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

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

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

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

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

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

Andrew Xue,COO & Co-Founder at Offsight

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Since its inception in 2017, Boxabl has revolutionized the modular housing industry with its innovative approach to solving one of the most persistent challenges in construction—scaling mass production. Founded by Paolo and Galiano Tiramani with the vision of producing homes in the same way factories churn out cars or electronics, Boxabl seeks to make high-quality, affordable housing accessible to all. The company’s key innovation lies in its ability to fold room modules, drastically reducing shipping costs and paving the way for large-scale production that could reshape the housing landscape.

 Galiano (left) and Paolo Tiramanim co-founders of Boxabl

Boxabl’s journey from concept to reality hasn’t been without its hurdles. While the company anticipated manufacturing would be their biggest challenge, it quickly became clear that navigating the complex web of building regulations across different states was a far more significant obstacle. Boxabl’s leadership has been relentless in their pursuit of overcoming these regulatory barriers, advocating for a standardized national building code that could streamline the factory-built housing approval process and accelerate production on a broader scale.

Despite these challenges, Boxabl remains at the forefront of innovation in the modular construction industry. Their flagship product, the Casita, offers a glimpse into the company’s larger ambitions, with plans to expand beyond small, standalone units to interconnected and stackable room modules that could cater to a variety of housing needs. By continuously improving their designs and working closely with regulatory bodies, Boxabl aims to prove that mass-produced homes are not only viable but essential in addressing the growing affordable housing crisis in the U.S. and beyond.

Gary Fleisher, co-founder Offsite Innovator: Boxabl has made significant strides since its founding in 2017. Can you share more about the innovative decision-making process behind the launch of Boxabl? What challenges did you encounter while scaling up?

Galiano Tiramani, co-founder of Boxabl: The idea behind Boxabl was to solve housing by mass producing buildings in a factory. Most other modern products (like cars, TVs, iphones and sneakers) take advantage of a factory and an assembly line to make products rapidly at the lowest cost, but about 90% of houses are still built on site. So why is that the case? Our theory was that since houses are so big, they cant be easily shipped long distances from the factory. Most factory built houses are shipped with special wide load permits and follow cars since they dont fit on the road, this increases the shipping costs dramatically.

Gary: Why is that a problem?

Galiano: Because if you cant ship far from your factory, you cant have mass production, and this means most house factories are small regional factories that dont take advantage of scale. The first  innovation we needed at Boxabl was to solve the shipping problem so we could mass produce the houses to drive down costs. We achieved this by folding up the empty space in the rooms we manufactured so we could ship them in a cost effective manner. The room modules we make are finished in the factory with windows, electric, plumbing, flooring and more that can ship to site and be setup in a few hours. This innovation is critical because it will allow us to scale up production in an attempt to bring down costs. Most car factories put out one car per minute, our goal at Boxabl is to match that level of efficiency with houses. 

When we started the company we thought that manufacturing would be our biggest challenge. It turned out that wasnt the case. We were able to scale up manufacturing quickly and deliver on our first order of 156 houses to the federal government. Our biggest road block turned out to be… Regulations. Different laws and regulatory agencies exist that slow down and block housing in the USA. Anyone that has ever tried to build a housing development understands that its very difficult and can take several years to achieve… If its even allowed. In most cases, applying for a permit to built something, like an apartment, complex will be met with pushback from neighbors and local government. A builder will be faced with town hall meetings where people try to stop the project, elected government officials trying to stop it, and then later building department officials adding many restrictions added cost and timeline delays to the project. The builder will be required to wait on building inspectors to come visit the project and inspect it at many stages during the building process.

These restrictions exist for regular building construction thats done on site, when you add factory built buildings into the process the situation gets worse. An extra level of regulation exists soley for factory builders. Most states have an additional regulatory agency that adds more restrictions and delays into the process. This includes factory inspections, quality control programs, building plan review and more. All of these extra steps must be completed before a builder even tries to apply for a building permit. They can add years to the process and stop a house factory in its tracks. Did you know that the building code is almost 1000 pages long? And many sections are up for interpretation, building codes also differ by state. So creating one building plan that works in multiple states can be very challenging and introduce further delays. Factory home builders must also apply for each of these state programs and go through the process one by one, so that makes it even more difficult to mass produce a product.

The list of regulatory challenges doesn’t stop here… Many other issues exist that have made it difficult for modular builders to succeed. I would say regulation is one of the biggest reasons why most modular builders have failed over the years. At Boxabl we realize this is a challenge, but also an opportunity to drive down costs if we can solve these issues. We are working hard with state regulators to show them that a standardized mass produced product relives the risks that these regulations are setup to avoid. We want to see a national building code thats the same for every state, and a national process for modular house approval that can reduce the roadblocks we see. I think Boxabls scale and standardized product uniquely positions us to solve these regulatory issues.

Gary: Affordable housing is a crucial focus for Boxabl. How are your latest initiatives positioning Boxabl as a leader in this space, and what role do your new facilities play in accelerating production to meet growing demand?

Galiano: Affordable housing is a crucial focus for Boxabl. How are your latest initiatives positioning Boxabl as a leader in this space, and what role do your new facilities play in accelerating production to meet growing demand?

Boxabl has big plans, we are trying to prove the concept of mass-produced housing at our first 3 factory buildings here in Las Vegas. We are dialing in our technology, testing the market, improving our manufacturing methods and scaling up fast. The goal right now is to show the market that we can make it work, then continue commanding resources to scale. Housing is a big problem with millions of housing unit shortage here in the USA. We think the only way to fix this is to scale and brute force the problem. 

