In our quest for a great product, speed, efficiency and precision is at the forefront of every decision. So we have taken a look at all the time expensive processes that we currently have with traditional construction and looked for ways to improve them.
For now exclude in this discussion the wall system itself which eliminates most trades and already is hugely fast, efficient and precise. What comes after this is what others so far have failed to master.
Plaster - At this stage no plaster is to be used in this system unless we find that certain rooms we need to add for a number of reasons. But assume there is none.
Doors, skirts, arcs - No need for skirting as all walls and floors are precision cut and do not need 'hiding' (which is what skirts and arcs do). Doors, windows and arcs are all pre-fabricated and include a pre-fabricated arc - all that these need to be done is bonded into place via precision pre-cut openings. The entire house should take only a couple of hours.
Paint - all walls and ceilings to be painted while the panels are laying flat - this allows quick even cover of paint via a boom spray then into an oven - then repeat 2 - 3 times. We expect a module can have 3 coats of paint in 1 x 8 hour shift. There is no need for 'cutting in' of walls to ceilings or walls to arcs, nor the masking tape that is normally associated with it. So a perfect finish, with considerably less time spent.
Cabinetry / Bench tops - this is all done via a deal where the cabinets and bench tops are pre-assembled so all that we need to do is fix them into position. This process should take around 3-4 hours per house (depending on size and complex if course).
But what excites us is the newest addition to our system being a high -pressure waterjet cutter. More precisely the use of CNC cutting tables for normally complex and slow tasks.
Imagine a large piece of cement sheet / tile underlay (9m long x 2.4m wide) that has been laid with tiles in one massive panel and bonded using an aerospace type adhesive. This is plain, square and extremely easy to lay (being flat on ground and no cuts at all).
Then place this sheet into a waterjet and have it cut out (extremely cleanly and accurately) the walls, and floor of the bathrooms including the pipe penetrations and what ever else needs cutting.
The laying of the tiles would take around 1 hour, cure within 30mins, then the waterjet would take around 15mins to cut out. Then lift each panel onto the correct module panel and bond into place (around 45mins)
The entire tiling of a house would only take around 2.5hours!
Now, use the same principal for timber flooring (using a normal router CNC) and even external cladding or roofing sheets. This will be a major aspect of our system we will develop in the near future.