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Professor Develops Prototype Wall Framing Machine to Revolutionize Construction

A University of Alberta professor has prototyped a light-gauge steel framing machine that can assemble wall panels in a matter of minutes, with more precision and less material waste than traditional framing.

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A professor from the University of Alberta has developed a prototype for a light-gauge steel framing machine to use in residential construction. The semi-automated machine assembles steel members into framed wall panels quickly, with more precision and less material waste than traditional on-site framing. 

Mohamed Al-Hussein, the university’s industrial research chair and member of its department of civil and environmental engineering, developed the light-gauge steel prototype as a means to reduce labor demands, speed construction, and create a sustainable alternative to traditional framing. 

Faster, More Efficient than Tradition Framing

With the construction industry facing a shortage of skilled labor, automated machines that can prefabricate building components are essential. According to the most recent U.S. Chamber of Commerce Commercial Construction Index, skilled labor shortages are widespread — 92% of contractors have reported difficulty finding construction workers. 

“There will be less physical strains and demands on workers compared to traditional framing and it will be faster and more efficient,” says Al-Hussein. 

A growing number of contractors are embracing prefabrication to build sustainable structures. According to Dodge Data & Analytics, 25% of contractors are now invested in prefabricated projects. This is expected to increase to 33% by 2024. 

Dr. Mohamed Al-Hussein, University of Alberta, discusses the industrialization of the construction process.

Al-Hussein believes his prototype can reduce the environmental impact of the built environment. “The machines will reduce the environmental footprint on a per-unit basis due to the reductions in material and process waste,” he says. 

To reduce environmental impact, cold-formed steel (CFS) is the ideal match for Al-Hussein’s prefabrication machine. 

CFS meets the highest sustainability requirements set in all major green building standards and rating programs, including the Leadership in Energy and Environmental Design (LEED®) from the U.S. Green Building Council, the National Green Building Standard (ICC-700) for residential buildings, ASHRAE Standard 189.1 for commercial construction and the International Green Construction Code (IgCC). 

Steel Coil Framing

Steel is widely recognized as the most recycled material on the planet.

According to the American Iron and Steel Institute:

  • Steel framing contains a minimum of 25% recycled steel and is continually and completely “remade without any loss of quality”
  • Most other construction products can only be down-cycled into lower-quality products
  • Steel framing minimizes construction site waste

 

The Steel Framing Advantage

Cold-formed steel (CFS) leads the way as the preferred framing material for prefabricated structures for multiple reasons. CFS is:

  1. A pre-engineered material that can be cut to exact lengths
  2. Dimensionally stable and does not expand or contract with changes in moisture content
  3. Lightweight compared to wood and concrete
  4. Resilient and will not warp, split, crack or creep when exposed to the elements
  5. Sustainable and 100% recyclable
  6. Durable and has a high tensile strength
  7. Non-combustible and is a safeguard against fire accidents

 

Early Stages of Commercialization

A team of graduate students, post-doctoral fellows, undergraduate interns and university researchers began the design of the machines in 2016, using a variety of software applications, such as finite element analysis, according to ConstructConnect Canada. Construction of the full-scale prototypes started in fall 2016 and was completed in 2017.

Over the past five years there has been further testing, verification and the design of a second version, notes ConstructConnect. 

“We are still at the early stages of commercialization,” says Al-Hussein. “But, the objective is to mass produce [the machines].”

The research initiative was funded by the Natural Sciences and Engineering Research Council of Canada.

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