Offsite construction as a segment of the homebuilding industry, often times suffers from a common bafflement, lack of an understanding coupled with an appreciation for Building Science. In a recent conversation with Mark Eckard,President of Restoration North he attempts to cut to the chase. Mark is a veteran builder as well as the owner President of a material supply firm known for their progressive and passionate approach to the homebuilding industry.

Mark Eckard, President of Restoration North

Bill Murray, Offsite Innovators: Would you describe in layman’s terms what Building Science is and is not?  What comprises Building Science? 

Mark Eckard, owner president of Restoration North: Building Science is learning ways to create better structures through learned experiences, innovation, and testing.  It is not the act of doing things the way we have always done them. 

Bill: In your opinion why does Building Science matter? 

Mark: It matters because just like same way technology advancements matter.  One should always want to strive to learn, grow, and to be better across everything we do.  We spend the majority of time in our homes, offices, structures, and buildings.  It is imperative to make them efficient, while increasing longevity and reducing maintenance.  It is the prudent, responsible approach. 

Photo – Energy Vanguard

Bill: Does Building Science apply any more or any less to offsite construction?  It is applicable across all building types and job sites. 

Mark: There is more of a controlled atmosphere to build better in offsite construction, but also immense room to integrate offsite with onsite into a high performance hybrid solution. 

Bill: What role does Building Science play when considering the plea for affordability? 

Mark: When affordability comes into play, one must look at the cost of goods, as well as the cost of insurance, energy, repairs, replacement, and the inflationary environment.  The longer a building is in service with high performance materials, and building tactics in place, the more value the owner receives as it ages.  The inverse it to build it cheap and junky then replace things all the time, contribute to waste and all the factors that go into new materials, and having work done, it is wasteful, and it does not promote a better world for future generations.

Bill: You have stated that “the system is broken”.  Would you explain what the “system” is and how you believe it is broken? 

Mark: I say that because it is true based on many years of experience across various verticals.  I am a builder, and have been, for decades.  I also run a material supply firm that carries proprietary goods and high-performance solutions.  That was born from the broken construct of how materials were being procured, I wanted better, faster, and cheaper. 

I supply directly to builders, capital groups, developers, modular factories, hoteliers, and even end users.  The number one headwind I face is when I present people with solutions, then they just stare at the cost of goods versus performance, and the totality of operations and benefits.  They all think they have a better way, and it’s purely just false, admitted to me by others who have tried and failed.  Even when presented with high performance solutions, people cannot make the appropriate decisions.  I have concluded that it is because most lack broad spectrum experience, everything is segregated knowledge.  Business owners aren’t builders, and builders aren’t business owners.  Decision paralysis gallops through the industry, perpetuating the failures that happen in construction.  Factoring in that people lack the time and/or desire to continue education to learn about new materials and ways of building, coupled with the cost of inefficiency and low-quality relationships, you have perpetual failure which keeps costs on the rise.  Nobody wins that game.

Bill: What has to change?

Mark: Many things have to change, regulations, policy, zoning, permitting, education, the labor force, and the individual mindset about how trades are viewed as second-rate citizen fields. 

Bill: How is Restoration North addressing the role of Building Science and the changes that you feel must be made? 

Mark: We aim to educate the people we work with and keep driving our ecosystem into the lives and operations of the industry, as it provides bankable change and ultimately helps everyone do better. 

Thanks to Mark for his provocative and compelling summarized take on Building Science. I have learned through several conversations with Mark that he is passionate about the homebuilding industry in general and specifically about Building Science. Building Science is far more than a buzz word for Mark and his appreciation for its importance is contagious. We need more of his attitude in our industry, to foster innovation which will consequently lead to much needed growth.

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Bill Murray

Contact Bill

Bill Murray has over 40 years of operational management experience in the Modular industry.  Bill began his Offsite career as a contractor/builder.  He then entered the manufacturing side quickly advancing through the sales ranks to become a General Manager/COO of multi plant operations.  Bill provides professional advisory service to owners, prospective owners and builder developers considering Offsite construction.  He has consulted throughout the U.S., and Mexico, as well as overseas assignments.

Gary’s viewpoint is for informational purposes only…and a few chuckles!

Starting a modular home factory is easy! All you need is a building, some equipment, a few workers, a design, a sales team, a delivery system, a set crew, a finishing crew… oh, and a small fortune. Simple, right?

Today, I sit down with Karen, one of two enthusiastic imaginary entrepreneurs, who’s convinced she can build a better, cheaper, and more affordable modular home than anyone else. Let’s see how her dream is coming along.

Gary: Karen, welcome! You’re diving into modular construction with no experience. What could possibly go wrong?

Karen: Oh, nothing at all! I mean, how hard can it be? It’s just a big LEGO set, right?

Gary: Ah yes, the famous “LEGO Theory of Modular Construction.” Just don’t forget that those LEGO blocks need permits, structural engineering, transportation logistics, and a highly trained workforce. Have you hired anyone with actual modular experience?

Karen: Not yet, but my cousin’s friend built a shed once.

Gary: Perfect. He can run quality control.

Gary: Let’s talk about funding. What’s your budget?

Karen: Well, I’ve got some savings, and I might ask my friends and family. Also, I heard there’s money in crowdfunding!

