SFIA member Howick LTD is applying prefabrication technology to drive a rapid evolution in cold-formed steel (CFS) framing construction. Recently, the New Zealand-based manufacturer of high-precision roll-forming equipment leveraged technology to reduce by 50% to 70% the steel framing labor input for a 16-story hotel.
Nick Coubray, CEO of Howick, shared his experience with prefabricated steel framing and the hotel project during the podcast, On the Road with Amr.
Compressing Project Timelines
Coubray is the driver in Howick’s pursuit of innovation. He is the third generation of Coubrays to champion this family-owned business and has been involved with steel-framing technology since his late teens.
Howick’s built its first roll-forming machine 30 years ago.
“It’s grown from a very simple machine to quite a complex machine,” said Coubray. “Our customers build everything from garden sheds to 10- to 15-story buildings that are fully cold-formed steel framed.”
Coubray said the construction industry has shifted towards prefabrication.
“Prefabrication has grown a lot, driven by labor shortages and the cost of building traditionally,” says Coubray. “The accuracy [of steel framing] allows you to do a lot of different things to compress the timeline for projects.”
Manhours Cut in Half
As an example, Howick applied prefabricated steel framing technology to a 16 floor hotel project in New Zealand.
“We cut between 50% to 70% of the labor for manhours for the framing installation,” said Coubray.
Significant time savings were achieved through the use of prefabricated steel framing for the bulkheads, which were specifically designed to act as barriers to prevent the spread of fire and smoke between floors.
“[The contractor] planned to use traditional timber for the bulkheads, cutting pieces of timber and hammering them together and putting them into the space,” says Coubray. “It was taking them 7 days per floor.”
7 Days Per Floor Cut to 2 Days
By employing prefabricated steel framing techniques, the construction time was shortened to just 2 days per floor.
“So, you can see the real advantage in the accuracy of steel framing,” says Cobray.
Why Prefab with Cold-Formed Steel?
- Site Impact – Fewer onsite materials reduce congestion and injury potential while improving traffic flow
- Safety – Construction staff stand at floor level instead of working above their heads on ladders
- Improved Design – Virtual Design and Construction models all aspects of the building components. This enables innovation, improves quality, reduces errors and neutralizes escalation costs
- Speed to Market – Prefabricated building components advances supply chain deliverables and accelerates early revenue
- Cost Control – Prefabricated building process identifies cost commitments early on in the process thanks to proven predictability of outcomes. This increases the likelihood each project to meet budget
- Offset Worker Shortage – Prefabrication enables greater production offsite, reducing the need to increase labor
- Collaboration – Designers, contractors, trade partners and engineers all work together toward a unified goal and plan
Perspectives on Steel Framing Are Changing
Builders professionals are increasingly using prefabricated cold-formed steel (CFS) framing to improve the efficiency, cost-effectiveness and affordability of construction projects. However, some feel that prefabricated assemblies can limit an architect’s designs.
“There is a misconception that with a prefab, everything has to be in boxes,” said Coubray. “That is kind of a historical thing.”
39 Curved Steel-Framed Walls
Coubray highlighted a project in Auckland, New Zealand, showcasing the captivating architectural possibilities of modern prefabricated steel framing.
“We worked on a project for a law firm that had 39 different curved walls with different radiuses,” says Coubray. “In the past, someone would have had to go and mark everything out.”
By applying the accuracy of high-precision roll-forming equipment, the law firm’s steel-framed radiused walls were prefabricated off site.
“There was not a straight wall in the whole building,” said Coubray. “I’m not sure where they’re going to put the desks.”
‘Amazing Things Are Coming’
Coubray provided straightforward advice to architects and builders interested in exploring the possibilities of prefabrication.
“Go to the trade conferences and talk to people about what they’re doing, there are lots of amazing things coming!”
Additional Resources
- Prefabricated Steel Framing Drives Cost-Efficiency, Reduces Labor Expenses
- Proof of Concept: Roll-Forming Machines Can Do Much More Than Roll Steel Studs
- Steel at Forefront of Rise in Prefabricated Construction to Meet Housing Demand