Under the Hard Hat

Tag: Building

  • The top 10 most expensive cities to build in

    The top 10 most expensive cities to build in

    Building costs in major global cities have skyrocketed, and it’s not hard to see why. Limited land availability, high labor costs, and strict building regulations make construction much more expensive, especially in cities such as Hong Kong, London, and New York. For developers, these challenges can turn a simple project into a costly venture.

    The 10 most expensive cities to build in

    London, England

    London is one of the priciest places to build, and it all comes down to a few key factors. First, land costs are through the roof, with so much demand and so little space to build on. Then, you’ve got tight building codes that add extra layers of complexity and cost to any project. On top of that, there’s a shortage of skilled labor, which drives wages up. When you put it all together—limited space, tight rules, and higher wages—it’s no surprise that London sits high on the list of expensive cities to build in.

    Geneva, Switzerland

    Geneva’s construction costs are some of the world’s highest, largely due to a few key factors. Wages in Switzerland are generally very high, so labor costs for construction projects quickly add up. Geneva also has strict environmental regulations that builders must follow, which can slow down projects and increase costs with eco-friendly materials and energy-efficient systems. To top it off, the city’s competitive real estate market drives demand, making everything from land to materials more expensive. Geneva’s strong emphasis on green building standards and practices only adds to the price tag.

    Zurich, Switzerland

    Zurich is no stranger to high construction costs, and a big reason is Switzerland’s overall high labor costs. Skilled workers in Zurich are well-paid, making any building project pricier from the start. On top of that, Zurich is known for its tight building standards, emphasizing quality and precision, so meeting these requirements often leads to more expensive materials and longer timelines. The city also faces a land shortage, which makes available plots highly competitive and expensive, driving up development costs even further.

    Munich, Germany

    Munich’s booming economy is one of the main reasons construction costs are so high. With businesses thriving, there’s a huge demand for new buildings, particularly in the commercial sector, which pushes prices up. On top of that, local regulations are very rigorous, adding more complexity—and cost—to any construction project. Land in Munich is also expensive, thanks to its popularity and limited availability. Altogether, these factors make building in Munich a pricey endeavor for developers.

    New York City, New York

    New York City is notorious for its sky-high construction costs, and there are a few reasons why. First, land in the city is incredibly expensive, especially with the constant demand for prime real estate. Construction labor shortages also play a big role, increasing wages and making projects costlier. Add to that the city’s complex building regulations, and even a simple project can become a financial headache. With NYC’s iconic skyline and the constant push for new developments, it’s no wonder the Big Apple ranks among the most expensive places to build.

    San Francisco, California

    San Francisco’s tech boom has driven real estate prices through the roof, making land some of the country’s most valuable—and expensive. As a result, construction costs have skyrocketed to match. On top of that, the city’s location on the San Andreas Fault means that builders must use specialized techniques and materials to ensure structures can withstand seismic activity, which adds even more to the cost. With the high demand for development and the added expense of earthquake-resistant designs, building in San Francisco is expensive.

    Philadelphia, Pennsylvania

    Philadelphia’s construction costs are rising, and several factors contribute to that. Rising labor expenses are a big driver, as the city’s skilled workforce comes at a premium. Regulatory requirements and building codes also add to the expense, particularly in older neighborhoods where infrastructure upgrades are often needed before new projects can even begin. As Philadelphia’s real estate market continues to grow, the increasing demand for residential and commercial developments further pushes construction costs, making it a pricier city to build in.

    Copenhagen, Denmark

    Copenhagen is known for its high construction costs, and there are several reasons why. Denmark’s strong labor unions mean that wages are relatively high, driving up labor costs for any project. The city also has strict building codes that must be followed, adding complexity and expense to construction plans. On top of that, Copenhagen strongly focuses on sustainability, so eco-friendly construction methods and materials are often required, which can be more expensive than traditional options.

    Hong Kong

    Hong Kong is one of the most densely populated cities in the world, and with such limited land available, construction costs are sky-high. The city’s steep terrain adds another layer of complexity, often requiring advanced engineering solutions that drive up prices even more. Labor and material costs are also higher due to Hong Kong’s booming economy, making every aspect of a building project more expensive. With all these challenges combined, it’s no wonder construction in Hong Kong comes with such a hefty price tag.

    Bristol, England

    Built around the River Avon, Bristol’s construction costs have climbed in recent years, mainly due to high demand for housing that has outpaced supply. Labor shortages in the construction industry are another big factor, leading to higher wages and increased project costs. The city’s dedication to preserving its rich historical architecture also means that many building projects face complex building codes and additional expenses to maintain Bristol’s unique character. On top of that, there’s a growing emphasis on sustainable building practices, which can add extra layers of cost to any construction effort.

