48 | Sector Focus: Timber Construction
◄ An integrated technology solution was developed to lay boards onto the floor framing and for efficient T&G gluing. This is where DTS’s astute recruitment and inspiration from the automotive industry helped.
When the Honda factory in Swindon closed, several automotive engineers were recruited, bringing fresh ideas and solutions to the Witney timber frame operation. One of these was the decision to buy a 3D printer to solve the T&G board gluing issue. A twin chamber nozzle was designed and printed to provide an effective solution and ensure NHBC certification for the fully finished floor cassette system, giving customers confidence of optimum performance. “We have moved advanced timber frame manufacturing away from the image of some guys with a bunch of nails and a hammer,” added Mr Allan. “Automation, repeatability, technology
transfer, production monitoring such as thermal imaging and vibration analysis – this is the direction of travel.”
DTS is also working with timber/board raw material suppliers to supply bespoke sizes to the factory in order to reduce the number of machining and processing activities and reduce forklift movements.
LOOKING FORWARD Currently, the DTS operation across Witney and Aberdeen now has a capacity of about 9,000 houses per year. “We have this hub and spoke strategy, which allows us to add capacity very
quickly if we need to,” said Mr Allan. “We could easily produce 12,000 without breaking sweat [by increasing shift patterns].” Mr Allan said DTS will produce about 5,000 houses in 2024, a reduction of 20-25% on normal levels due to the current market situation. And he estimated DTS’ share of the UK timber frame home market to be approximately 14-15%.
“There are two directions of travel in timber frame manufacturing, either volume, volume, volume, or there’s value,” said Mr Allan. “We’ve covered the best of both worlds in that we’ve added volume but we’re also adding value by industrialising the Sigma II system.”
DTS’ full timber frame panel product range starts with Alpha as a standard open frame system, then Delta, which includes insulation, before the top-of-the-range Sigma II product. The Omega fire-rated variant product utilises Fermacell class zero boards.
Elsewhere, photovoltaic (PV) solar cells have been installed on the factory roof and will produce just under one megawatt of electricity, covering the factory’s own energy needs and an excess of green energy that is exported back into the national grid for other local businesses and homes to use. This significantly reduces the site’s environmental footprint and, combined with new electric vehicle charging points for staff and visitors, supports DTS’ sustainability goals. “The installation of this new machinery in a working factory is unusual for the industry and the process required a phenomenal amount of logistical planning over a period of
a couple of years,” concluded Mr O’Reilly. “We’re all really proud of the results.
We’re creating the capacity and technical capabilities customers require to continue building more advanced and energy-efficient homes and buildings – and future proofing our own business in the process. “We’re also excited about what this means for our colleagues, as it is revolutionising the operations process. Now a less physically demanding role, we can hire a wider variety of people to work on site, helping to plug the current skills gap in construction. These efficiencies also provide an opportunity to increase production, creating more positions in time, and allowing us to redeploy people to more value-added roles.”
Mr Allan said DTS would continue to look forward and innovate. “We have created the scope to add more capacity and capabilities to the factory over time without the need for a large-scale overhaul like this one, and we have created a platform for more R&D.
“This is a significant investment but one that will set us and our customers up for continued success in reducing carbon for years to come.”
For DTS’s main technology partner Randek, prefabrication isn’t just about constructing buildings; it’s about co-creating solutions with its customers, refining their processes, and integrating its technology to drive efficiency and automation. “This synergy not only makes housing more affordable but also paves the way for a sustainable future,” said Ola Lindh, Randek chief executive officer. ■
Above: A robotic cell adding OSB sheathing panels TTJ | July/August 2024 |
www.ttjonline.com
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