LIFTbuild’s innovative approach to high-rise construction addresses the industry’s productivity decline by implementing a ground-level assembly process that significantly enhances speed, efficiency, and safety.
The conventional approach to high-rise construction is full of inefficiencies, contributing to a significant decline in productivity. The construction industry has seen a 40% drop in productivity since 1970, largely due to the inability to efficiently convert intermediate goods into finished products.
Rethinking the Way Tall Buildings are Made
At LIFTbuild, we’ve reimagined tall building projects as a synthesis of processes that occur on the ground. Likened to an automotive assembly line, the manufacturing environment is at the heart of LIFTbuild’s approach. We employ many complementary technologies and processes throughout each phase of the project to ensure they work together to produce the ideal product — a successful building and a positive experience for all stakeholders.
The LIFTbuild system significantly increases assembly efficiency, reduces structural complexity, enhances quality, and improves construction safety. The system uses concrete spines and steel-framed roof and floor plates, with all assemblies done at ground level. This method allows for more cost-effective procurement and assembly efficiencies, resulting in faster project completion.
Revolutionizing High-Rise Construction: The LIFTbuild Assembly Process
The building assembly process behind LIFTbuild’s approach begins with constructing structural spines, installing a patented lifting system, and setting up a manufacturing environment at grade. The roof and floor plate construction occur on — or at an ergonomic level on the assembly pad that serves as the central workspace. The steel erection process leverages a pedestal system, and workers then install decking, reinforcing, and concrete. Next, workers spray fireproofing and install mechanical, electrical, and plumbing (MEP) systems above and below the floor plates, taking advantage of the ergonomic height to increase efficiency, quality, and safety. Simultaneously, small cranes install the façade, leveraging prefabricated panels to reduce schedule.
Prior to lifting each floor plate to its final position, floors are strategically loaded with a just-in-time delivery of materials for buildout post-lift. These materials are pre-purchased, then stored, kitted, and labeled at a dedicated warehouse nearby to minimize supply chain disruption and ensure speed-to-market.
As the floorplate lifted utilizing a strand jack lifting system, a central controller closely monitors the massive floor plate — each approximately one million pounds at Exchange — as strand jacks hoist it at an impressive average speed of 20-30 feet per hour to its final height. The controller continuously assesses and adjusts each strand jack to ensure precise positioning before locking-in the floor plate.
Following lock-in, the lifting system is disengaged from the floor plate and reset at the assembly pad below, allowing workers to commence the layout and assembly of the next floor plate. Simultaneously, the interior fit-out process begins on the locked-in floor plate, which is considered weathertight, eliminating the risk of elements compromising materials or work put in place. Various system connections also addressed at this stage include façade and MEP. These activities are all conducted in a fall-safe space while the floors below continue to be assembled and lifted into position, maximizing speed. Workers adapt to the unique process floor-by-floor, reviewing/implementing opportunities for improvement and further enhancing productivity.
Proven Efficiency: LIFTbuild‘s Success at the Exchange Residential Tower
An assembly pad workday cycle time assessment provides a picture of total workdays to complete each floor plate. On LIFTbuild’s proof-of-concept project, the Exchange Residential Tower in downtown Detroit, the goal was to complete a floor plate every 10 production days by Level 11, understanding that there is an opportunity for improvement as the crews learn the project. The team hit its cycle target of 10 days, reducing total assembly time by up to 33%.
Overall, LIFTbuild’s approach to building assembly transforms how the world is built, prioritizing safety, quality, speed, and efficiency, all while setting a new standard for the construction industry.