    Building in these cities is not for the faint of heart (or wallet). Whether you’re a developer or just curious, understanding these cost drivers can provide valuable insights into the global construction landscape.

  • Making construction sites safer: The advancement of fire-resistant building materials

    Making construction sites safer: The advancement of fire-resistant building materials

    One of the more prevalent, although often forgotten, hazards on construction sites is fire. To combat fire hazards head-on, companies have been recently leveraging safer practices and using more fire-resistant building materials. Buildings are being upgraded and fitted with high-performance fibers, bio-based materials, and more advanced coatings and treatments to maintain integrity and stability. Proper fire-resistant material is the key to stopping the spread of a fire.

    Fire safety in construction

    Between 2017 and 2021, fire departments across the U.S. responded to an average of 4,440 buildings under construction annually. These caused an average of $370 million in direct property damage per year, 59 civilian injuries, and 5 deaths. The construction fire rate has increased since 2014 after declining between 2006 and 2010. 

    Roughly 3 out of 4 of these fires involved residential properties, and the leading contributing factors included heat sources too close to combustible materials, electrical failures, and abandoned or discarded products. 

    There is no singular, truly fireproof building material, but advancements in well-constructed fire-resistant materials have resulted in less property damage and fewer injuries. Building damage is inevitable with fires, but the key is to build a structure where a fire would catch and escalate slowly, allowing more time to contain the fire and for occupants to escape. 

    This is how these new materials are rated: how long a fire would take to impact its structural integrity. Some heavy timber, for example, could be classified as fire-resistant according to this measure. In contrast, metals like steel and aluminum aren’t combustible but tend to buckle faster under intense heat. 

    What are fire-resistant materials?

    Fire-resistant materials, not to be confused with fire-retardant materials, are made to withstand heat and resist burning. They are designed to maintain structural integrity and prevent flames from catching and escalating. Think of bunker gear or PPE worn by firefighters to protect them from fire.

    On the other hand, fire-retardant materials, such as iron, plywood, brick, and concrete, are designed to burn slowly. While no material is entirely fire-proof, integrating fire-resistant and fire-retardant materials into building practices can mitigate the risk of significant losses.

    Advancements in fire-proof building materials

    Fire-resistant glass and steel rebar

    fire resistant glass

    Under extreme temperatures, regular steel can diminish and significantly impact the structural integrity of a building. Stainless steel rebar, however, is fire-resistant, more durable, and maintains its structural performance in the same conditions that deteriorate steel. Because of its reliability, steel rebar is expected to have the fastest-growing CAGR between 2023-2031. 

    Regular glass shatters quickly when exposed to high heat, but fire-resistant glass is made to withstand extreme temperatures and mitigate the spread of smoke and flame. This glass will maintain its structure for 30 minutes to several hours, depending on the quality. Ceramic glass, wired glass, and intumescent glass are just a few examples of several types of fire-resistant glass. They are crucial for containing fires in a particular area, giving building occupants more time to evacuate safely. 

    Intumescent coatings and paints

    firefree coatings
    Photo source: Firefree Coatings

    Intumescent paints and coatings are designed to swell at high temperatures, forming an insulated char layer and protecting the underlying material or substance from heat and flame damage. More recent advancements in these coatings involve nanotechnology, including nano-clays, graphene, and carbon nanotubes, which improve char strength, efficiency, and thermal stability. 

    New intumescent coatings also include ammonium polyphosphate, melamine, and pentaerythritol, which, when combined, create a more effective fire protection system. When applied to the undercoat of a new residential house or building, the paint creates a thick protective layer that deflects heat from bushfires and reduces the temperature at the substrate surface to approximately 30°C from 1000 to 1200°C. These advancements in intumescent coatings are pivotal for elevating fire safety standards.

    Bio-based materials

    bio based materials
    Photo source: Metropolis Magazine

    Biomaterials from renewable sources, such as biopolymers and plant fibers, are being explored for their fire-resistant properties. Researchers have developed fire-resistant composites from flax, hemp, and jute combined with bio-based resins. 

    Australian scientists are also researching using fungi as a nontoxic, bio-based alternative to the more toxic flame retardants in building materials. So far, molasses-fed sheets of fungi have been successfully developed, and they could be used as a fire-resistant coating in construction or as a leather alternative.

    These materials take advantage of the fire-resistant properties of mycelium, the root-like structure of fungi. This research could replace hazardous plastics and chemicals as a reliable fireproof material.

    Advanced coatings and treatments

    advanced coatings
    Photo source: Geopop

    Aerogels, ceramic coatings, self-healing coatings, and hydrogels each protect against fire damage and serve a specific purpose. For example, ceramic coatings are designed explicitly for composite surfaces and metals to enhance their resistance to fire and extreme heat. 