Gary: There’s been considerable excitement about Boxabl’s innovative folding homes. Can you tell us more about the new advancements in your designs or manufacturing processes that have the potential to revolutionize the industry?

Galiano: Since we started we have been continually improving our process, our product and our operations. Learning how to navigate regulatory challenges and drive down costs. We are constantly updating our product design to lower cost and increase ratings. We are investing in new automated manufacturing equipment. 

Gary: You’ve previously mentioned partnerships and collaborations as key to Boxabl’s growth. How have your recent partnerships, like the one with Catholic Charities and creating a builder network, shaped your approach to providing affordable housing solutions?

Galiano: At Boxabl we are always looking for competent partners to help push projects to the finish line. Boxabl is a room module manufacturer, we aren’t necessarily interested in developing real estate projects ourselves. We seek developers to be our customers and buy our products hoping that they see the value in speeding up and lowering costs on a project. We have sales team that fields leads from developers everyday to find the best partners who can create amazing projects. We are very happy to have been able to work with Catholic Charities and hope to do more projects after this pilot project is proven a success.

Gary: Boxabl has always aimed for innovation. What new features, technology integrations, or construction methods are you currently exploring to stay ahead of the curve in modular housing?

Galiano: We have lots of exciting stuff in the pipeline. For example if you look at chart that shows our material and labor cost to produce our product you can see that it continues to trend down with lower costs. 

You might have heard of the Casita, its our first product, a 361 square ft house thats a studio apartment, bed, couch, kitchen and bathroom. https://www.boxabl.com/casita On important thing to mention is that Boxabl is not just a tiny house company. Our plans extend far beyond the “Casita”. This is our foot in the door, but we plan for a larger building system where different room modules in different sizes can connect and stack to create larger homes. The idea is that Boxabl house might look no different than the house you live in now. 

Although we have lots of exciting stuff planned, unfortunately I cant discuss much detail on new stuff before it has been announced to the public for our SEC compliance.

Gary: As Boxabl continues to scale, what are your biggest goals and priorities for the company in the next few years, and how do you envision the broader impact of your work on the affordable housing crisis?

Galiano: Recently we established a dealer network. This is basically a list of local contractors that can help our individual customers get a Casita installed in their backyard. https://www.boxabl.com/directory We urge anyone that wants to sell Casitas to sign up for our dealer program. This will give them access to our customer pipleline and allow them to sell Casitas.

Gary: I want to thank Galiano Tiramani for taking the time to share his innovative idea turned into a reality. It hasn’t been an easy ride for Boxabl but positive things are happening for Galiano and Paolo, his father, efforts to bring affordable housing to the US,

Paul Richards, a dynamic leader and innovator in the offsite construction industry, is
making waves with his latest venture, The Thunderhaus site production system. Known
for his forward-thinking approach and extensive experience in construction, Paul is
pushing boundaries once again with these innovative systems designed to streamline
and enhance the efficiency of building processes in even the most challenging
Environments.

With 40 years of experience in construction, Paul Richards has a multidisciplinary
background that spans 20 years as a factory owner/operator, specializing in DFMA
and delivering thousands of projects. In parallel, he self-financed an R&D facility for
over a decade focusing on ballistic composites for retrofits/newbuild, designing &
building machinery and developing processes for mass production, training
manufacturers globally, and integrating robotic production systems. His advisory roles
include contributions to the UK Government’s Construction Innovation Hub and various
European retrofit/newbuild sustainability programs. Paul is also the developer of the
Thunderhaus site production system, a cutting-edge innovation aimed at improving
onsite life while delivering efficiency and building truly affordable energy energy-efficient
Housing.

I interviewed Paul to learn more about him and his innovative Thunderhaus concept, exploring its impact, potential, and
what it means for the future of offsite construction.

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Gary Fleisher, cofounder of OffsiteInnovators: What was the initial inspiration behind the Thunderhaus site production system,
and how did it evolve from concept to reality?

Paul Richards, Thunderhaus innovator: well it started out like most innovations as a solution to a simple problem, I can
trace my early attempts back to the 90’s when one of my guys approached me during a
long wet winter, and a very wet start to the new year, they’d had enough, he opened up
to me and I knew I needed to act, so I bult a cover to protect a site and I thought that
could give them a good few weeks dry work, and try to kick start the year, it worked well,
sort of , yeah not perfect but it worked, and then the storms came and it didn’t! but that
was the spark, and the idea was brewing, but I sold that business and left the onsite
world, or at least I thought I had. Only to return years later having worked around the
globe and seeing how everyone else was building, and adopting new methods, but I
thought this would never be allowed in the UK or Would it? And unfortunately for me
that was the start of everything.

But guess what it still rains here in the UK and people can’t work! How dumb, no other
industry would work like this, its time for a shake up!

The penny was starting to drop during my Retrofit for the Future investigations our
Government held a £150million program to retrofit the Uk’s existing housing stock, they
stripped back various existing houses and re built them with every emerging technology
to bring these homes into the future, but I could see a pattern running throughout these
100 test houses, and I could see what was lacking, so again this was only fueling my
Thoughts.