Gary: Right, because nothing says “trustworthy investment” like a GoFundMe page titled Help Me Build a Factory! Have you looked into actual investors or industry-specific funding sources?

Karen: Oh. There’s industry funding?

Gary: There is, but investors tend to like things like, oh, I don’t know… business plans.

Gary: Instead of starting from scratch, why not buy an existing factory?

Karen: But I want mine to be new!

Gary: So does every factory that has ever gone bankrupt. An existing facility has the equipment, production line, and maybe even workers who know what they’re doing. You’d be saving years of work and millions of dollars.

Karen: But then I wouldn’t get to design the factory floor plan in my college colors.

Gary: And that would be a true tragedy.

Some are for sale right now.

Gary: Have you talked to a consultant who’s actually started a modular factory before?

Karen: Oh, I don’t need one! I’ve watched so many YouTube videos.

Gary: Ah yes, the great YouTube Academy. While you’re at it, try learning brain surgery from a TikTok tutorial.

Karen: Okay, okay. Where do I find a consultant?

Gary: Lucky for you, there are experts out there who have helped launch successful factories. They can save you time, money, and painful rookie mistakes.

Karen: Like realizing halfway through that I need a transportation plan?

Gary: Exactly. Or that the modules don’t magically set themselves on a foundation.

Gary: Last question—what’s your backup plan if this doesn’t work out?

Karen: Oh, I don’t need one. This is definitely happening.

Gary: Famous last words. But hey, I love the enthusiasm! Now, let’s get you a consultant before this dream turns into a very expensive nightmare.

And there you have it, folks. A little humor, a little wisdom, and a whole lot of reality for anyone thinking about starting a modular home factory. If you’ve got a dream like Karen’s and Seth’s, make sure you get the right people on board—before your bank account learns the hard way!

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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.

For centuries, builders have relied on natural ventilation to keep buildings cool and dry. Before the era of modern air conditioning, homes featured elevated roofs, ventilated attics, and airflow gaps behind exterior materials to regulate temperature and moisture. These passive cooling techniques not only enhanced comfort but also preserved the longevity of structures.

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However, as modern construction methods evolved, these time-tested solutions were largely abandoned. The result? Buildings that trap heat, accumulate moisture, and suffer from premature material degradation—all while increasing energy costs. But what if there was a way to bring passive cooling back into modern modular and offsite construction?

Enter DrainStrip™, an innovative ventilation and drainage solution that reintegrates these essential building science principles, delivering a simple, cost-effective way to enhance durability and energy efficiency in offsite-built structures.

What is DrainStrip™?

DrainStrip™ is a built-in rainscreen and ventilation system seamlessly integrated into TSUPS™ (Thermal Studs Ultimate Panel System) wall, roof, and floor panels. It introduces a continuous ventilation and drainage gap behind cladding, siding, and roofing materials, preventing moisture buildup and thermal stress.

Another plus is DrainStrip™ can be used in any wall or roof assembly!

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This groundbreaking approach offers a host of benefits, including:

✔ Enhanced Energy Efficiency – Improves airflow and reduces heat retention, lowering cooling costs.
✔ Moisture Protection – Prevents trapped condensation, eliminating mold, rot, and siding failures.
✔ Material Longevity – Extends the lifespan of exterior finishes by reducing expansion, contraction, and water damage.

How DrainStrip™ Works on Walls

In conventional construction, cladding and siding are directly attached to sheathing, leaving no space for airflow or moisture drainage. This leads to excessive heat buildup, material warping, and trapped moisture—problems that contribute to premature siding failure and structural damage.

By incorporating DrainStrip™ within TSUPS™ panels, a natural ventilation gap is created behind exterior cladding, allowing:

✔ Passive cooling to reduce thermal stress on siding.
✔ A continuous drainage plane to channel moisture away.
✔ Improved air circulation, which dries materials faster and prevents mold growth.

This built-in rainscreen system eliminates the need for additional furring strips or labor-intensive drainage layers, making it a hassle-free solution for both builders and factory-produced modular structures.

How DrainStrip™ Works on Roofs

Heat buildup under roofing materials is one of the biggest contributors to high cooling costs, especially in prefabricated and modular homes. Roofs act like thermal batteries, absorbing and radiating heat into attics and living spaces. Without proper ventilation, various roofing materials suffer:

✔ Steel roofs trap heat, turning attics into ovens.
✔ Cedar shake roofs accumulate moisture, leading to accelerated rot.
✔ Clay tile roofs retain water, causing long-term material degradation.

DrainStrip™ eliminates these problems by creating a breathable air gap between the roofing material and TSUPS™ panels. This passive ventilation system allows hot air to escape, preventing excessive heat transfer into the structure. The result?

✔ Cooler roof surfaces that reduce AC demand.
✔ Efficient moisture drainage, stopping rot and mold before they start.
✔ Extended lifespan for all roofing materials.

A Smarter Way to Build: DrainStrip™ and the Return of Passive Cooling

Historically, homes were designed to breathe. Tall ceilings, shaded porches, ventilated attics, and strategic airflow gaps all worked together to keep homes cool and dry without artificial climate control. As modern construction methods emphasized airtight designs, we inadvertently suffocated our buildings—leading to higher energy consumption and costly material failures.