    These advanced coatings typically consist of aluminum oxide or silicon carbide, creating a strong barrier that reflects heat and prevents structural damage. Silica aerogels, for instance, have been enhanced with fire-retardant additives to improve their flame resistance. These gels could be used in various construction applications, such as insulation and PPE. 

    Hydrogels are being categorized as an innovative solution for fire-resistant fabric treatment. They can be strategically applied as a coating to act as an effective char layer against flames. Recent research has been dedicated to elevating durability and reusability with some of these coatings. Using self-healing materials, these coatings can repair themselves after sustaining heat damage, which could ensure better long-term protective properties. 

    High-performance fibers

    high performance fibers

    Polybenzimidazole (PBI), aramids, and poly(p-phenylene-2,6-benzobisoxazole) (PBO) are high-performance fibers that have become invaluable in applications that require extreme fire resistance. Aramis fibers like Nomex and Kevlar are renowned for their thermal integrity and fire resistance. 

    These fibers are often used in firefighting PPE, aerospace components, and combat and military applications. Aramids’ chemical processing and treatment advancements have significantly increased their flame-retardant properties and durability. 

    PBO and PBI fibers offer even greater fire-resistance qualities than aramids. PBI fibers don’t melt, making them ideal for hot environments. PBO fibers have superior thermal stability and are used for firefighters’ and industrial workers’ PPE. Fiber-reinforced polymers are gaining popularity due to their lightweight and excellent mechanical properties. 

    Smart materials 

    In a phase transition, phase-change materials absorb and dispel thermal energy, providing fire resistance and thermal regulation. When used and integrated into building materials, they can uphold structural integrity and lower temperature spikes in the event of a fire. 

    Thermochromic materials are designed to change color in response to temperature shifts, visually identifying heat exposure. These materials could be used in fabrics and coatings to monitor a fire risk. Thermoresponsive polymers shift their physical properties at a temperature change and are being explored for their potential advancement in fire protection. 

    The pros and cons of fire-resistant materials

    Switching to more fire-resistant materials seems like the way forward, but there are a few things to consider. 

    Pros

    • Sustainability: Bio-based materials to replace toxic plastics could provide the same fire resistance with less environmental impact. 
    • Improved performance: Upgrades in the compounds that make up sealants, glass, and rebar make more durable materials. 
    • Decreased risk of injury or fatality: The increased durability and fire resistance allow occupants to leave a building safely in the event of a fire. 
    • Decreased property damage: Stronger building coatings that protect the core structure mean more buildings that could be salvaged and easily fixed.

    Cons

    • Expensive: Some newer, stronger materials are often less available and could be more costly to order and implement. 
    • Less ventilation: Fire-resistant constructed roofs mean little to no ventilation.
    • Time-intensive implementation: Switching to an improved fire-resistant building requires more training, slower implementation, and retroactive integration.

    Bottom line

    Construction fire safety is most effective when workers implement proper safety protocols. However, if a structure does catch fire, a fire-resistant material could be the difference between safety and fatality. Implementing more advanced materials like fire-resistant glass, intumescent coatings, and bio-based materials will make the projects more sustainable and stronger, preventing injuries and reducing potential property damage. 

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  • Rate cuts spark optimism for 2025 construction growth

    Rate cuts spark optimism for 2025 construction growth

    The construction industry is gearing up for a promising 2025, driven by federal interest rate cuts in late 2024. The Federal Reserve slashed rates by 0.5% in September and an additional 0.25% in November, reducing borrowing costs and making new projects more financially viable. This comes as welcome news for an industry that has grappled with rising costs and project delays over the past two years.

    How rate cuts impact construction

    Lower interest rates make it cheaper for developers and contractors to secure loans, encouraging investment in previously stalled projects. Analysts predict a resurgence in both residential and commercial construction, fueled by easier access to capital. In residential construction, the National Association of Home Builders (NAHB) expects a boost in housing demand as lower mortgage rates improve affordability. Meanwhile, large-scale infrastructure and commercial developments could see renewed interest as developers benefit from decreased financing costs.

    Challenges that could limit growth

    Despite the optimism, the construction sector still faces hurdles that could temper growth. Material prices, which skyrocketed during the pandemic, remain volatile. Key inputs like steel and lumber continue to experience price fluctuations, which may cut into profit margins.

    Additionally, the ongoing labor shortage remains a pressing concern, with 75% of employers reporting difficulties finding skilled workers in 2024.

    These challenges underline the importance of strategic planning for construction firms as they prepare for a potential surge in activity. Expanding hiring pipelines and securing bulk material contracts could help businesses capitalize on favorable market conditions.

    The road ahead

    The construction industry’s outlook for 2025 hinges on how quickly it can adapt to changing economic conditions. Federal rate cuts present a rare opportunity to unlock growth, but businesses must navigate lingering obstacles to maximize gains. If borrowing remains affordable and demand continues to climb, 2025 could mark a turning point for the sector.

