Foreground: Truss and panel machines create light-gauge steel (LGS) structural parts with exact dimensions from sheet-roll steel. Background: Under-construction LGS modular housing units.
Overview
This GTI Energy project sought to develop a scalable solution for producing homes with 50% energy savings and a low-cost premium relative to site-built residential homes. Starting with an existing modular construction factory operated by Dvele, Inc. and a skilled workforce trained in modular construction with enhanced energy efficiency, the project focused on reducing the cost of highly efficient modular homes through energy-focused design, factory automation, and an enhanced factory software platform.
| Project Type | Problem to Solve | Solution | Location | Timeline | Partners |
| Residential new construction | Barriers related to high fabrication costs of energy-efficient modular houses | Scalable modular home design and automated construction process | Loma Linda, CA | September 2020–May 2024 |
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Project Goals
The project aimed to define cost and performance-optimized efficiency measures and modular home manufacturing processes capable of achieving 50% energy savings over IECC 2018 code-minimum homes at no additional life cycle cost and a low first-cost premium when ramped into volume production. This was achieved through energy modeling and thermal performance testing to prioritize energy upgrades to Dvele’s product line as well as the implementation of automated framing systems and software to improve factory productivity.
Impacts
This project has the potential to significantly transform the housing industry by providing cost-effective modular homes that exceed energy efficiency standards, leading to reduced energy consumption and lower utility bills for homeowners.
Technology Impact
Automated steel-framing machines commissioned through this project increased automation in Dvele’s manufacturing process, demonstrating a 46% improvement in construction efficiency compared to wood-framing methods. This results in reduced production time, reduced production costs, and increased worker safety, and it positions Dvele to increase production volume of energy-efficient modular homes.
Market Impact
The developed workflow will help the adoption of high-performance modular homes. This project demonstrated a production method that incorporates energy efficiency measures as a key attribute and reduced construction costs through software tools and automation.
[This] project was transformative in our production line updates to build highly efficient steel-framed structures.
Left and center: Software files showing roof truss parts to be “printed.” Right: Printed roof truss parts for final assembly.
- Performed an energy-modeling study to prioritize modular home envelope upgrades.
- Performed a laboratory thermal performance test to validate modeling results on selected envelope assemblies.
- Factory commissioned a light-gauge steel (LGS) stud-printing machine to enhance productivity.
- Performed a time and motion study to validate the labor and time savings of automated LGS printing versus traditional wood framing.
- Automation-assisted LGS framing showed up to a 46% reduction in construction time compared to traditional wood framing.
- Through energy modeling and thermal performance testing, it was found that installing exterior continuous insulation in LGS wall assemblies reduced construction labor and costs while improving thermal performance compared to cavity-insulated wood-frame assemblies.
Leveraging this project’s findings, Dvele is planning further process improvements, including:
- additional production automation and robotics
- use of standard modular home designs
- increase of production rate by prefabricating envelope components off the main assembly line
- ramping up of production volume using automation.
The combination of these measures is expected to significantly reduce the cost of future modular homes, bridging the cost-parity gap of modular and site-built construction.
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About the ABC Initiative
The Advanced Building Construction (ABC) Initiative, led by the Building Technologies Office (BTO), integrates energy efficiency and advanced technology solutions into industrialized construction processes to drastically increase the speed and scale of high-performance, low-carbon building retrofits and new construction.
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Page last updated: June 4, 2024