The Wall Line
Production starts with the most precise robot in our factory, a high speed saw that cuts the top and bottom plates for our wall, and pre-drills for the installation of plumbing, venting and electrical rough-in that is soon to be installed.
It’s all pre-determined by the contract drawings you have approved. Everything in our factory is pre-cut: drilled, trimmed, fastened and routed with CNC precision.
Once we have prepared the framing materials, we move to the Framing Station. Here the wall frame is assembled with robotics in accordance with wall specific shop drawings. Because robots are executing the framing, the framed wall is incredibly precise.
The wall comes out of the framing station and moves to our # 1 Bridge Station. Here we put a layer of OSB on the interior face of all exterior wall frames. The #1 Bridge is also where any openings in the wall, doors, windows, outlets and switches are precisely cut to perfectly square dimensions.
We leave the #1 Bridge Station for the Butterfly Table, which raises the wall upright into the Vertical Station where we install the electrical, and plumbing systems. Our expert trade professionals are standing at the Vertical Station, tools beside them, working with uncommon accuracy and precision as our CNC robots have already located and cut the openings for fixtures, outlets and switches.
From the Vertical Station, we move the wall via trolley to the Insulating Station. The robots lay the wall back down with the stud up and the OSB down, and it’s ready for insulation. We use dense pack cellulose as it is among the healthiest and most effective types of insulation. At Blueprint Robotics, we build our walls, floors and roof horizontally. As a result, we are able to use advanced technology to dense pack cellulose, applying it evenly at 3.4 lbs. of pressure per square foot, thereby ensuring that the cellulose is tight throughout each cavity.
From the Insulating Station, the wall moves on to the Exterior Station. Here robots apply the exterior sheathing. Our standard is a Huber product called Zip-R which provides a value of R-6 on the outside of the frame. Alternative sheathings are available for specific project requirements (i.e. fire walls, high performance walls, passive construction). Following the application of the exterior sheathing, the door and window openings are cut by robotics to project specifications.
Now we move to the Wall Finishing Station. All exterior sheathing is taped and all nail penetrations are liquid flashed.
We come out of the Wall Finishing Station and move the wall to install windows and exterior doors. A pneumatic gantry picks up the window or door, places it in the pre-framed and cut opening, and secures it in place while our carpenters complete the fastening and flashing.
When the wall is finished, it’s packaged and placed on a specially configured vertical pallet that ensures its protection during transportation.
The entire system is managed by optimization software that specifies the sequence of production so as to insure each component is packaged, and shipped in the correct order for assembly on your foundation.