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  • Building for tomorrow: Climate resilience in the built environment

    Building for tomorrow: Climate resilience in the built environment

    Extreme weather and natural disasters can cause massive damage to homes, businesses, and public spaces, leaving communities struggling to recover financially and physically. As climate change leads to more intense storms, flooding, and heat waves, the importance of creating resilient buildings becomes even clearer. Adopting smarter, climate-ready building practices like green roofs and solar panels can reduce these impacts and help communities withstand and adapt to a changing environment.

    Quick look

    • Climate resilience in the built environment minimizes damage from extreme weather, helping communities withstand storms, floods, and heat waves.
    • Reducing financial costs through durable, climate-ready buildings is essential as climate-related repair expenses surge globally.
    • Sustainable building practices like low-carbon materials and energy-efficient designs cut emissions and support long-term environmental health.
    • Climate-resilient designs—such as green roofs, solar panels, and elevated foundations—prepare infrastructure to endure and adapt to future environmental challenges.

    The financial impact of climate change on infrastructure

    Climate change is driving up the cost of weather-related damages, with extreme events like floods, hurricanes, and wildfires becoming more frequent and intense. For example, Canada’s Green Buildings Strategy reports that climate-related infrastructure repairs could soon cost the country billions annually. Additionally, North Carolina Governor Roy Cooper announced that damages and recovery needs for the state in the aftermath of Hurricane Helene have topped at least $54 billion—and that’s only in NC.

    Globally, communities and industries, especially construction, face increasing financial strain as the costs of rebuilding and repairs rise with each disaster. Designing buildings to withstand harsher weather may help reduce these expenses and support safer, more resilient communities in the face of climate change.

    How climate change impacts building durability

    Climate change is pushing buildings to their limits, with structures facing new stress levels from rising temperatures, powerful storms, flooding, and wildfires. Older buildings, especially, are feeling the impact since they weren’t designed for today’s extreme conditions. Heat can lead to cracks in building materials, storms and flooding can weaken foundations, and wildfires present intense threats to nearby structures.

    Adaptation measures are being applied to new builds and retrofits to counter these impacts. For instance, elevating foundations in flood-prone areas, reinforcing walls with durable materials, and installing fire-resistant barriers can help structures withstand harsh weather. These adaptations are increasingly necessary as climate risks are expected to grow. Preparing buildings to endure these challenges is essential for creating infrastructure that survives and serves communities well into the future.

    Reducing emissions through sustainable building practices

    Buildings and construction are responsible for a significant portion of carbon emissions worldwide, adding to the challenges of climate change. From the materials used to the energy required to heat, cool, and light them, buildings have a lasting environmental footprint. To cut down emissions, sustainable building practices are becoming a priority. Using low-carbon materials like recycled steel and sustainably sourced wood and implementing energy-efficient HVAC systems can significantly reduce a building’s overall carbon impact.

    Designing healthy, climate-friendly buildings goes beyond energy savings and contributes to broader climate mitigation efforts. Healthier buildings with efficient systems and greener materials lower emissions and create more comfortable and sustainable environments for occupants. Taking these steps in construction and building design supports a future where infrastructure not only endures environmental changes but actively helps reduce them.

    Building for low-carbon resilience

    Low-carbon resilience is about designing sustainable buildings prepared for climate change’s impacts. It combines efforts to lower carbon emissions with strategies to strengthen buildings against extreme weather. This approach helps create infrastructure that can withstand climate-related challenges while minimizing environmental impact.

    Methods like green roofs, solar panels, and energy-efficient design are critical components of low-carbon resilience. Green roofs, for example, help insulate buildings, manage rainwater, and reduce urban heat. Solar panels reduce reliance on fossil fuels, while energy-efficient designs reduce overall power usage, making buildings less vulnerable to energy shortages during extreme weather. Many eco-conscious agencies are at the forefront of these efforts, working to integrate low-carbon resilience into building policies to help communities build smarter, stronger, and more sustainable.

    Climate hazards and adaptation strategies for resilient buildings

    Buildings today face a variety of climate-related hazards, each posing unique challenges that call for specific adaptation strategies. Flooding, for instance, is an increasing threat in many areas, especially those near rivers and coastlines. To address this, flood-proofing measures like elevated foundations, water-resistant materials, and drainage systems are being added to new and existing structures. Similarly, buildings in areas prone to extreme heat incorporate features like reflective roofing and shading systems to manage rising temperatures. At the same time, improved insulation helps maintain interior temperatures in extreme cold regions.

    These adaptations aren’t just practical—they’re essential. As climate-related events grow more frequent and intense, adapting buildings to handle these conditions protects communities and reduces costly damages. These strategies offer long-term security for both infrastructure and residents by making buildings more resilient to their environments.