Years later I heard Mark Farmer speak, and it was as if I wrote his message, Modernize
or Die! I heard that and filled in the Blanks, this was it for me, he was effectively saying,
we the industry needed to adopt new technology and solutions within the Built
environment “well that’s what I was hearing” this was my time. I had a housing system in
my head that was formed when I was a teenager on commercial sites, and would be
building huge commercial buildings across the UK while my mates were rolling around
back at home in the mud, still trying to place a brick on a brick in the Rain, my wealthy
friends would pay good money to watch mud wrestling with beautiful ladies showing
their underwear while wrestling with each other in the mud, well you could see this
every day onsite in the winter for free, except the beautiful, and the ladies, but the guys
were as covered in mud, and you could see their underwear, so not so different. But that
type of work wasn’t for me and its certainly not for the youngsters of today. So, another
reason for change. Over the next few years, I had perfected the housing system and
developed it into a Kit of parts, but industry wasn’t interested. They were interested in
large scale factory production, factory built homes were being hailed as the panacea for
the industry hailed by everyone who has probably never paid to set up or operate a
factory for the construction industry out of their own pocket, but I have, when I opened
my first facility, in my early 20,s, I grew my business and needed a bigger factory, and a
bigger one, and a bigger one, you get the picture, but maintaining that model is costly, in
every way imaginable, I used to work “silly o’clock” I’ve always done it 7 days a week,
silly o’clock, but my team was getting fed up, we didn’t know what day of the week it
was, we were just working and working, but I was young and naive.

Again, one of my team approached me and said, “we had to change”! He was right, so
we reached out to the supply chain and I started engaging with effectively my
competition, and it worked, they started to make our components, “subassemblies”
eventually we stopped working 7 days and started taking weekends off, ok they did, it
took a while for me, but the atmosphere was much better, and I started developing ways
to communicate with my supply chain, there were no computers back then that we knew
how to use, and my supply chain were at different levels of understanding technology,
“Sounding familiar”!! so that could lead to costly mistakes.

But our business continued to grow, and we invested in technology, and working with
the supply chain, which freed me up, and it didn’t need me so much, and as we refined
our models, we didn’t need large Factories, so that enabled me to start on a idea I had,
and I started my first R&D facility. I ran that in Parelle with my other business, I learned
so much not all of it good, but that’s crucial to this journey.

I went on to set up other manufacturing facilities one in Wales and a production line in
Canada, so my understanding of factory needs and more importantly, don’t need, come
from lived experiences, and how to simplify how we communicated.
Back to the Thunderhaus, I know I have simplified the system, (the kit of parts), and that
opens the market, for anyone to engage, mixed that with digital technologies making
understanding sharing correct information easier and people start to get interested.
So, do I need a factory? that word “Need” would define my understanding of every
aspect of what “Needs” to happen, and “defining those Needs” are Key to solid fact-
finding solutions.

So, I have a system that can build Homes, now I had to validate it! And inform industry,
I grew up in a cold house! It was a solid structure but cold in winter, during my time in
Vancouver my friends were building a home after they had just sold their business to
Mrs “G”, so money wasn’t a problem. it was December and cold outside, as I walked
into the house it was warm, I asked the builder how you are heating this place? he said
they weren’t! a house at the same stage of construction in the UK would be a very cold
environment and unpleasant working conditions but this was a bright and warm place to
work, and I discovered how! That was my first real experience of Passive Haus
principles. And I was hooked! Eventually this would influence my system, although the
term Passive hadn’t been termed until a few years later, but I just had to design my
system to PHP by default, But I also knew industry won’t pay extra for this, so I
designed the products with the supply chain to enable this by default. That took a while,
but during that time I went out to the market to shout about it, just when they had
announced they were investing hundreds of millions in Volumetric factory production,
and didn’t understand passive Haus or a kit of parts approach, that simply went against
the Grain of their factory investments.

But I carried on and woke up a land broker that had several sites on stop due to funding
constraints and started to bring him up to speed with offsite technology, but we would
need a factory he said, and I pitched The Thunderhaus, he arranged meetings with
bigger and bigger land brokers which lead me to the big table, ok it wasn’t so big, but
the people were or rather the money they represented was. By then the mega Factory
keys had started to lose their luster, and I found myself sat at the table of plenty, and
they had an idea of what I was trying to address with my Thunderhaus, I can’t say that
they were the people behind the funding of the Largest volumetric factory here in the
UK, I’ll leave that for someone else, but they knew something was amiss with large
factory production and they were sat with me.

“The Carrot and the Thunderhaus” I had several meetings driving up to Manchester
from Bristol we met at the same place, and the Carrot was dropped “booom.“ the

People sat at that table represented big money/ in fact the biggest carrot I’ve heard to
date. One had a fund of £12Billion, yeah with a “B” the other had a fund of £28Billion,
yeah BBBB BBB, but they were still stuck with a fixed factory mindset, they wanted to
do the same thing as before but with a different outcome? I thought. I was going
backwards, tell me about your Factory idea! so I did, “The Thunderhaus”, and I went on
to describe its functions, but it sounded to simplistic to be a viable investment they
weren’t getting it. Nor was I really trying to sell it, But I was asked to find a large factory
in the North for me to set up and operate and they saw this as a business model they
could understand, and a starting place to develop the Thunderhaus, but that wasn’t for
me, I had to decline, as my gut wasn’t happy, and I’ve ignored it in the past to my regret,
Yeah, I had to walk away it took a few days to sink in, because of what I was walking
away from, but I’ve had factories and fixed Factories aren’t for me any more, and once
you start them you can’t just change direction. Oh, and I lied about the Days it still
haunts me now years later because I knew these guys were real and so was their
Money.

