With construction costs soaring over the past few years, it isn’t uncommon for projects to be unexpectedly paused by builders who had agreed to fixed-price construction costs, only to realise they could no longer profitably build within that budget. In other instances, buyers are simply unable to afford increased construction costs due to the cost-of-living crisis, which has severely pressured discretionary spending.
Added to the mix are issues such as labour shortages and an increasing focus on sustainability in the construction of homes and commercial buildings.
Construction products manufacturer Big River Group is addressing these challenges through offsite prefabrication of components, including wall frames and roof trusses.
The group highlights its Trade Centres at Dry Creek, South Australia, and Breakwater, Victoria, as key facilities advancing its prefabricated components.
“Both Dry Creek and Breakwater are focused on supporting builders with prefabricated roof trusses, wall frames and floor trusses, which are becoming increasingly critical in addressing on-site inefficiencies and labour shortages,” Big River Group executive general manager Ray Ferretti says.
“By tailoring our solutions to meet the specific needs of projects – whether boutique homes in South Australia or multi-residential developments in Victoria – we’re helping builders embrace offsite construction methods that improve efficiency and manage costs in today’s challenging market.”
The company has also integrated advanced AI tools across its operations. At Dry Creek, it uses AI-powered design software, while Breakwater features Hundegger saws alongside skilled estimators and designers utilising cutting-edge design programs. At Breakwater, the company uses Pryda’s software to optimise prefabrication processes.
“At Breakwater, we are exploring AI-driven design programs and how we can integrate them with BIM (Building Information Management) systems,” Ferretti says. “This technology will allow builders to see in real-time where trusses or beams may intersect with services in the structure, improving accuracy and reducing lead times.”
Managing the supply chain and building sustainably
As global supply chains were forcibly redrawn after the pandemic, Big River says it has worked closely on managing the supply rates through the transition period. “Our stock management system ensures we can meet production requirements at all times, giving builders the confidence that their projects will stay on track,” Ferretti says.
The company says it supports Australian timber mills. It has also taken steps to reduce waste during the production process.
At its Breakwater facility, Big River is attempting to reduce the volume of timber offcuts, strapping and general waste that goes to landfill. It partners with recycling organisations, including Visy, SIM Metal, GT Recycling and Mulch Company, to achieve a claimed 95 percent reduction in landfill waste.
Timber offcuts are repurposed into garden mulch and industrial products, saving approximately $65,000 in landfill fees annually.
Plastics from timber packs and strapping are recycled through GT Recycling, while metals such as plates and strapping are processed through SIM Metal.
“By recycling all our materials – from timber offcuts to plastic and metal – we’ve significantly reduced our environmental impact while optimising our processes for greater efficiency,” Ferretti says.
Image: Supplied
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