    Case studies in climate resilience

    Across the globe, cities and projects are leading the way in climate resilience by implementing strategies that protect communities and adapt to changing weather conditions. For example, New York City has made significant progress with stormwater management systems to reduce flooding risks. By upgrading its drainage infrastructure and creating more green spaces to absorb rainwater, the city is preparing for heavier rainfalls and rising sea levels.

    Images of green infrastructure infiltration areas retrofitted into the neighborhood of Østerbro Klimakvarter, Copenhagen. The new Klimakvarter (climate quarter) uses an elaborate green infrastructure system to retain stormwater for later use and allow stormwater to flow, slow, and infiltrate. Photo: SLA, Mikkel Eye.

    Denmark has adopted climate-adaptive retrofitting, transforming urban spaces with permeable pavements and green roofs that manage excess rainwater and reduce heat. These measures help the city handle extreme weather and improve urban living conditions.

    The bottom line

    Climate-resilient infrastructure is essential for communities facing increasingly unpredictable and severe weather. Buildings that meet environmental and safety demands are better equipped to protect people, property, and resources. For builders, policymakers, and communities, investing in resilience offers long-term benefits that extend beyond immediate safety—helping reduce future repair costs, minimizing disruptions, and supporting a sustainable environment.

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  • How mass timber is transforming sustainable building practices

    How mass timber is transforming sustainable building practices

    In the quest for sustainable construction, mass timber is emerging as a revolutionary alternative to traditional materials like concrete and steel. Recent large-scale projects, such as Walmart’s corporate campus in Arkansas and the record-breaking Ascent tower in Milwaukee, showcase the material’s potential. Its ability to reduce buildings’ carbon footprint while also providing strength and durability capable of matching traditional materials makes it an exciting development in the construction industry. 

    What is mass timber?

    Mass timber refers to a category of engineered wood products created by layering multiple pieces of wood, often laminated together using adhesives, nails, or wooden dowels. The most common form, cross-laminated timber (CLT), features wood layers set at right angles to one another. What truly sets mass timber apart is its ability to serve as a viable substitute for steel and concrete, offering comparable load-bearing capabilities and structural resilience. The CLT structure grants mass timber strength and stability, making it suitable for large-scale construction up to 18 stories high. However, mass timber is being used in more than just large-scale projects. 

    Photo source: APA — The Engineered Wood Association

    Types of mass timber being used in construction

    Mass timber products are versatile and adaptable across various applications in construction due to their structural strength and design flexibility. Here’s a breakdown of the commonly applied mass timber products:

    • Nail-Laminated Timber (NLT): Commonly used for floors and decking in commercial and industrial buildings. NLT’s simplicity and cost-effectiveness make it suitable for shorter spans.
    • Glue-Laminated Timber (Glulam): Glulam is frequently used for large beams, columns, and arches. Its ability to be curved and shaped means it is often found in architecturally complex buildings like sports arenas and churches.
    • Dowel-Laminated Timber (DLT): Known for its strong connections without adhesives, DLT is commonly used in industrial and commercial floors, allowing for efficient construction with low environmental impact.
    • Cross-Laminated Timber (CLT): Primarily used in high-rise buildings, walls, floors, and roofs, CLT’s ability to bear heavy loads makes it ideal for tall structures. It’s also preferred for its quick assembly and precise prefabrication.

    Mass timber’s rise to spotlight

    A major breakthrough for mass timber came in 2021 when updates to the International Building Code (IBC) allowed for the construction of mass timber buildings up to 18 stories tall. This milestone was significant because it removed a regulatory barrier that previously limited the height and scope of timber structures. The new codes acknowledged the advancements in mass timber technology, particularly its structural integrity, fire resistance, and ability to meet stringent building requirements.

    For example, in terms of durability, mass timber has proven resilient against natural disasters like earthquakes due to its high strength-to-weight ratio. Its lower weight reduces the load on foundations, and its flexible structure can better absorb seismic activity than heavier materials like concrete. Additionally, mass timber has demonstrated fire resistance. During fire tests, mass timber develops a char layer on the outer surface that insulates the inner core, maintaining its structural integrity. This performance under fire conditions, combined with proper encapsulation techniques such as gypsum or drywall layers, makes it as safe as traditional materials under modern building codes.

    While these proven advancements have allowed mass timber to be used more commonly in a wider variety of projects, from mid-rise apartment buildings and office spaces to large-scale developments like Walmart’s campus, there is more to mass timber than just meeting code regulations.  

    The Ascent Tower, located in Milwaukee, Wisconsin, is the tallest mass timber structure in the world, sitting at 25 stories. Architect: Korb + Associates Architects, CD Smith. Photo source: Thornton Tomasetti.

