LIFTbuild leverages standardization by envisioning the jobsite as a factory floor and re-engineering the typical manufacturing process to achieve vertical production – or Vertical Manufacturing.
After installing foundations and constructing concrete cores – or spines – LIFTbuild establishes a controlled work environment around the base of the spines, clearing the site and pouring a concrete assembly pad. Crews then begin the choreographed sequence of roof/floor plate assembly, all at a safe, ergonomic level just above grade.
Floor Plate Assembly
Floor plate assembly is a highly synchronized set of activities involving multiple trades that repeat their scope of work for each floor, thereby requiring fewer workers on site throughout production.
This process begins with structural steel erection or the installation of a post-tensioned concrete slab. Regardless of materials, these activities occur a few feet above the ground, eliminating the need for a costly tower crane and drastically reducing travel time for workers and materials.
With the structure in place, tradespeople spray fireproofing on the underside of the floor plate while any finishing activities occur above. Prefabricated mechanical, electrical, and plumbing (MEP) sub-assemblies are installed, and small cranes mount façade panels on the perimeter. The same small cranes load the floor plate with a just-in-time delivery of select materials to be used for fit-out post-lift.
LIFTbuild uses a strand jack system to lift the floor plate to its final height at an impressive average speed of 20-30 feet per hour before being locked into place.
System connections and the interior fit-out process begin on the locked-in floor plate, which is considered weathertight, eliminating the risk of elements compromising materials or work put in place. These activities are all conducted in a fall-safe space, and the assembly pad below is restored to a clean site, where the next floor plate can begin.
With a repetitive assembly process and an intentional focus on continuous improvement, work crews can improve efficiency floor by floor, increasing overall project speed.
Is LIFTbuild Different than Modular Construction?
LIFTbuild identifies the optimal mix of off-site fabrication opportunities and on-site assembly for each individual project. While entire pods can be easily loaded onto a floor plate, similar to a modular construction approach, LIFTbuild focuses on maximizing value for project stakeholders by creating a unified design, optimizing resources to put the work in place, and establishing a seamless assembly process on site.
Proven Results
On LIFTbuild’s proof-of-concept project, the Exchange Residential Tower in downtown Detroit, the goal was to complete the assembly of a floor plate every 10 production days by Level 11, recognizing that there is an opportunity for improvement as the crews become more familiar with the project.
Leveraging time/motion studies and after-action reviews, the team hit its cycle target of 10 days, reducing full floor plate assembly time by 33%. The steel team alone reduced its cycle time by 45% through improved sequencing, bolt kitting, and minimizing downtime during lifts.
