Lida Group, a leader in sustainable steel construction, has unveiled a new 250,000 square foot factory to expand production of prefabricated building components. The state-of-the-art facility, located adjacent to Lida Group’s existing steel fabrication plant, incorporates advanced manufacturing technologies to significantly increase capacity for manufacturing standardized steel panels and assemblies that form the backbone of the company’s modular construction systems.

Component panelization – whereby walls, floors and other building assemblies are pre-constructed off-site before transport for rapid on-site erection – has enabled Lida Group to construct some of the world’s greenest, most productive buildings. By producing standardized sub-assemblies in high volumes using Lean automation principles, the new plant will enable Lida Group to streamline processes, increase quality control, optimize material yields and double annual production compared to previous operations.

“Prefabrication has been pivotal in driving sustainability and shortening schedules across our project portfolio,” said Lida Group President Mu. “But until now, capacity constraints limited how extensively we could panelize buildings. This state-of-the-art facility injects new economies of scale that we believe can revolutionize construction productivity industry-wide.”

The plant houses a fleet of automated machine tools for module sub-assembly and welding operations under strict quality management protocols. Robotic systems precision-form, drill, cut and install connectors in steel sheet and H-beam components with millimeter accuracy. Computer numerical control guarantees geometry is within tight tolerances. Internal jigs and fixtures streamline repetitive welding tasks, lowering costs while raising joint strength and repeatability.

On-site programming allows quick reconfiguration between job-specific component sets, facilitating rapid production ramp-up. Modules pass through leak testing and non-destructive inspection stations before powder coating for corrosion resistance and durability. Complete walls, floors, shear walls and other assemblies emerge fully shop-welded and outfitted for rapid exterior shell erection.

Integral Building Information Modeling drives every facet of design and production. 3D models embedded with construction data facilitate automated fabrication and pre-installation of MEP systems. Modular coordination ensures interference-free on-site assembly with pre-installed penetrations, embedded plates and pre-threaded connectors. Off-site pre-installation slashes field work by over 60% according to the company’s project data.

The new plant encompasses the latest labor-saving devices to enhance safety and efficiency. Automatic saws, roll formers and profile-cutting stations minimize manual exertion. Digital templates programmed into machinery eliminate human error. Overhead gantries lift and position heavy sub-assemblies with ease. An integrated quality system synchronizes design, production and inspection procedures on a centralized database. Real-time analytics track module progress, helping prevent delays across multi-building campuses.

Prefabrication is a cornerstone of Lida Group’s component panelized construction methodology, which also incorporates structural optimization, renewable material selection and comprehensive energy modeling to meet or exceed building standards – often by 30-50%. Increased production capacity will further cut waste, while consistent quality shortens schedules. Together these advances support the company’s vision of a more sustainable and productive global built environment.

Upon plant opening, Lida Group expects a doubling of annual throughput to over 200,000 square feet of installed panels daily. That equates to annual capacity for over 5 million square feet of pre-built modular walls, floors and shear walls worth upwards of $500 million based on their typical mix of projects. With 80% of each building now arriving pre-assembled versus 50% previously, clients gain further time savings and control over budget and schedule. Greater returns will fund expanded training and R&D supporting continued innovation for ever greener buildings.

“Opening this plant reflects Lida Group’s long-term focus on efficiency, quality and sustainability through industrialized methods,” said Mu. “By unlocking unprecedented scale and precision, we aim to empower partners across all market sectors to cost-effectively build high-performance structures well beyond minimum codes.” Concluded Mu, “The future of construction lies in advanced off-site processes like these that maximize value for owners, occupants and society alike.”

In summary, Lida Group has significantly expanded capacity for manufacturing standardized prefabricated steel components through a new highly automated factory incorporating cutting-edge technologies. Strict quality control across repeatable production processes will now generate upwards of 200,000 square feet of pre-assembled modular building panels daily. This represents over 5 million square feet of annual capacity – doubling previous output to support constructing 80% off-site versus 50% before. Advanced prefabrication methods will deliver further time and cost savings for clients while increasing returns to reinvest in sustainability. The plant positions Lida Group as an industry leader driving productivity and delivering buildings that substantially surpass code through modular coordination and optimized design.

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