But when I was describing the Thunderhaus they mentioned their sites were in
Manchester and my idea of the “super tent” as it was then, wasn’t going to prevent
some scallywags from looting the place, so right there I had the idea of steel structurers
as opposed to an all-fabric building. And the dots started connecting, endless
possibilities.

I haven’t gone back to that table but those sorts of funds seem to pop up along the way
so who knows.

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Gary: Thunderhaus is designed to work efficiently in challenging conditions, such as
night-time and wintertime. Can you elaborate on the key features that enable this
adaptability?

Paul: Yes, you treat this the same as a fixed factory, but its on site, all the factory kit but
on site. I say if the teams can get to site then they should be able to work protected from
the elements, I’ve worked in Canada and the US and yeah the snow can stop people
getting to site, or even stop work all together, but when I was a kid I got to work by hook
or by crook, but I got there, but the Thunderhaus is effectively a big cover that keeps the
teams dry and warm and protects the build and materials, but that’s the very basic
function of the Thunderhaus, It started out as a building Rig to hold and position
components precisely while they are being assembled, I wanted to de skill this or de risk
the build, using the Rig as the quality and precision enabler by default, I wanted non
skilled people to engage with Housebuilding, ok women, they will make fantastic house
builders, and by using a building Rig with a cover over it derisks the assembly and
enables them to work better than most blokes, I’ve seen it work before and this is the
opportunity for them to thrive. Factory production techniques, we teach people to
specialize is efficiencies, and we advance our subassemblies to enable this, and
develop the support tooling to enable this, but like no other housing site we can
introduce a 3 shift working system, or a much more flexible working environment, that
enable family life to continue while the parents work, I’ve even designed a creche
Thunderhaus, and that will transform the housing industry forever. But it must be
implemented at the earliest stage, it’s a site production system, and everything must be
designed to maximize efficiency of onsite production, and that’s not easy, usually I get
called in when the housing has been designed and the plans been approved but funding
is asking more from the site. This isn’t ideal for the Thunderhaus, although its not
impossible, as I have tried to introduce the Thunderhaus but the benefits were not
enough seeing as they already had a factory and don’t care if everyone and every thing
gets soaked, but that’s changing the teams can still get wet, they aren’t worried about
them, but the warrantee providers are changing the way, if the product isn’t protected
throughout the build stage, they wont be warrantying it, and that applies to Timber
structures more than most.so protecting your product & building in a controlled
environment and making use of factory processes and procedures , what’s not to like?

.

Gary: How do you see Thunderhaus impacting the current workflow of site production,
particularly in terms of speed, cost efficiency, and labor demands?

Paul: The Thunderhaus is a production enabler, how many times have people
doublehanded product, built the right thing but in the wrong place, materials damaged or
unfinished or uncompleted tasks lied about the stages of build and that only misinforms
the next trade of their ability to complete their job, this has been the norm for decades
on site, and thousands are lost through in efficiencies. but the Thunderhaus can work
with the builder as a support mechanism, breaking down the tasks and aiding building
efficiencies, it can have & hold parts or tools, but that’s just the basics, decent lighting
and power creating a warm environment and even serve the coffee, this is about
working smarter not harder, let the Rig carry the load, and introduce production
mindsets not builder, pay better because of efficient build processes and advance
subassemblies that can be replicated throughout all your developments, but the
Thunderhaus will prove it worth and will be used In may forms, from subassembly 1
through to multiple riggs traversing on site.

The Thunderhaus will attract the best tradespeople as well as non-trades as builders
are looking to work in a better safer environment and not kill themselves doing so, it will
also open the opportunity for older trades to come back on site in a more respectful
environment,

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Gary: One of your recent posts mentioned that Thunderhaus is a “catalyst product.” Can you explain what makes it a catalyst and how it could potentially disrupt traditional site
production methods?

Paul: Oh, this is a big one, over the last 5- 10yrs industry has really ramped up its
efforts to push innovations, but they are Siloed, usually great ideas but disconnected
from the real opportunity, where are they going to come together? and certainly not
accessible or visible to the masses, so take up will de prolonged due to the mindset of
the builder, their no nonsense approach to technology has to be taken into
consideration, they need to try it kick the Tires, and see the benefits in their pockets,
before they will believe the hype. So how can this be addressed? Where can they see
these new advancements being used, and what environment will it need to work
effectively, The Thunderhaus is a hosting system, an onsite environment that enable
Man and Machine to work in a controlled environment, it protects the delicate machinery
from the elements , but enables known innovations to actively work on construction
sites, “BOTDEX” is a site floor matting system, this simple floor mat used by the Military
and festival industry simply creates ground surfaces that enable clean floors suitable for
heavy kit to move onsite without difficulty, this simple solution opens up the possibility to
use off the shelf Robotic carriers that are common place in large warehouse activity, it
also enables the Thunderhaus to work 360 degrees, as the need for set tracks have
been eliminated, BOTDEX can do much more than this, it can assist with setting out as
its perfectly square and can be marked at fixed build positions, again connecting
technologies, the gantry systems can be hydraulically controlled, so setting heights and
projections can be altered to support comfortable build heights and prevent
overreaching, the gantry’s at different levels can be accessed by external lifts never
utilized in housebuilding, this could enable wheelchair access and open up untapped
people to work on site. The main bodies of the Thunderhaus can be kitted out for
manufacturing or as office space, The working body of the Thunderhaus can be fitted
out for bespoke requirements with internal gantry cranes for lifting and positioning, we
can set cameras into the frame of the Thunderhaus for safety and monitoring, but I
believe the Real innovation will be a live feed enabler, opening up the possibility to track
build schedules without having to visit the site, and this opens up JIT production linked
to digital ordering but the new opportunity will be the ability to open up new funding
mechanisms, this real time quantifier will enable new funders that invest at set stages,
smaller funders similar to Crowd funding, opening up Housebuilding like never before.
All because of The Thunderhaus.