    Benefits of using mass timber

    Lower carbon footprint

    One of the primary advantages of mass timber is its contribution to reducing carbon emissions. Unlike steel and concrete, which require energy-intensive production processes, wood naturally stores carbon. By using sustainably harvested timber, construction projects can significantly lower their carbon footprint, making mass timber an eco-friendly choice in the fight against climate change. This benefit is crucial as cities and industries work toward more sustainable building practices.

    Aesthetic and biophilic benefits

    Mass timber buildings offer a unique aesthetic appeal, with the natural warmth and texture of exposed wood creating inviting spaces. This biophilic design—connecting occupants with nature—has improved mental well-being, increased productivity, and even reduced stress in office environments. Whether used in residential homes or commercial buildings, mass timber creates spaces that feel both modern and natural, enhancing the overall consumer experience.

    Faster construction times

    The prefabrication of mass timber components allows for faster assembly on-site, reducing labor costs and minimizing construction time. This speed makes mass timber especially beneficial for large-scale commercial projects or developments that require quick turnaround times. In many cases, entire structures can be assembled in a fraction of the time it would take to construct a similar building using concrete or steel.

    Versatility in application

    Mass timber is highly versatile and can be used across various construction types, including residential, commercial, and institutional projects. It has proven effective in everything from low-rise homes to high-rise buildings. 

    Walmart’s new home office sits on a 350-acre campus of native-seeded greenery and will consist of more than 2.5 million square feet of mass timber construction spread over 11 buildings. Photo source: Woodworks Innovation Network.

    Are we ready for mass adoption?

    While the hype is building behind mass timber, several hurdles must be addressed. 

    • Workforce training: Many workers in the construction industry lack experience with mass timber building techniques. Developing specialized education programs and apprenticeships will be crucial in scaling its use. 
    • Sustainable harvesting practices: While timber is a greener product than concrete and steel, guidelines that are strictly enforced are needed to ensure that mass timber’s environmental benefits are realized without contributing to deforestation.
    • Building a sustainable supply chain: This is another critical step, especially since prefabricated components are typically manufactured off-site. To minimize delays, it will be necessary to ensure consistent and quality production and secure transportation methods. 
    • Managing the long-term lifecycle of mass timber buildings: How the material will fare in different climates is still to be fully determined. In addition, implementing strategies for maintaining and repairing these structures after fires is still an issue that needs to be solved and will be essential for securing investor and public confidence.

    Mass timber’s full potential may remain untapped without addressing these logistical, regulatory, and ecological considerations. 

    Bottom line

    Mass timber rapidly emerges as a key material in sustainable construction, offering lower carbon emissions and faster build times. Its versatility allows for use in everything from residential homes to high-rise buildings. As regulatory frameworks evolve and technical challenges like workforce training and sustainable harvesting are addressed, mass timber is poised to play a crucial role in the future of eco-friendly construction practices.

  • Kyowa Kirin to build $530 million facility in NC

    Kyowa Kirin to build $530 million facility in NC

    Japan-based pharmaceutical company Kyowa Kirin recently announced plans to build a new biologic facility in Sanford, NC. When built, the facility will cover 171,700 square feet and have two reactors that will speed the development and production of biological therapies for patients with rare and serious diseases.

    The disruption of supply distribution lines during the COVID epidemic has prompted yet another company to invest in a production facility in the U.S.

    Biologic therapies will be the focus

    The facility will manufacture biologic therapies for the company’s planned clinical trials and future commercial use and create more resilient supply lines. The planned 75-acre campus in Sanford, NC, will allow for future expansion.   

    Construction of the facility will begin this year and is expected to be fully operational by 2027. Kyowa Kirin’s investment of up to $530 million will be supported by Leaders in the Tarheel State, who wholly back the facility plans and provide $10 million in performance-based state and local incentives to Kyowa Kirin over 12 years. According to the North Carolina Department of Commerce, the investments should grow North Carolina’s economy by $1.05 billion over 12 years. 

    The plant is expected to create more than 100 new high-paying local jobs, with an average salary of $91,496. 

    Images courtesy of Kyowa Kirin

    Research Triangle sweet spot

    Kyowa Kirin said part of the reason the company chose North Carolina is the area’s existing base of skilled workers.

    “The extraordinary complexity of the medicines we manufacture requires specialized skills and resources that are in plentiful supply in Sanford and the Research Triangle region,” said Paul Testa, Executive Vice President, Regional Head of North America/EMEA Manufacturing, Kyowa Kirin North America. “We’re excited to collaborate with area colleges, universities, businesses, and civic leaders to ensure that our plans align with Sanford’s vision for growth, anchored in a rejuvenated manufacturing economy that offers diverse job opportunities and returns value to the community.”

