Autovol Inc. is breaking new ground as the first fully automated volumetric modular factory in the USA, and the most advanced of its kind across the globe. The company’s primary mission is to solve the affordable housing crisis by setting the standard for large-scale multi-storey/multi-unit housing, and it has taken a leaf from the automotive industry by using advanced robotics in its manufacturing process.
The housing units are built in Autovol’s factory as individual volumetric modules, complete with all wiring, plumbing, and final fixtures. A new system for moving them into the storage yard before shipment to the building site is now in place, using a Combi-SC Straddle Carrier from the Irish handling specialist Combilift.
According to Merrick Macomber, EA to CEO and Co-Founder of Autovol, this very manoeuvrable machine that is now at home in the high-tech headquarters in Nampa, Idaho, has substantially cut loading times, reduced the risk of product damage and improved the deployment of the labour force.
"For decades, our industry has traditionally used a combination of a tractor unit and a custom built lifting chassis to move modules," said Merrick, "but along with all the innovations we incorporated in our new facility, and the fact that we were starting with a clean sheet, we decided it was time to take an updated approach to handling procedures. Since we started production a few months ago the Combi-SC has proved to do everything the manufacturers promised. Out of all of the new equipment we bought, it was by far our best investment."
All Combi-SCs are customised to specific requirements and Autovol’s model is diesel powered with a lift capacity of 45 tonnes, with a 1.8m telescopic facility and .5m side shift, and a camera and weighing scales were also incorporated. Compared to the tractor/chassis method the time savings are impressive: navigating a modular from the factory door to the storage yard and landing it onto the cribs previously involved four to six personnel and took up to two hours. This can now be done in a maximum of 20 minutes and requires just one operative to steer the Combi-SC using the wireless remote-control facility. The machine is also fitted with a driver’s cab, with air conditioning, so these two operational modes offer flexibility on site.
Using chains and straps to cradle the modular within the framework of the Combi-SC makes for much more secure transportation and avoids previous problems associated with the camber on the chassis, which caused stress to the centre floor load, creating cracks in the drywall. This required repairs to be carried out to the interior, adding extra labour costs to what are already very valuable products.
Various lift points on each side of the fixed frame attachment enable drop chains to be fixed in the most suitable position for each individual load, allowing easy configuration for the different sizes of modules that Autovol produce – which can be up to 30.5m long and almost 5m wide.
The scales enable Autovol to determine and log the exact weight of each unit, which is also a beneficial service for the transportation company moving them to their destination as well as the crane company that sets the structures up on site.
Merrick sums up: "When we embarked on this new project we were aware of Combilift’s range of forklifts and the reputation these had for efficiency, cost effective operation, quality and durability, and the Combi-SC is no exception – you can tell it was built to last by a quality team who takes pride in their work. It has made a significant contribution to enabling our breakthroughs in construction cost, productivity, and quality – and it will have paid for itself in a matter of a few years."