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Gary: Given the rapid advancements in offsite and modular construction, what role do
you envision Thunderhaus playing in the future of the industry, especially in terms of
scalability and sustainability?

Paul: so I’ve been asked to design different models of the Thunderhaus, and the Block
Builder is based of a Volumetric assembler and install, it’s a little bit Fantastical for some
but the Guts of the idea are there, but the real value is it’s a cheap factory its yours
kitted out how you want it but more importantly its where you need it, fixed factories can
be hundreds of miles for the build site and this enables everything to go wrong, if it can
it will, but the Thunderhaus can be on site or near site, or both, its not limited, and the
best part , when your finished with it you can pack it away and take it to your next site
and start again, I believe the Thunderhaus will be a rental option with the component’s
being generalized, this will enable proven systems that have been perfected by the
industry to be used across the Globe, and simply installed on the build site following a
set sequence laid out by the Thunderhaus. Or “Thousands of Thunderhaus”!

Gary: What were some of the biggest challenges you are facing in the development of
Thunderhaus, and how are you overcoming them to bring this innovation to market?

Paul: well, they still are, The Thunderhaus seems too easy, why hasn’t it been done
before? And then people try and find reasons why it won’t work, they don’t like change,
but that’s nothing New, however, something must change! The need for housing is
greater than ever before, and without trying we aren’t going to know! I can find lots of
reasons why it won’t work, but thousands of reasons why it will, I’ve been around the
Block and construction particularly house building doesn’t appeal to the new generation
of workers and site Life has to change, there are Thousands of young people that will
absolutely thrive onsite and make a fantastic life for them and the people who the Build
for, but they are not thinking construction as their first choice Why? Because getting wet
cold and treated like shit isn’t for them, and its not for me it never has been and it never
will, we need to Respect our young and especially our future trades people, without
them our housing stock will perish and so will our economies, for too long has the
Housing industry been left to stew in a mess created by non-industry pressures and that
has to change. And I believe the Thunderhaus is a great start. But Who’s interested
who’s listening who understands where to start?

Gary: Looking ahead, what future enhancements or additions do you have planned for
the Thunderhaus system, and how do you plan to keep it at the forefront of site
production technology?

Paul: Absolutely, I’ve started the imagination of some very clever people, and they are
onboard, very senior engineers that took a while to get it, have got it, and they are
joining the dots, I’ve been fortunate to work with some clever people, and that’s what
gets me through the negative meetings, these people get it, they know it’s a Catalyst

system in every sense, what the construction industry doesn’t know is these teams have
been looking for solutions for decades but you can have a clever factory somewhere
producing magic, but the magic needs to be seen, and I think the Thunderhaus will be
bringing the magic to your site! Just needs you to be on the stage.
Gary like most innovations we will never know where it will end up or evolve, the World
is full of smarter people than me and I cant wait to see what they can do with the
Thunderhaus!

Gary: I can’t believe all the work and thought you’ve put into this innovative project and want to thank you for a great interview.

As the founder and CEO of S.I. Container Builds, Rory Rubin is at the forefront of transforming shipping containers into innovative modular solutions that go far beyond single-family homes and Auxilliary Dwelling Units (ADU). Her company’s approach exemplifies creativity and sustainability, finding versatile applications for repurposed containers in industries such as education, healthcare, and commercial spaces. 

Rory Rubin, on the right talking with factory visitors

Rory Rubin’s passion for innovation and social impact is evident in the projects she leads at S.I. Container Builds. From creating safe spaces for young girls in need to developing commercial solutions for businesses, her company is changing the narrative around what can be achieved with single-use shipping containers. 

S.I. Container Builds is not just a company that repurposes shipping containers—it’s a brand driven by innovation, social responsibility, and a commitment to quality. Under Rory Rubin’s leadership, the company has pioneered new applications for container-based construction, addressing community needs while setting new standards in modular building.

Rory Rubin, founder of S.I.Containers (left) and Audree Grubesic, founder of Offsite Dirt

In this discussion with Gary Fleisher, Rory shares insights into her work, highlights groundbreaking projects, and offers a glimpse into what’s next for S.I. Container Builds as it continues to lead the way in sustainable construction.

Gary Fleisher, Offsite Innovators: S.I. Container Builds has expanded beyond single-family living solutions. Can you share some of the most innovative projects your team has completed that use shipping containers for purposes other than residential living?

Rory Rubin, Founder/CEO S.I. Container Builds: Yes, we are driven by our passion projects.  Projects such as our collaboration with Taraji Henson’s foundation Boris L. Henson and Kate Spade NY to place wellness and therapy pods on HBCU campuses. Supporting the mental wellness of young women of color. Our collaboration with Housing Opportunity Development Corporation and Shelter Inc. to build the very first safe home for girls who have been trafficked in IL and others in the works.

Gary: Your work often intersects with community impact, such as the project supporting young girls. What inspired you to focus on projects like these, and how do they align with the company’s goals?

Rory: My little-known trivia is that I started as a clinical social worker. To be able to align my “first life” in the building world is not so strange.  SI Container Builds is focused on recycling a structure that will outlive our wood frame structures for causes that are truly needed—housing, commercial spaces etc.

