’s largest and oldest building materials companies—CertainTeed continues to push the boundaries of what’s possible in modern construction, helping builders and homeowners create high-performing, comfortable, and sustainable spaces. Learn more at www.certainteed.com.