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

Curtis Edgecombe, Executive VP, FrameCad

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Mobile Factory revolutionises remote and disaster relief construction

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

A.V. Birch, based in Shropshire, England, has long been a leader in the design and manufacture of industrial automation and timber engineering solutions. Founded in 1977, the company has built a strong reputation for its expertise in mechanical handling, bespoke automation, and bespoke machinery design, serving industries ranging from automotive to aerospace but with its main focus being Timber Engineering. With over five decades of experience, A.V. Birch continues to innovate, pushing the boundaries of what’s possible in industrial engineering by offering customized solutions that meet the unique demands of each client.

At the heart of A.V. Birch’s continued success is a fantastic team, whose vision has guided the company through both industry challenges and technological advancements. Known for their forward-thinking approach, they have been instrumental in expanding the company’s portfolio and fostering a culture of innovation within the business.

The team at A.V. Birch has maintained its competitive edge in an ever-evolving market while staying true to the core principles of quality and reliability that have defined the company since its inception.

In this exclusive interview, we sit down with one of A.V. Birch’s owners to discuss the company’s journey, its commitment to engineering excellence, and the future of industrial automation. We explore the pivotal decisions that have shaped the business and gain insight into the strategic vision that continues to drive A.V. Birch toward future growth and innovation.

all photos – AV Birch Limited

Gary Fleisher, Offsite Innovators: A.V. Birch has a long history of creating bespoke engineering solutions. How do you foster an innovative culture within the company to ensure it stays at the forefront of industrial automation?

Graham Clark, A.V. Birch: The message is simple, don’t be afraid to think outside of the box, we have designed many bespoke machines using this principle, innovation is key to our business and what keeps us ahead of the competition, our team consists of skills that would guide us through the whole process of designing a machine, it’s not always the latest components we use that may give us that edge but sometimes things like how easily it can be maintained and serviced is something that always gets our attention, this is where having a variety of skill levels in the team can really come Into play. 

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Gary: Can you share a recent project where A.V. Birch introduced a groundbreaking solution? What was the driving force behind the innovation, and how did it impact the client’s operations?

Graham: We recently designed and built a machine for creating V notches in wooden fence posts to accept an arris rail, Historically this secondary process has been achieved by using a variety of old antiquated machinery and sometimes even cross-cut saws to achieve the V notch,  We started by looking at the existing machinery available and could see that safety and speed were areas that needed some serious thought, also the age of the existing equipment in the industry meant that parts were becoming increasing difficult to get hold of so maintenance/downtime was also an issue, these became the primary targets for design.

The next stage was to come up with a way of cutting the V notch efficiently and safely,  again thinking outside of the box we looked at CNC machines that were used in different industries and soon came to the conclusion that a specially designed rotary cutting tool would give us this, we also found that unlike the existing saws and chisel type machines using a cutting tool like this gave us priceless feedback to its longevity as we were able to study the data fed back to us from the loads on the motors during the cutting process so the design of the control and tooling was focused around this.

Speed and efficiency are always very important to any customer, and we looked at the current numbers supplied by the customer who was using a mix of saw and chisel machines to create the V notch, their existing process would involve many members of staff and countless hours, we were told that to cut a pack of timber posts would take them on average 2 hrs., so in essence the target was set.

Designed then progressed and we were very happy to deliver a machine that is the first of its kind, possibly the most important aspect for a business owner sometimes is as simple as “how fast is it “ well our machine is fast, if you compare cutting times alone we have gone from the existing process taking 2hrs to our machine delivering the same numbers in 7-15minutes. Not only did it deliver impressive production figures but perhaps more importantly we delivered a machine that was safe and met current regulations, parts were easily accessible, the quality of cut was far superior and the machine required half of the labor to operate.    

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Gary:  With technology evolving rapidly, how does A.V. Birch integrate emerging technologies, such as automation and digital solutions, into its core services while maintaining the company’s longstanding values?

Graham: We have been in the business long enough to see how machinery has evolved and we have played a large part in delivering safe efficient machinery to the truss and floor joist world of timber engineering, it’s easy to see that modern technology can make a huge difference in certain applications, but not all, it’s having the knowledge to know when and how to use it. This takes a team time to break down the requirements of each inquiry and to understand what the customer actually requires and it is sometimes not what they think, there seems to be a misconception that robotics for example are the future, yes in some circumstances they are, however when looking at some applications it doesn’t stack up.  

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Gary: What role do customer needs and feedback play in shaping the direction of A.V. Birch’s innovation strategy, and how does the company stay agile in responding to changing industry demands?

Graham: The customers’ needs are undeniably what drives us, delivering more is always the objective. Without forward-thinking businesses, we wouldn’t be designing new machinery. It generally starts with a conversation about inefficiencies or difficult time-consuming processes that don’t have a solution, could you tell me this is something we often hear, how we then go about solving this is the real heartbeat of everything we stand for.   

Gary: As a leader in timber engineering equipment, what are some of the key trends you see in the industry today, and how is A.V. Birch positioning itself to capitalize on these trends through innovation?

Graham: The key trends aren’t necessarily any different from what they always have been, the strive for innovation, efficiency, productivity, and safety is at the top of any manufacturer’s agenda,  we like to think that we have positioned ourselves to be the supplier of the best machinery, we have a reputation for building bomb-proof equipment with a focus on easily maintainable equipment that lasts, we have truss presses that are still producing trusses 30-40 years down the line.  Having said that, continual innovation is the key and we are always looking at how we can improve efficiencies.    

Here’s one of our 50T lifting beams. They’re designed for picking up large steel coils that weigh up to 50 tons. The hooks are rated at 20T each.

Gary: Looking ahead, what are your priorities for A.V. Birch in terms of future innovation? Are there any emerging markets or technologies that you believe will significantly shape the company’s direction in the coming years?

Graham: Looking ahead it is to stay at the forefront of Timber engineering equipment, the emerging markets in MMC show a willingness to move with the times, we have all seen the benefits of this type of construction within the UK already and we are there to support with machinery,  our latest Truss Auto Press sits nicely between others in the market giving options to customers depending on their preference and budget which is important, We have also witnessed the growth in metal webs for floor joists, our uni-roll is the best selling machine in the market. 

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I want to thank Graham and the wonderful team for allowing us to look behind the curtain at one of the world’s best-run and innovative timber engineering equipment companies.

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