Gary: When transforming single-use shipping containers into finished modules, what challenges do you face, and how have you addressed them in unique ways? 

Rory: I spend 80% of my time around education.  There still is a misconception that the shipping container is a too cold or too hot –a rusty old box. We repurpose only one-tripped containers so we can guarantee their quality and what was transported in them and we strictly follow all building codes so when you enter our units you feel like you do when you enter any other home or room.  The advantage that we have is that we are working with steel.  This steel is the way we build, and engineered to far outlast other builds against things like fires, hurricanes etc. We are also licensed, certified and supervised by a third-party entity owned by the ICC.

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Gary: In terms of commercial and industrial applications, what are some of the most exciting innovations S.I. Container Builds is currently working on?   

Rory:   We are currently engaged in a couple of very cool local projects for Chicago, that we cannot talk about quite yet..but stay tuned!

Gary: Looking to the future, what trends or opportunities do you see for container-based builds? 

Rory:  Containers are made to stack 9+ high. We are looking at multifamily apartments because we are just so perfect in design.  It is another way for us to support the ever-growing housing crisis.

Gary: What’s next for S.I. Container Builds? Can you give us a sneak peek into any upcoming projects or innovations that your team is excited about? 

Rory: We just launched our new P3 line. They are builds made to be transported for onsite worker housing.  Now developers can own units including bedrooms and bathhouses to support workers in more remote locations. They no longer must rent out motels several hours away or rent run-down RV’s. Our units are made to fit on a trailer and be used anywhere.

Gary: With sustainability being a core value in your work, how do you balance eco-friendly practices with the need to deliver cost-effective solutions? 

Rory: I am still amazed that eco-friendly isn’t always less expensive, but we know that this is not true yet.  We at least can say we start from a place of recycling something that would just go to waste—stacked in a “container graveyard”.  We hope as we scale, we will be able to provide things like standard solar etc.  It is coming!

Gary: For other innovators in the offsite construction space, what advice would you offer as they look to integrate new ideas into their business models? 

Rory:  Make sure not to jump too far ahead before you perfect what you can do now.  We are in such a desperate need for housing that there is room for many, many strong companies.  It is also nice to collaborate and work together so that we don’t have to reinvent the wheel.  

Gary: I want to extend my heartfelt thanks to Rory Rubin for taking the time to share her insights and experiences with us. As the founder and CEO of S.I. Container Builds, Rory is truly at the forefront of transforming the way we think about modular construction. Her passion for innovation, coupled with her commitment to social impact, is not only inspiring but also setting new benchmarks in the industry.

Through projects that range from supporting the mental wellness of young women to pioneering worker housing solutions, Rory and her team at S.I. Container Builds are proving that sustainable, container-based construction can be both versatile and impactful. It’s been a pleasure to learn more about the incredible work her company is doing, and I’m excited to see what the future holds for S.I. Container Builds as they continue to lead the charge in sustainable construction. Thank you, Rory, for your dedication to innovation and for sharing your journey with us.

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

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

 Nigel Watts, Vice President of RHEIA, LLC

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Bill: What inspired the formation of Offsitek?

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

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

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

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

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

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

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

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

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

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

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

Bill: What are Offsitek’s goals for growth?

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

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

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

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

I traveled to beautiful New Hampshire in April to visit Jason Van Nest and his Logic Building Systems studio. I had a great conversation with Jason and learned why his new company could bring needed change to the offsite construction industry.

Jason Van Nest

When it comes to innovation in architectural design and offsite construction, few names stand out as prominently as Jason Van Nest. With a keen eye for blending cutting-edge technology with sustainable building practices, Jason has carved out a niche in the industry that’s both forward-thinking and deeply rooted in practical application. His work not only pushes the boundaries of what’s possible but also challenges conventional norms, making him a leading voice in the conversation about the future of construction.

In this interview, I delve into Jason’s innovative Logic Building Systems. From his early days of architectural exploration to his current role as a thought leader in offsite construction, Jason shares insights that are as inspiring as they are informative. Whether you’re a seasoned professional or new to the field, his perspective offers valuable takeaways for anyone interested in the evolving landscape of modern construction.

Gary Fleisher: What inspired you to create Logic Building Systems, and how did you come up with the initial concept for this innovative approach to construction?

Jason Van Nest: Logic exists to commercialize years of research done at New York Tech’s Center for Offsite Construction.

I had been a consultant to the US modular industry for years, and seen smart friends and colleagues struggle to remain profitable using the techniques we call “Modular 1.0.” Unfortunately, our colleagues were forced to use a lot of “indoor construction” techniques to advance offsite construction, and the core benefits of manufacturing were still elusive.

Logic brings the practices of “Modular 2.0” to the US construction industry. We’re collaborating with the Center to introduce a standardized “coupler” that converts any dwelling unit into a home that can accept modular kitchens, bathrooms, and utility rooms. We are offer the industry’s first modules that plug-and-play with that coupler. Developers can buy a kitchen from a website, enjoy price transparency with an MSRP, and have tenants cooking dinner minutes after delivery! 

We know others will bring their own modules to interface with the standardized coupler – interoperability is the point! The US faces a worsening affordable housing crisis and evolving the industry to Modular 2.0 is how everyone can get more productive and build our way out of this challenge! 

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Gary: What were some of the biggest challenges you faced during the development of Logic Building Systems, and how did you overcome them?

