Featured image: Wall-tech erected the wall and flooring systems for this 8-story apartment building in just 14 weeks using panelized cold-formed steel (CFS) framing.
Over the past 10 years, the construction industry has undergone major changes in how buildings are constructed. One system contributing tremendous improvements in both the residential and commercial construction is prefabricated steel framing.
SFIA member Wall-tech Companies, based near Madison, Wisconsin, has developed cutting-edge practices using prefabricated cold-formed steel (CFS) framing to enhance efficiency, improve safety and compress schedules for building construction.
Wall-tech Companies uses prefabricated cold-formed steel framing to enhance efficiency, improve safety and compress schedules for residential and commercial projects. Courtesy of Wall-tech
‘The Biggest Thing’ is Speed
For over 35+ years, Wall-tech has built a reputation for helping contractors and owners build faster. As technology evolves within the construction industry, the company has taken its proven methods for success and tweaked them, optimizing their manufacturing and installation procedures to save time and money on projects. At the heart of this technology is prefabricated CFS framing.
Prefabricated steel frames offer multiple advantages over wood frames. That includes lower cost, fire resistance, quick installation and greater strength, says Pete Braun, Wall-tech chief executive officer.
“The biggest thing with prefabrication is speed,” says Braun. “it’s much faster than traditional construction and less risky. You need far fewer individuals, too.”
The Steel Framing Advantage
Cold-formed steel (CFS) leads the way as the preferred framing material for prefabricated structures for multiple reasons. CFS is:
- A pre-engineered material that can be cut to exact lengths
- Dimensionally stable and does not expand or contract with changes in moisture content
- Lightweight compared to wood and concrete
- Resilient and will not warp, split, crack or creep when exposed to the elements
- Sustainable and 100% recyclable
- Durable and has a high tensile strength
- Non-combustible and is a safeguard against fire accidents
Quantified Benefits of Prefabrication
The benefits of prefabrication are well documented, and as more projects adopt prefabrication the benefits can be quantified. A SmartMarket report from 2020 surveyed companies from across the construction sector about their approach to and views on prefabrication and modular construction. In total the survey generated 608 responses from architects, engineers, general contractors/construction managers, trade contractors and modular builders/manufacturers. The report showed:
- 91% of general contractors indicated a positive impact of modular construction on project cost
- 48% of general contractors reported a 10% or better reduction in cost
- 47% of architects and engineers reported a similar positive impact on project cost
Wall-tech has experienced similar results with their customers. Since CFS framing can be erected quickly, it reduces costs and keeps projects on schedule. By speeding up installation of the framing, “the masonry can get started sooner, the roofing can get started sooner, the windows can get installed,” says Braun.
Wall-tech manufactured a prefabricated cold-formed steel (CFS) wall and roof system for a minimalist home in Michigan.
Smaller Crews, Faster Install
The construction industry will need to attract an estimated 546,000 additional workers on top of the normal pace of hiring in 2023 to meet the demand for labor, according to a proprietary model developed by Associated Builders and Contractors.
“The construction industry must recruit hundreds of thousands of qualified, skilled construction professionals each year to build the places where we live, work, play, worship, learn and heal,” says Michael Bellaman, ABC president and CEO. “As the demand for construction services remains high, filling these roles with skilled craft professionals is vital to America’s economy and infrastructure rebuilding initiatives.”
Wall-tech’s prefabricated cold-formed steel (CFS) framing helps enclose buildings faster, safer and on budget. Courtesy of Wall-Tech
The industry-wide challenge of finding new workers, however, might hit Wall-tech Companies with less impact. In addition to being a speedy process, installing CFS framing does not require a large crew.
“Many times, we can get a building erected in a couple of weeks that otherwise might take a couple of months and a lot more people to install with traditional construction methods,” says Braun.
Looking ahead, Braun predicts Wall-tech will continue to emphasize the use of prefabrication. But, growth will also depend on educating their customers on the benefits of prefabricated construction.
“Customers might not be aware of everything you can do with prefabrication,” says Braun. “So getting that message out to architects, builders, developers [is important]. There are a lot of people in the industry that just don’t know how you can use prefabrication with cold-formed steel framing.”
Additional Resources
- Luxury for Less: Cold-Formed Steel Saves $250,000 in Building Mid-Rise Apartments
- Builders Embrace Steel Framing for Offsite Construction
- 5 Reasons Why Cold-Formed Steel Can Save Time and Money on Projects