DrainStrip™ and TSUPS™ panels offer a smarter alternative, reintroducing passive cooling into offsite construction without the added cost of extra materials or labor. By integrating built-in ventilation and drainage, modular builders can deliver:

✔ More durable, energy-efficient homes that require less maintenance.
✔ Reduced heating and cooling loads, cutting down on operational costs.
✔ A more sustainable construction approach that aligns with net-zero and high-performance building standards.

As the offsite industry pushes for innovation, DrainStrip™ presents an opportunity to rethink how we build, embracing both modern technology and timeless building science.

Let’s stop trapping heat and moisture inside our buildings—and start letting them breathe.

Bureaucratic delays, logistical challenges, and high costs have long marked the journey of disaster relief housing. But now, a pioneering solution is rolling down the highways, offering wildfire survivors not just a roof over their heads but a renewed sense of stability. Nano Nest, a modular housing innovator, is changing the landscape of emergency shelter solutions, one home at a time.

photo – Maui Now

A Bold Vision for Modular Disaster Relief

Nano Nest, a company dedicated to building sustainable, efficient, and transportable housing, has stepped up in the wake of the devastating Maui wildfires. With their compact yet functional designs, these units serve as both short-term emergency shelters and long-term affordable housing solutions. Unlike traditional FEMA trailers or hastily built shelters, Nano Nest homes are designed with durability, efficiency, and sustainability in mind, making them a viable permanent solution for displaced residents.

photo – Nano Nest

Built with high-quality, energy-efficient materials, Nano Nest homes incorporate modern insulation techniques and sustainable energy options like solar panels. Their innovative design allows for rapid manufacturing and deployment, enabling relief agencies and government organizations to provide swift housing solutions without sacrificing quality.

The Road to Recovery: Transporting Hope

The delivery of these modular homes is no small feat. Between February 26-28, a fleet of transport vehicles will be hauling Nano Nest homes across the island of Maui, delivering much-needed housing for wildfire survivors. The logistical operation involves careful coordination between local authorities, housing agencies, and the Nano Nest team to ensure smooth transport and on-site assembly.

photo – Nano Nest

Each unit is precision-engineered to be transported efficiently, making use of specialized hauling equipment that navigates the island’s challenging terrain. Unlike traditional home construction, which can take months or even years to complete, these modular units can be fully installed and move-in ready within a matter of days. This efficiency is a game-changer for residents who have been living in uncertainty since the fires upended their lives.

Designed for Resilience and Comfort

Nano Nest homes are not just about speed and efficiency; they prioritize livability. Each unit is thoughtfully designed to maximize space, featuring modern amenities that provide comfort and dignity to their residents. Smart storage solutions, energy-efficient appliances, and climate-adaptive materials ensure that each home can withstand varying environmental conditions while maintaining a comfortable indoor climate.

For wildfire survivors, the psychological impact of displacement is profound. Providing a stable, private, and dignified living space is crucial in the recovery process. Unlike mass shelters or temporary camps, Nano Nest homes offer a sense of ownership and normalcy, crucial elements in helping survivors rebuild their lives.

The Future of Disaster Housing?

As natural disasters become more frequent and severe, the demand for fast, sustainable, and cost-effective housing solutions is higher than ever. Nano Nest’s model presents a scalable blueprint that could be replicated across the country, addressing not just emergency housing needs but also the broader affordable housing crisis.

With innovative companies like Nano Nest leading the way, disaster relief housing is no longer about temporary fixes but sustainable futures. As these modular homes make their way to survivors in Maui, they bring more than just shelter—they bring hope, resilience, and the promise of a fresh start.

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.

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What were you doing in high school? Struggling through trigonometry? Fumbling through extracurriculars? Meet Ajith Varikuti, a Charlotte, NC high school student with a passion for design and an eye on the future. While most teenagers are figuring out prom dates, Ajith is designing homes to tackle rising sea levels—and winning scholarships for his efforts.

Ajith Varikuti

His story, originally shared by The Charlotte Observer, is nothing short of inspiring. It’s also a rallying cry for the offsite homebuilding industry: if we want to stay ahead of the curve, we need to look to the next generation for bold, innovative ideas. And guess what? Sponsors like Autodesk are making it possible for students like Ajith to bring those ideas to life.

Ajith’s Design: A Blueprint for the Future

Ajith took on the challenge of creating a home design tailored for coastal resilience. His concept included elevated living spaces, water-resistant materials, and structural elements that could endure intense flooding. While her peers were working on typical class projects, Ajith’s design was a fully realized vision for climate-resilient living.

Thanks to his efforts—and a little help from tools like Autodesk Tinkercad—Ajith didn’t just complete a project; he made a statement. His work earned him a scholarship and a spotlight in the construction world, proving that even high schoolers can leave a mark on this industry.

Autodesk’s Role in Empowering Innovators

It’s impossible to talk about Ajith’s success without giving a nod to Autodesk, the industry-standard design software that sponsored his competition. Autodesk isn’t just a tool—it’s a launchpad for young innovators. By providing students access to professional-grade software, Autodesk equips them with the skills they need to turn their ideas into reality.

For those of us in offsite construction, this is huge. Imagine what happens when a generation raised on intuitive, cutting-edge design software enters the workforce. The possibilities are endless.