Jason: In an industry where it takes an average of 23 subcontractors to deliver a home, the answer is always “collaboration.”

Here is a general industry and a company-specific challenge, there are many more we’re still working on!

The biggest general-industry challenge is the relative wariness toward offsite construction with the billion-dollar failures of Katerra, Veev, etc. Before 2021, more developers had the experimental stance of early adopters. Since then, everyone wants to be a second customer. Who can blame them?! 

Developers have grown more comfortable when they learn about Logic’s alliance-building stance — requiring us to partner, where these firms used to hire. We explain how developers can still tap all their same GCs and subs, not abandon whole project delivery models. Empowering all the customer’s own skills and relationships makes the difference.

A company-specific challenge was responding to customer’s request for price transparency. Developers are tired of bid surprises, change orders, and widening contingencies. We asked “Why cant we put an MSRP on our website, like car companies do?!” (By the way, today, every module now has one at the top of its project page.)

Again, the answer was collaboration. The products with an MSRP easily interface with other products. Early smartphones interface with power/data with a USB plug. US Toasters have a standard 3-prong cord. All today’s pod manufactures design this interface per project. We’re working with the Center to standardize an interface, which gives Logic the ability to skip most of the re-design, and offer unprecedented price transparency.

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Gary: Can you explain the core technology behind of Logic Building Systems and how it differentiates from other modular construction methods available in the market?

Jason: Logic’s core technology is working with people who are energetic, curious and engaged. Such smart people are always the engine that make innovation work, regardless of the industry.

I’m old enough to have put forward YCombinator and TechStars applications together for my teams’ software in the aughts. It look a lot of exploration to realize that software couldn’t cure the 100-year old means of production that hampers US construction.

I also hold US and international patents for construction assemblies. In design and construction, patents are easy to navigate around, and hard to enforce.

The key evolving our industry will be building company and customer relationships that make everyone more productive and profitable. 

That takes and open mind, energy to do exploratory work, and the willingness to keep showing up. 

Gary: How has of Logic Building Systems evolved since its inception, and what are some of the significant milestones you have achieved so far?

Jason: Like good all startups, Logic started as a long feasibility study. 

It took 18 months of interviews, research, reading, and re-starts. It wasn’t enough to ask, “What is holding US offsite construction back?” We need to know the answer to, “How have other industries addressed these challenges?” to know if we were on to something.

The first Senior Research Fellows at the Center for Offsite Construction were naturally the folks who had been heavily engaged in the study. They helped found the Center, define its charter projects, and fund the open-source efforts.

In many ways, starting Logic was “step six” after all that other groundwork had matured. 

We’re finalizing Logic’s functional and manufacturing prototypes in Q3 and Q4 of 2024, simply to complete the go-to market strategy we mapped a year ago. We’re having advanced first-customer talks now. 

Gary: What are your plans for Logic Building Systems, and how do you envision this technology impacting the construction industry in the next 5 to 10 years?

Logic’s goal is to drive down the cost of US affordable housing nationwide. 

In the short term, we are refining our supply chain, and module assembly processes, to quickly partner with other manufacturers and reach markets nationwide.

On the 5-10-year timescale, Logic will implement the entire scope and vision of the Center for Offsite Constructions “Modular 2.0” vision. We’ll offer interface products that empower builders with unimaginable interoperability. We’ll offer modular products that establish a new normal of price transparency. In doing so, we’ll help other modular companies offer whole product platforms, not just design services.

That effort lays the groundwork for Logic software to bring it all together. Designers will easily connect large-scale building products into a single site-specific building. Then order it with a fixed price, reliable timeline, reliable installers, and with the click of a button. 

We wake up every day to make this future happen ASAP. Anyone interested in joining the project should contact me at the Center or Logic. 

Gary: Jason, I want to thank you for your time and especially for letting us peek behind the scenes of what may become an integral part of the offsite construction industry in the next few years.

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

I am genuinely excited to have this opportunity to interview Yudhisthir Gauli, a true pioneer in the field of autonomous industrial robotics. His extensive experience, innovative mindset, and remarkable contributions to the manufacturing sector make him an inspiring figure. I look forward to learning more about his groundbreaking work at Framebotix.

Yudhisthir Gauli

Yudhisthir Gauli, the founder and President of Framebotix, is a visionary in the world of autonomous industrial robotics. With several decades of experience in manufacturing and a portfolio of multiple patents, Gauli is recognized as a trailblazer in transforming how modern factories operate. His career has been dedicated to pioneering advancements that integrate cutting-edge efficiency and innovative practices into the manufacturing process, fundamentally reshaping the industry.

As a full-blood robotic entrepreneur, Gauli’s contributions have had a profound impact on the evolution of autonomous industrial robotics. His work focuses on optimizing manufacturing environments, allowing factories to operate with unprecedented levels of precision, speed, and flexibility. By developing and implementing autonomous solutions, Gauli has enabled the manufacturing sector to leap forward, enhancing productivity while reducing costs and errors.

Under his leadership, Framebotix has become a leader in integrating robotics into manufacturing, helping companies around the world adopt state-of-the-art automated systems. Gauli’s journey, marked by his relentless pursuit of innovation, offers invaluable insights into the future of manufacturing and the role of robotics in driving the next generation of industrial efficiency.

Thanks, Yudhisthir, for talking with me about all innovative ways you are working on with robotics.

Gary Fleisher, Offsite Innovators: Can you describe your journey and role at Framebotix? How has your vision shaped the company’s direction and its current standing in the offsite construction industry?