    Another impetus behind this considerable investment is the company’s desire to help treat rare diseases that affect hundreds of millions of people worldwide.

    “Our North American presence continues to grow through strategic investments that are adding new capabilities, new therapeutic expertise, and new talent to our global organization, all in service of meeting patients’ needs,” said Steve Schaefer, Kyowa Kirin North American President. “Among the many qualities that drew us to North Carolina are our shared values, such as harmony and teamwork—known as Wa—which is deeply ingrained in our culture at Kyowa Kirin, evident in our longstanding corporate partnerships, and fundamental to high-quality pharmaceutical manufacturing.” 

    Kyowa Kirin’s global manufacturing network includes sites in Takasaki City, Gunma Prefecture, Ube City, and Yamaguchi Prefecture in Japan.

    The planned facility in North Carolina’s Research Triangle Park region, home to universities and community colleges offering specialized curricula and training, will enable the company to tap the human talent available there. Kyowa Kirin will also benefit from the network of biomanufacturing resources already present.

    The Research Park Triangle is home to many pharmaceutical companies, including Impact Pharmaceutical Services, Cloud Pharmaceuticals, Inc., PharPoint Research, Inc., Aerie Pharmaceuticals Inc., and others. The area also has about 450 life science companies, including Eli Lilly, Novartis, and GlaxoSmithKline.

    Advancing methods through investment

    Kyowa Kirin’s investment in North Carolina will enhance the company’s manufacturing productivity by building upon its methods and technologies. 

    “The new facility will be scalable with our Takasaki Plant in Japan to help ease technology transfer between the two plants and add production capacity. We believe this will help accelerate drug development and production,” said Toshiyuki Kurata, Chief Supply Chain Officer, and Global Manufacturing Head at Kyowa Kirin.

  • RENCO blocks provide a lighter and simpler building solution

    RENCO blocks provide a lighter and simpler building solution

    Miami-based construction materials manufacturer RENCO is changing the way people build structures. Their lightweight stackable molded blocks—composed of recycled glass fibers, recycled plastic, resin, and stone—are ultra-durable building materials capable of withstanding a category 5 hurricane, making them ideal for use in disaster-prone areas.

    Real-life LEGO for contractors

    RENCO USA offers a LEGO-like building system using blocks made of resins recovered from the boating industry, glass fibers, and stone—or “renewable composite”, which is how the company’s name arose. 

    The idea behind the structural building system is to help contractors do their jobs faster using a system of interlocking building components, including various sizes of blocks, columns, beams, joists, headers, decking, and connectors. The components are joined together by an adhesive. The blocks and other components are comprised of about 40% recycled materials. 

    The system was originally developed to accelerate rebuilding following a natural disaster in Turkey, but it can be used for buildings as tall as five stories, even in natural disaster-prone areas. 

    The block components are rectangular and topped with knobs that interlock and stack like LEGO blocks. The blocks are typically 8x8x16 inches and weigh 20% less than a typical concrete block.

    Selling point: RENCO’s blocks are similar to stackable concrete blocks but they are lighter, quicker to assemble, require little training, and are cheaper to transport. 

    Lakewood Village in Palm Springs, FL

    RENCO’s interlocking blocks system was recently used to construct four 3-story apartment buildings at Lakewood Village in Palm Springs, FL. The project was completed in November 2023 and employed 10 workers. Each of the four buildings was completed in about eight weeks.

    Led by architectural firm Arquitectonica, the Palm Springs project created 96 apartments in four identical buildings. The RENCO components for this project were manufactured and shipped from Turkey—a cost that nearly quintupled from $3,500 to $15,000 per shipping container post-pandemic, necessitating the construction of a U.S. plant for the company. The international supply chain has been seemingly permanently disrupted since the pandemic, and materials and shipping costs have skyrocketed. That trend is leading to more industrial investment in the U.S.

    The rise of prefab

    Prefabrication in construction has been gaining popularity for years. Entire buildings (sans foundation) are fabricated offsite and shipped to the work site for assembly. The same process happens with bridges, piers, and other larger structures. The reason: fabricating components of structures offsite is cheaper and often more accurately accomplished than building them onsite. It’s also faster.

    There’s a simple reason why RENCO’s building system is gaining traction: it offers precise, pre-construction component fabrication and building construction that’s affordable, lighter, and quicker to transport. 

    The technology is easy to assemble. The blocks are stacked on a concrete foundation and “mortared” with an adhesive that binds them together. It doesn’t require much more than a forklift operator and trained workers, a glue gun powered by a small generator, and a mallet to complete. No cranes, scaffolding, cutting, welding, or grinding of components is needed.

    RENCO’s system also offers the prospect of far less construction material waste on a job site. Construction sites typically create dumpsters full of waste materials, and contractors add about 10% extra materials when calculating what they need to account for waste. RENCO provides a nearly waste-free solution. Even the tailings from the blocks are recycled by the company to be used in mixes for more building components.