Why the Industry Needs Young Talent

Ajith’s story is a reminder that the future of construction—offsite or otherwise—depends on nurturing the next generation. Here’s why it’s crucial to get them involved now:

1. Fresh Perspectives: Young people approach problems like rising seas or housing shortages with fresh eyes. They’re not tied down by traditional methods, which allows them to think outside the box.
2. Digital Natives: This generation has grown up with technology. They’re fluent in design software, data analysis, and even AI, making them invaluable as the industry continues to evolve.
3. Passion for Sustainability: Climate change isn’t an abstract concept for today’s teens—it’s their reality. Many of them, like Ajith, are deeply motivated to design sustainable, resilient solutions.

Building a Path for Future Innovators

If we want more Ajiths in the industry, we need to invest in their potential. Here’s how we can do it:

• Competitions and Challenges: Like the one AutoDesk sponsored, “Make it Resilient”, these events spark creativity and give students a platform to showcase their ideas.
• Mentorship Programs: Pairing young designers with industry veterans helps turn raw talent into refined skills. (Ajith worked with the construction firm AECOM)
• Educational Partnerships: Schools and colleges are the perfect places to introduce offsite construction concepts and tools.
• Access to Tech Tools: By offering students access to software like Autodesk Revit, we give them the means to transform their ideas into tangible solutions.

Ajith’s Story: A Lesson for Us All

Ajith Verikuti has shown us that the next generation is ready to take on the challenges of tomorrow—if we’re ready to give them the tools and support they need. His journey, aided by sponsors like AutoDesk, is proof that young talent is out there, waiting for an opportunity to shine.

Whether you’re designing modular homes, running a prefab factory, or simply dreaming about the future of offsite construction, it’s time to look beyond your current team. Let’s inspire, support, and celebrate the next wave of innovators. The future of our industry depends on it.

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Here’s to Ajith and the power of innovation. And here’s to sponsors like AutoDesk, who recognize the importance of investing in young talent. Together, we’re not just building homes—we’re building a better future. Do yourself a favor and click on the link below to read the entire article. It’s a short read and oh-so encouraging.

CLICK HERE to read the entire WSOCTV article

Dive into the future of sustainable solutions with Joel Wurschmidt, Director of Business Development at Envirobon. Known for their groundbreaking innovations, Envirobon is reshaping the way industries approach eco-friendly products. In this exclusive interview, Joel reveals the vision and technology behind their innovative offerings, providing a glimpse into how Envirobon is making a difference in offsite construction and beyond.

JOEL WURSCHMIDT, Business Relations for Envirobon and his wife, Abbi, Envirobon’s Chief Marketing Officer

Bill Murray Offsite Innovators: Would you describe the Thermal Studs innovation and how it differs from traditional framing systems? 

Joel Wurschmidt Director of Business Relations at Envirobon: EnvirobonThermal Studs redefines framing by addressing persistent challenges such as thermal inefficiency, material waste, and warping in traditional wood and metal systems. The technology focuses on enhancing both structural performance and energy efficiency, reducing heat transfer through walls by up to 40%, as validated by independent testing. This reduction in thermal bridging significantly lowers energy consumption, offering homeowners measurable savings on heating and cooling costs. 

A defining feature of Thermal Studs is their exceptional strength. Engineered to be three times stronger than standard 2×6 lumber, the Tstud line (R19 and Un-Insulated) is versatile enough to function not only as studs but also as headers, eliminating the need for separate materials in framing openings. This built-in strength and adaptability reduce complexity in the construction process, saving builders time and resources. 

Precision engineering ensures a near-perfect usability rate, with less than 1% material culling compared to the 10–20% waste rate typical of traditional lumber. This consistency minimizes material loss, simplifies installation, and results in higher-quality construction outcomes. 

Bill: What are the main benefits that builders, contractors, and homeowners experience when using Thermal Studs in their projects? 

Joel: Thermal Studs deliver tangible benefits for builders, contractors, and homeowners alike: 

• Builders gain efficiency and cost savings through the material’s strength and versatility. The ability to use Tstuds as headers simplifies the supply chain and reduces labor time. The increased strength also enhances structural integrity without requiring additional reinforcements, particularly in load-bearing walls. Additionally, the consistent straightness of Thermal Studs eliminates sorting and discarding warped materials, saving time and reducing waste. 

• Contractors benefit from streamlined project workflows, as Thermal Studs reduce the need for supplementary materials like foam board insulation or separate headers. Integration with the DrainStrip™ Rainscreen System provides added protection against moisture, lowering the risk of callbacks due to wall damage. 

• Homeowners enjoy lower energy costs, with heating and cooling savings averaging up to 30% over the lifespan of the home. The built-in strength and durability of Thermal Studs ensure long-term performance, reducing maintenance needs and increasing the lifespan of wall assemblies by 10–15 years. 

3. How do Thermal Studs contribute to long-term energy cost reduction, and how does this fit into the broader trend of sustainable building practices? 

Thermal Studs significantly enhance energy efficiency by minimizing heat transfer through walls. With reduced thermal bridging, buildings require less energy for heating and cooling, translating into savings of $5,000–$15,000 over a typical 30-year home lifespan, depending on size and climate. 

Beyond energy savings, the sustainable design of Thermal Studs helps reduce environmental impact. By incorporating stronger materials and reducing the need for additional insulation or reinforcement, these studs lower overall material consumption and transportation emissions. Additionally, their dual functionality as studs and headers further decreases resource usage. 