Yudhisthir Gauli, Founder/President: My journey at Framebotix as both CEO and CTO has been driven by a commitment to innovation and solving challenges in the offsite construction industry. Leveraging our decade-long experience in autonomous robots and factories, We have focused on revolutionizing home manufacturing to make custom homes both affordable and durable.

Our expertise in autonomous robotics supports various offsite applications, helping our customers achieve greater efficiency and precision. My vision has shaped Framebotix’s direction, driving us to create sustainable, high-quality manufacturing processes. By emphasizing natural materials and regional manufacturing, we’ve reduced costs, increased efficiency, and minimized environmental impact.

Gary: What are some of the most innovative technologies that Framebotix is currently utilizing in offsite construction? How are these technologies improving efficiency and productivity on construction sites?

Yudhisthir: At Framebotix, we’re utilizing cutting-edge technologies that are revolutionizing offsite construction. Our AI-powered autonomous robots handle all machining, assembly, and handling applications, capable of operating 24/7 to reduce cycle times, lower costs, and ensure precise quality.

We also use a data-driven High-Performance Volumetric Manufacturing management system that optimizes manufacturing in real-time, minimizing downtime and ensuring every part meets exact specifications. Additionally, we incorporate advanced materials like cold-formed steel and sustainably sourced wood to create durable, eco-friendly components.

These innovations streamline manufacturing, boost efficiency, and enhance productivity, resulting in faster project turnarounds and superior quality outcomes for our clients.

Gary: Could you share insights into any new robotic systems or technologies that Framebotix is currently developing? How do you foresee these advancements transforming the offsite construction landscape in the near future?

Yudhisthir: At Framebotix, we’re excited to be developing our 8th generation autonomous robotic systems, which we plan to complete by the end of this year. These cutting-edge systems are designed to further enhance precision and adaptability in offsite construction, handling complex tasks like advanced machining, intricate assembly, and seamless material handling with even greater efficiency and accuracy.

One of the standout features of this new generation is the integration of AI-driven decision-making capabilities. This allows our robots to learn and adapt to various construction environments, optimizing processes in real-time and minimizing the need for manual intervention.

We believe these advancements will significantly transform the offsite construction landscape. By enabling greater customization and faster production times, our 8th generation robots will help construct high-quality, affordable homes more efficiently, while also reducing waste and environmental impact. This will move us closer to fully automated, smart construction sites, meeting the growing demand for sustainable housing.

Gary: In what ways do you believe robotics and automation will revolutionize the offsite construction industry? What specific challenges do you think these technologies will address most effectively?

Yudhisthir: I believe robotics and automation are set to revolutionize the offsite construction industry by dramatically improving efficiency, precision, and scalability. These technologies will streamline the entire construction process, from machining and assembly to material handling, allowing for faster production times and reduced costs. One of the most significant impacts will be the ability to produce custom homes at scale, something that has been challenging with traditional methods.

Specific challenges that robotics and automation will address most effectively include the skilled labor shortage, which has been a major bottleneck in the industry. With autonomous robots, we can maintain high productivity levels 24/7, reducing the reliance on manual labor and minimizing delays. Additionally, these technologies will greatly enhance quality control, ensuring that every component is manufactured to exact specifications, which reduces waste and rework.

Robotics and automation will also help tackle sustainability challenges by optimizing resource use and reducing carbon emissions through more efficient processes and the use of eco-friendly materials. In summary, these advancements will make offsite construction more efficient, cost-effective, and sustainable, ultimately transforming how we build homes and other structures.

Gary: Looking ahead, what are your predictions for the future of robotics in offsite construction over the next decade? How is Framebotix positioning itself to be at the forefront of this evolution?

Yudhisthir: Looking ahead, I see robotics igniting a revolution in offsite construction over the next decade. Rather than a gradual evolution, we are on the brink of a transformative leap where AI-driven robotic systems will redefine how we build. These robots won’t just be more autonomous—they will be capable of learning and adapting to diverse construction environments in real-time, bringing unprecedented levels of customization, speed, and precision to the industry.

This revolution will lead to fully automated, smart construction sites where robots handle nearly every aspect of the process—from design implementation to final assembly—with minimal human intervention. This shift will drastically reduce costs, enhance quality, and make sustainable practices the industry norm.

At Framebotix, we are positioning ourselves at the forefront of this revolution. Our development of 8th-generation autonomous robotic systems, set to be completed by the end of this year, is a prime example of how we’re leading the charge. These advanced systems are engineered to tackle complex tasks with even greater precision and efficiency, directly addressing critical challenges like labor shortages, cost control, and sustainability.

In addition, our forward-looking manufacturing technology, incorporating closed-loop systems and comprehensive traceability, will further revolutionize the industry. These innovations will ensure that every aspect of production is monitored, optimized, and documented, delivering unparalleled quality and accountability.

By staying ahead of technological advancements and maintaining a sharp focus on customer needs, Framebotix is poised to lead the next wave of innovation in offsite construction, helping to shape a bold and transformative future for the industry.

Gary: What a unique insight into how robotics will help the future of offsite construction. Yudhisthir, thank you for talking with me about all the things you are working on.

Contact Yudhisthir Gauli: [email protected]

Framebotix website: https://framebotix.com/

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Timber Age Systems Interview Questions

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

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

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

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

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Bill: What inspired you to found Timber Age Systems?

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Matt Betts, Value Stream Manager

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

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

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

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

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

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

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

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

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

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

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