    The system is attracting the attention of eco-minded builders and owners who want to build faster, cheaper, and more accurately while creating a smaller carbon footprint. Fewer trucks are required to ship RENCO’s lighter-than-concrete components, and the company says RENCO’s components have passed over 400 rigorous safety tests.

    RENCO’s building system also creates monolithic structures that can resist forces in excess of 160 pounds per square foot and 85-mile-per-hour winds.

    According to the U.S. Green Building Council (USGBC), the RENCO Structural Building System has been tested, analyzed, and evaluated in American National Standards Institute (ANSI) certified laboratories to American Society for Testing and Materials (ASTM) standards for material and physical characteristics, structural performance, fire resistance, and environmental resistance. USGBC is backing the technology’s dependability and has issued an Evaluation permitting the use of the RENCO Structural Building System in Florida’s High-Velocity Hurricane Zone.

    RENCO blocks prove ultra-practical—but not completely sustainable

    While RENCO USA claims its products as sustainable, it’s unclear whether that is entirely correct. The company uses resins from the boating industry, in part, to construct its building components. 

    There are three main types of boat resins: 

    1. Polyester
    2. Vinylester
    3. Epoxy

    While these materials may withstand degradation and the composite blocks are insect and rodent-resistant, they are susceptible to sunlight and must be covered in an exterior facade within three months of construction. 

    It should also be noted that the above chemicals are toxic to the environment and people, making them unsuitable for anyone looking for sustainable building materials. 

    While repurposing wasted boat building materials is laudable, in this case, it’s encapsulating them in a heat-sensitive composite material that might, in the future, be compromised in some way and have negative effects on the environment.

    During assembly, the block system is bolted to a foundation and the block courses are glued together, forming a monolith of the structure. The system appears to be similar to Autoclaved’s concrete building system, which uses aerated concrete blocks that are lighter than conventional concrete blocks for building construction.

    But according to RENCO president Kenneth Smuts, RENCO’s components are lighter than the competition, faster to assemble, more economical, and longer lasting.

    The firm is currently building a 50,000-square-foot manufacturing plant in Jupiter, FL, which is set to be completed by mid-July. The plant will be able to produce $100 million in products annually. RENCO plans to create other plants as regional facilities across the U.S.

    The system provides an obvious benefit that contractors and owners might want to get: a savings of 5% overall on a construction project’s costs, Smuts said. RENCO’s components last two to three times as long as conventional products.

    “They say the greatest buildings are those you don’t have to rebuild,” Smuts said.

    RENCO USA’s parent company is Coastal Construction, a Florida-based contractor performing $1 billion in projects annually in Florida.

  • Construction backlog declined to 8.1 months in February

    Construction backlog declined to 8.1 months in February

    Contractors may be losing confidence in the backlog of work they believe they are facing, according to a recent Associated Builders and Contractors members survey. But good news: according to a survey that concluded on March 5, ABC’s Construction Backlog Indicator declined to 8.1 months in February. 

    The reading is down 1.1 % since February 2023. Even so, ABC said contractors remain confident about the work they will have to tackle over the next year.

    Backlog declines slightly

    The backlog of work fell in February for every size of contractor, with one exception: those with under $30 million in annual revenue. But over the past year, contractors with more than $50 million in revenues have experienced the greatest decline in backlog, the report said.

    “Backlog is declining, and confidence began to fade modestly in February,” said ABC Chief Economist Anirban Basu. “While it is far too early to predict an industrywide downturn given that confidence readings continue to signal growth along sales, employment, and profit margin dimensions, it appears that a rising tide of project cancellations and postponements has begun to make its mark.”

    It’s unclear what is driving the project cancellations, but inflation of the U.S. dollar, volatile materials and shipping prices, and other factors constantly impact construction pricing. The same factors could also be impacting the financial sector to some degree, slowing its ability to fund construction projects.

    “With excess inflation remaining stubbornly durable, at least according to certain measures, interest rates are poised to remain higher for longer. “That gives higher borrowing costs more time to upset the economic momentum that has so surprised economists over the past two years and has provided support for various nonresidential construction activities,” Basu said.

    But it’s hardly all gloom and doom—there’s a lot of positive news. Infrastructure spending through the U.S. federal government is spurring the creation and/or expansion of many projects across the country.

    “With so much federal money still entering the economy, there will continue to be support for growth in certain construction segments, including public works and manufacturing-related megaprojects,” Basu said. “But industry weakness is more apparent in segments that rely more purely on private financing.”

    ABC’s Construction Confidence Index readings for sales, profit margins, and staffing levels declined, but only slightly in February. All three readings are still above the threshold of 50, which indicates positive expectations for growth, at least through August.