Paired with systems like the DrainStrip™ Rainscreen, Thermal Studs ensure moisture management and extend the life of wall assemblies, aligning with the industry’s push for sustainable, durable, and energy-efficient construction practices. 

Bill: What challenges have you encountered in educating the industry and potential customers about the advantages of using Thermal Studs, and how are you overcoming them? 

Joel: Adoption of new building materials often faces resistance due to entrenched practices and misconceptions about cost or complexity. Builders and contractors may hesitate to shift from familiar methods to innovative solutions without clear evidence of their benefits. 

To address these challenges, Thermal Studs prioritizes education and transparency: 

• Demonstrations: Real-world applications are showcased through collaborations with trusted industry influencers and hands-on training sessions. 

• Data-Driven Insights: Sharing detailed performance metrics and case studies highlights measurable benefits, such as reduced material waste, lower energy costs, and stronger structural outcomes. 

• Product Accessibility: Licensing partnerships with manufacturers have expanded production capacity, ensuring that Thermal Studs are widely available to meet growing demand. 

These efforts focus on presenting Thermal Studs not as a replacement but as an enhancement to current building practices, making it easier for builders to transition. 

CLICK HERE to read the “rise” article

Bill: What feedback have you received from builders who actively use Thermal Studs? Can you share a story or example of how it’s made a significant impact in one of their projects? 

Joel: Builders frequently highlight the superior strength and precision of Thermal Studs as key benefits. The ability to function as both studs and headers simplifies framing while maintaining load-bearing capacity. Feedback also notes the near-complete usability of delivered materials, with a 98–99% acceptance rate, compared to the significant waste seen with traditional framing lumber. 

One detailed example comes from Jake Bruton, a respected builder and content creator, who documented the use of Tstuds, namely the Un-Insulated Tstud, in a residential project. By incorporating Tstuds, Bruton achieved a substantial reduction in thermal bridging, enhancing the home’s insulation performance. This improvement directly translated to lower energy consumption and increased comfort for the homeowner. Bruton also praised the straightness and strength of Tstuds, which streamlined the installation process, reduced framing time, and eliminated material waste. The project highlighted how Tstuds could deliver both efficiency and superior energy performance in real-world construction. Another one of his videos highlighted that by using the Un-Insulated Tstud, using outside rigid foam sheating was not really necessary. This could save a homeowner a ton! 

Bill: With the growing interest in offsite construction, how do you see Thermal Studs playing a role in modular, panelized, or other prefabricated construction methods? 

Joel: Thermal Studs are particularly suited for modular, panelized, and prefabricated construction, where consistency and precision are crucial. Their engineered strength and multi-functional capabilities, including use as headers, make them an ideal component for factory-assembled wall systems. 

Prefabricated panels incorporating Thermal Studs deliver exceptional thermal resistance, meeting or exceeding stringent energy codes. In addition, the Ultimate Panel System (TSUPS™) enables manufacturers to ramp up production in as little as 60 days, reducing project timelines and accelerating delivery to market. 

The sustainability advantages of Thermal Studs further enhance their appeal in offsite construction. By reducing material waste and integrating insulation directly into the framing system, these panels align with the construction industry’s environmental goals while delivering superior energy performance and structural durability. 

Joel Wurschmidt has shared just a fraction of what makes Envirobon a leader in innovation. Visit Envirobon.com to explore their groundbreaking products and discover how they can bring value to your projects. Don’t miss the chance to see what sets them apart in the evolving landscape of sustainable construction solutions.

Are you ready to have your story told?

Innovation thrives when ideas are shared, celebrated, and built upon.  At Offsite Innovators we’re always on the lookout for the next big thing in construction or even the game-changing tweaks that make a difference.  Have you come across a brilliant innovation in homebuilding?  Are you working on something groundbreaking yourself that needs exposure?  My partner, Gary Fleisher, and I are in the perfect position to help.  Let’s shine a spotlight on it.  

Tell us your story 

Behind every groundbreaking innovation lies a journey of overcoming obstacles, and for Brian Iverson, the path to creating Thermal Studs was no exception. In Part One of his Interview, we talked about how solving problems in sustainability and energy efficiency was the idea for his innovative product the T-Stud. Today, he finished our interview by discussing the challenges he faced.

His pioneering system integrates closed-cell foam insulation and reimagined structural configurations to meet both thermal efficiency and strength requirements. By rethinking traditional building components, Iverson crafted solutions like the RhinoStud™ and WarmStud™, addressing challenges that have long plagued the construction industry—thermal bridging, energy loss, and structural vulnerability to extreme conditions. His work stands as a testament to the transformative power of combining modern materials science with practical building needs.

However, breaking through regulatory, production, and market-entry barriers presented their own hurdles. Iverson’s journey demonstrates not just technological ingenuity but also resilience and adaptability, relying on partnerships and innovative production methods to bring his ideas to market. From seismic and hurricane-resistant materials to cost-effective continuous insulation solutions, Thermal Studs redefines what it means to build sustainably and reliably in a constantly evolving industry.

Brian Iverson, Founder of TStud

Gary Fleisher: How did you ensure their durability, safety, and compliance with industry standards?

