Led by firms like Waypaver International, the construction industry has just recently begun to tap the kinds of exponential advancements the automotive industry has made by embracing technology. As the gap between housing supply and demand has left a vast shortage, houses have become unaffordable and apartments have become unattainable nearly everywhere. With real solutions desperately needed, Waypaver International and global leaders in factory automation united the best minds of modular factory design and advanced automation to conceive a new kind of manufacturing plant for offsite construction that’s repeatable, scalable, and turnkey. No wheels to reinvent.
By 2030, more than 85 million jobs will go unfulfilled worldwide. That’s roughly equal to the entire population of Germany. The construction industry faces an immediate worldwide shortage of 650,000 workers.
Britain shipped prefabricated panelized houses to the Americas and Australia.
Sears Roebuck set up its Modern Home, with hundreds of house plans in the Sears Catalog that could be shipped as DIY kits.
The first Leavittown prefabricated house sold and production peaked at 12 houses per day in the late 1940s.
Mobile home manufacturing grew to more than 15 percent of US housing, and modular homes were born in factories like National Homes in Lafayette, Indiana.
Two modular pioneers form Prefab Logic, helping developers get housing and hotel projects ready to build in modular plants. Waypaver was founded to help modular factory startups design and operate modular factories.
The founder of Waypaver and co-founders of Prefab Logic unite with one of the nation’s largest affordable housing developers to form Autovol, the first automated robotic volumetric modular housing factory.
Autovol becomes the highest-volume modular builder in the West in just three years.
Pioneers of modular housing join forces with KUKA, uniting two teams of game changers: the originators of modern car automation, and the pioneers of the first automated modular construction factory of its kind.
Modern automation enables production under optimal conditions and guarantees continuous and complete quality control, which leads to a low single-digit rework rate. Data-rich software tools ensure flexibility and thus creative designs with high efficiency and mass customization possibilities.
All raw materials for multiple construction projects are delivered to a central location. Materials transportation and carbon footprint are reduced.
Automation builds walls, ceilings, and floors for each modular unit. The basic structures can be made of various materials.
Frames are sheathed and prepared for modular unit assembly, which can include insulation, electrical, and plumbing.
Individual panels are combined into a complete living space that typically includes in-factory installation, testing, and inspection of insulation, electrical, and plumbing.
Whether kitchen or bathroom, bedroom or living room, module interiors—flooring, painting, cabinets, appliances—are finished and inspected to the last detail.
Each module is inspected throughout manufacturing to assure quality and adherence to all applicable codes.
When modules leave the plant, the project construction work is up to 80% complete.
Manufacturing of modules occurs in parallel to the foundation being constructed onsite, greatly reducing total time of construction.
Modules are installed directly onsite Depending on the project size, this process is completed in a few days or weeks, dramatically reducing onsite construction noise, congestion, and time.