Brian Iverson: We take great care to exceed both U.S. and Canadian building codes. Each of the Thermal Studs products undergoes rigorous testing to meet or surpass ASTM (American Society for Testing and Materials) standards. This ensures they’re compliant in terms of structural integrity, energy efficiency, and thermal performance.

The WarmStud™ uses traditional framing members already approved by the American Plywood Association (APA), meaning no additional testing is required for these components. However, we’ve enhanced the WarmStud™ patent by including a simple way to manufacture it within the TSUPS by “levitating” the wall, roof, or floor assembly frame off the sheathing, creating the WarmStud™ patented product with a 100% thermal break, and providing up to 1000 pounds per linear foot of “ultimate” wind load capacity when created within the WarmStud™ Panel System.

The Warmstud

These innovations offer builders a way to differentiate themselves from other competitors with the durability, safety, and energy efficiency required for today’s challenging construction environment.

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Gary: How does your products contribute to sustainability, and what role do you see it playing in the broader movement towards eco-friendly and energy-efficient buildings?

Thermal Studs is all about sustainability. By reducing heating and cooling loads by up to 50%, our products directly cut down on energy consumption. This is achieved through superior insulation and the elimination/minimization of thermal breaks, which waste energy in traditional framing systems.

In addition to energy efficiency, our products are designed for durability, minimizing the structure’s carbon footprint. We demand our licensees use closed-cell foam insulation made with the HFO blowing agents, which have a global warming potential of ~4, contributing to reduced environmental impact.

As more builders and homeowners adopt eco-friendly practices, Thermal Studs provides an affordable, scalable solution that exceeds the strictest energy codes. Our products are designed to help the construction industry meet the growing demand for sustainable buildings, ultimately reducing our carbon footprint and conserving natural resources.

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7. From concept to reality, what has been the most unexpected lesson or challenge you’ve encountered, and how has it shaped your approach to innovation?

The journey from concept to reality has been full of unexpected challenges. From supply chain disruptions to closing borders, production issues, and equipment delays—it has been a constant learning process. One key lesson I’ve learned is that innovation is about persistence. A patent is just a dream until you get it to market and make it viable.

At times, the hurdles felt insurmountable, especially when builders resisted change. But each setback reinforced my belief that true innovation requires determination. It’s not just about inventing; it’s about creating a viable, scalable solution that addresses real-world problems.

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8. Where do you see Thermal Studs’ place in the future of construction, and what impact do you hope they will have on the way buildings are designed and constructed over the next decade?

I see Thermal Studs playing a key role in the future of construction, particularly as the demand for energy-efficient, sustainable, and resilient buildings continues to grow. Our products help builders meet increasingly strict energy codes and provide solutions that withstand the harshest conditions, making them ideal for both residential and commercial projects.

Over the next decade, I hope Thermal Studs will become a cornerstone in the evolution of building materials, helping the industry shift toward eco-friendly and energy-efficient construction practices. I envision our products becoming a standard in the building industry, offering cost-effective, high-performance solutions that reduce both construction costs and long-term operational expenses.

Ultimately, I want to leave a legacy of innovation, where buildings are designed to be energy-efficient, structurally sound, and sustainable for generations to come. Imagine this…the RhinoStud™ made from 316L stainless steel.

Brian, thank you for this unique interview and I hope you never stop bringing your innovations to the construction industry.

In an industry facing mounting pressure to balance energy efficiency, structural integrity, and affordability, innovation becomes the key to change. Brian Iverson, the visionary behind Thermal Studs, has taken up this challenge by addressing long-standing inefficiencies and sustainability issues in traditional building materials. The Thermal Studs system emerged as a solution rooted in practicality and inspired by a moment of personal necessity—a broken furnace during the COVID-19 pandemic. Iverson’s vision extends beyond temporary fixes, offering builders a streamlined approach to reduce energy consumption by up to 50% and increase overall building performance.

Brian Iverson, Chief Innovator at Thermal Studs (that’s not a Thermal Stud he’s holding)

At the core of the Thermal Studs initiative lies a simple yet powerful idea: eliminate thermal bridges, enhance structural resilience, and ensure ease of manufacturing for anyone, even from a modestly equipped space like an oversized garage. Through the Thermal Studs Ultimate Panel System (TSUPS), builders and developers gain a robust tool to revolutionize construction processes and energy use. Iverson’s approach combines built-in insulation with structural efficiency to create a sustainable path forward in the building industry—one that is scalable, innovative, and ready to meet the demands of the future.

Brian Iverson holding the R19 Tstud

I recently had the opportunity to talk with Brian about his latest innovation:

Gary Fleisher: What specific problem in the building industry inspired you to develop Thermal Studs, and how does your solution address it in ways that current options cannot?

Brian Iverson: The building industry faces a clear challenge: the need for energy-efficient solutions that reduce heating and cooling costs, improve structural integrity, and promote sustainability—all while remaining affordable. Traditional framing materials often fail in these areas, leading to higher energy costs, moisture problems, and compromised comfort.

I developed the Thermal Studs product line to tackle these issues head-on. It started with a simple realization: during the COVID-19 pandemic, I experienced a furnace malfunction and couldn’t find the replacement part. It’s called a “critical supply chain” challenge. That was when I decided to create a better, more cost-effective solution. The result? Thermal Studs, a system that combines built-in insulation and structural strength, reducing energy consumption by up to 50%. The beauty of the Thermal Studs Ultimate Panel System (TSUPS) is its simplicity—anyone with a spray foam rig and carpentry tools can build the Thermal Stud products, even in an oversized garage.

With Thermal Studs, we know how to eliminate thermal bridges and inefficiencies found in conventional framing methodologies, providing a high-performance, sustainable building system that can be replicated without reliance on complex supply chains. This is a game-changing licensing opportunity for builders, lumberyards, etc., to take control of their construction process and solve for energy efficiency while reducing the lifetime utility bills for their customers. Now that was a mouthful.

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Gary: Could you walk us through the core technology or materials behind your inventions?

Brian: The core technology behind Thermal Studs is the integration of closed-cell foam insulation with innovative structural configurations that enhance both thermal efficiency and structural strength. Our products, such as the WarmStud™, RhinoStud™, and Tstud™, utilize non-commodity materials to optimize performance, providing solutions that go beyond traditional building materials. And for those who do not want the foam component, we have the Un-Insulated Tstud™ as well.

For example, the metal RhinoStud™ incorporates a serpentine design combined with a built-in Z Girt system, which together create an effective thermal buffer that slows down heat transfer. While not a true thermal break, the foam layers surrounding the metal stud significantly reduce thermal bridging, offering superior thermal efficiency. This unique system also provides enhanced load resistance, allowing the RhinoStud™ to support up to 100% more axial compression weight of a typical metal C Shaped stud. Additionally, it offers excellent sound control and meets rigorous seismic and hurricane compliance standards.

The WarmStud™ delivers an affordable solution for achieving 100% continuous insulation, making it the most cost-effective choice for energy-efficient building. The Tstud™ outperforms LVL studs in terms of strength and resilience, offering enhanced performance for structures that need to withstand extreme conditions.

These innovations are designed to exceed energy codes across North America, ensuring that homes and buildings are both energy-efficient and structurally sound. The result is a sustainable building system that empowers today’s builders to create high-performance structures without sacrificing affordability.

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Gary: What makes them unique, or groundbreaking compared to traditional building materials or methods?

Brian: To reduce heating and cooling loads by ~50% or more, a fully integrated solution is necessary—one that combines insulation, structural strength, and sustainability. The Thermal Studs individual products and now the newly invented Thermal Studs Ultimate Panel System (TSUPS) is just that. It integrates all three in a way that traditional available materials can’t match.

Unlike conventional materials that require multiple components from various suppliers, Thermal Studs components can be sourced from anyone—foam, studs, nails, and screws from any supplier—and still deliver an industry-leading solution. You can even build walls up to 20 feet tall using our system. Moreover, the Tstud™ products feature a double thermal break when incorporated into the TSUPS, providing enhanced protection against extreme weather and drastically reducing energy loss.

The Thermal Studs Ultimate Panel System not only addresses thermal inefficiencies but also ensures long-term durability, creating a more resilient and eco-friendly building solution.

Gary: Building materials must meet strict regulatory standards. What challenges did you face in bringing your products to market?

Brian: Creating building materials that meet stringent regulatory standards was one of our biggest challenges. My goal was to design products strong enough to withstand the toughest conditions, whether hurricane-level winds or seismic activity, all the while avoiding the complexity of dozens of SKUs for different regions.

The real challenge was the production side. I’m not a manufacturing expert, which is why we rely on licensing for others to produce the products. It wasn’t just about developing the right solution; it was about figuring out how to get it to market and make it a business. Supply chain disruptions and delays in production equipment only added to the complexity. But through it all, we stayed focused on creating an easy-to-use, compliant, and affordable solution that could stand up to any regulatory standard.

Any Parting thoughts, Brian?

As the “old fart” who’s invented all of this, I’m too old to manufacture and I couldn’t get 20 people to sing kumbaya anyway. So, we’re licensing these game-changing solutions to anyone ready to take them to the next level. You get proven, high-performance products, and we get to support your successes. The opportunity is clear: manufacture Thermal Studs products with minimal upfront investment. With our TSUPS (Thermal Studs Ultimate Panel System), anyone with an existing facility can build these solutions. It’s an easy entry into the market, and we’re offering licenses for both the products individually or TSUPS wall, roof, and floor panel manufacturing, giving entrepreneurs a low-cost, high-reward chance to get started fast. If you’re ready to join us and make the future of construction as strong as the Thermal Studs we’ve created, let’s make it happen!

Look for Part Two of our conversation coming soon

In every industry, from technology and finance to the ever-evolving field of offsite construction, a particular breed of person stands out: the innovator. These individuals, no matter their field, seem to share certain quirks and traits that make them particularly suited for seeing things differently and—most importantly—acting on it. But here’s the kicker: are these traits inborn, or do they develop over time? And for those who might not seem naturally inclined to think outside the box, can these characteristics be acquired? It’s a question as old as innovation itself and one that reveals much about human nature, ambition, and adaptability.

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The Traits of an Innovator: A Quirky Checklist

To identify what makes an innovator tick, let’s start with a checklist of their defining characteristics. Across industries, innovators are known for a mix of curiosity, resilience, optimism, and a hefty dose of skepticism (the right amount, that is). They also seem to have a strange relationship with failure. For most of us, failure is a pit of despair. For them, it’s just another experiment with data points to analyze. And let’s not forget the sense of humor—many innovators find themselves laughing at the very processes they’re trying to improve, a trait that’s particularly useful when everyone else is still just scratching their heads.

Consider the construction industry, for instance, where innovation seems to be moving in at least three directions at once. For an outsider, the complexity of merging new tech, green building materials, and novel designs might seem overwhelming, but an innovator sees a web of potential solutions. The typical innovator here is the person whose office has blueprints wallpapering the walls, a desk crowded with models, and perhaps a plant or two just to remind them there’s a world beyond their designs.

Are These Traits Inherent?

Let’s get philosophical for a moment: are innovators born, or are they made? Are they the ones who, as kids, dismantled every gadget in the house and put it back together again (sometimes)? Many in the psychology field argue that some people are simply wired to think differently, right from the start. It’s a fascinating concept—perhaps these are the people who, early on, ask, “Why?” just one time too many, and discover something incredible in the process.

This inherent quality is often supported by studies showing that risk tolerance—a willingness to take a leap when everyone else is playing it safe—is largely genetic. Innovators often have a natural inclination to take risks, make quick decisions, and stick with their vision even when it seems far-fetched. Some researchers suggest that there might even be a “novelty-seeking” gene that predisposes some individuals to find joy in exploring the unknown, seeking solutions where others see none.

The Case for Acquiring Innovative Traits

Yet, just because some might be born with a tendency to innovate doesn’t mean others are doomed to play it safe. Take, for example, people who didn’t start out with big ideas but became industry leaders by necessity. For these individuals, the push toward innovation might have come from repeated exposure to the same problems, or even from failures that forced them to think in new ways.

One famous example is Thomas Edison. Although often considered a born inventor, Edison had plenty of failures that fueled his journey. He didn’t invent the lightbulb in a flash of inspiration—he tried thousands of materials for filaments before getting it right. His innovative spirit grew from persistence rather than inherent talent alone. Today, offsite construction innovators echo Edison’s journey, taking a piece of tech that doesn’t quite work, refining it, and testing it again.

Moreover, innovation often thrives on constraint. People who don’t have endless resources tend to come up with inventive solutions out of necessity, and that skill—creativity under pressure—can be learned. Industries like modular housing see this regularly; companies striving for affordability and sustainability face so many constraints that innovation becomes a survival tactic.

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Can You Learn to Be an Innovator?

There’s growing evidence that, yes, people can adopt innovative mindsets. While certain traits like curiosity might come more naturally to some, others can be cultivated. For example, even if you’re not innately curious, you can practice asking questions, challenging assumptions, and actively seeking new knowledge. For the would-be innovator, here are a few key skills to develop:

• Curiosity-Driven Learning: Start by diving into fields or topics you know little about. Get familiar with the unknown—it’s how you train yourself to approach things differently.
• Risk Management Skills: Rather than jumping blindly, learn to analyze risks methodically. Innovators don’t just take any risk; they take calculated risks.
• Resilience Building: It’s cliché, but building resilience through facing failure is crucial. When you fail, train yourself to dissect what went wrong rather than walking away disheartened.
• Networking with Diverse Thinkers: Surround yourself with people from different industries. Often, insights from outside your own field can lead to breakthrough ideas.
• Experimentation Mindset: Innovators love a good experiment. Make a habit of testing new ideas in small, low-stakes ways before a full commitment.

Inherent Innovators vs. Learned Innovators: Is There a Difference?

Does one approach to innovation yield better results than the other? Not necessarily. In fact, the combination of inborn traits and learned behaviors often produces the most successful innovators. Look at the tech industry: the so-called “wunderkinds” often pair up with seasoned professionals who didn’t start out in a garage at age 15. Both bring valuable perspectives—one with natural flair for thinking differently, the other with the experience to ground lofty ideas.

In the construction and offsite industry, similar partnerships are essential. While the naturally innovative mind might dream up the future of modular housing, it’s often the learned innovator—someone who has spent years understanding building codes, regulations, and material limitations—who turns that vision into reality.

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Do You Need to Be an Innovator to Innovate?

Here’s a comforting thought for all those who feel they might not be cut from the same cloth as the “natural” innovators: you don’t have to be an innovator to support innovation. Industries need both types—the “born thinkers” to come up with bold new ideas and the practical-minded to turn those ideas into tangible products. It’s a team sport, and often, the magic happens when an innovator meets a skeptic or a seasoned pro who challenges them to refine their vision.

Some of the most successful innovations are a result of dynamic partnerships. Take Steve Jobs and Steve Wozniak, for instance. Jobs brought the charisma and vision, while Wozniak’s practical, grounded approach turned their ideas into products people could actually use. Without this balance, Apple might have remained a garage dream.

Final Thoughts: Embrace the Quirk

Whether born or made, the qualities that make an innovator are often delightfully quirky. From the person who never stops asking “What if?” to the one who keeps a cluttered desk of odd prototypes, innovators refuse to let “normal” define their work. And that’s precisely what makes innovation possible.

So, if you find yourself at a crossroads, unsure whether you have what it takes to innovate, remember: innovation isn’t about a single trait or mindset. It’s about a willingness to try, to fail, and to try again. Whether you’re a born tinkerer or a late bloomer in the world of bold ideas, the path to innovation is open to anyone with enough grit and curiosity. Who knows? You might just be one quirky checklist away from the next big thing.

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