Return to flip book view

CADSTEEL GROUP CAPABILITY STATEMENT

Page 1

CAPABILITY STATEMENTCadsteel Group CompaniesCadsteel - C-Span - Modfloor - MMC Modular 10B - 84 Christensen South Road Stapylton Queensland 4207

Page 2

EXECUTIVE SUMMARYAll shares in the companies are held by the Davis family. John Davis has over 45 years international building experience and 30 years international experience in the manufacture and installation of light weight steel framing, trusses, floor systems and modular buildings.MANAGEMENTManaging Director John Davis Company Secretary Colleen Davis CEO Nicolle Ryan Business Development Arron Davis. Factory Manager Mark Armstrong Senior Estimator Michelle Hewitt Senior Designer Lourens Du Plessis Corporate Management Bradley Summerson BACKGROUND The Cadsteel group of companies evolved from the Harwood Pacific Group that was establish in Darwin in the wake of Cyclone Tracy in 1975 to assist in the city’s reconstruction. The family company relocated to Brisbane in 1988 and over the next decade established a reputation as a quality builder of family homes and small townhouse projects. In 1991 Delphin Property established Forest Lake as Brisbane’s first master planned community and Harwood Pacific developed the first townhouse projects and built over 300 homes in the community. In 1998 the company expanded to New Zealand with offices in Christchurch and Auckland and became the second largest builder of homes behind the Fletcher Group. In 1999 the company formed Cadsteel and commenced manufacture of light gauge steel faming for housing and in 2001 introduced light gauge steel framing to the USA with a plant in Orlando Florida. Development of hurricane resistant housing using steel fame construction expanded the business into the Bahamas and across southern Florida, Georgia, Alabama and was selected as key supplier by the USA Corp of Engineers to assist in the redevelopment of New Orleans after Hurricane Katrina and a military project at the Marine Base in Barstow California. Capitalising on the hurricane resistant steel framing systems, modular housing manufactured in Orlando Florida was shipped to The Bahamas for projects at New Providence, Grand Bahamas and Eleuthera. In 2011 the Australian and New Zealand Harwood Pacific companies were subject to a management buyout. In 2012 the company consolidated again in Queensland remains fully Australian family owned.

Page 3

Development of the latest innovative technology to produce lightweight galvanised steel frames, trusses, C-Span flooring systems and Modfloor (a revolutionary chassis system for modular housing) continued with a new plant was established at 4/84 Christensen South Road Stapylton in 2021 and in November 2022 due to the rapid growth of the company manufacturing was relocated to a larger factory at 10B/84 Christensen South Road offering over double the production space and an additional 300 M2 of office space to accommodate back of house services. In 2022 a state of the art rollformer was bought on line to manufacture revolutionary steel flooring systems C-Span and Modfloor. The rollformer, the only one in the Southern hemisphere and one of only five in the world is capable of manufacturing in excess of 2,200 lineal metres of product daily per shift. Modfloor is now supplied to modular builders in Queensland, New South Wales and Victoria and MMC Modular builds volumetric modular housing utilising Cadsteel frames and trusses and the Modfloor chassis system. GOALS AND OBJECTIVES The impact of COVID and significant delays in the completion of residential projects due to labor shortages and a global supply deficit of several common building materials has severely impacted the residential building industry. The demand for residential housing in Australia reached crisis point in 2022 and supply continues to fall well behind demand. The group is now transitioning into a supplier to the modular building industry through Modfloor and MMC Modular. The manufacture of modular dwellings has long been hampered by outdated engineering and led to the development of Modfloor as a replacement chassis system for modular housing. Modfloor is starting to make an impact in the modular industry with some of the largest manufacturers in Australia now using the system. Independent testing has proven the strength of the product and speed of assembly. Modfloor’s multi storey option (up to 4 floors) is undergoing final engineering assessment and is expected to launch in August 2024.

Page 4

MMC MODULAR MMC Modular now manufactures over 100 units per annum ranging from granny flats to full size homes and is building to NDIS requirements as required. International experience gained in cyclonic an hurricane zones has led MMC Modular to incorporate building products that are highly resistant moisture, mould and corrosion. For example: •Modfloor chassis used in all MMC Modular homes are manufactured from Modfloor’s MAGZAL ZM310 steel with 7-10 times the corrosion resistance of regular galvanised steel allowing for corrosion warranties of up to 50 years dependent upon location and a structural warranty of 20 years. •Magnesium board which is impervious to termite infestation and highly resistant to water is used a flooring in all projects and in dwellings that require internal wall claddings that may be subject to harder than normal use. •Cadsteel framing manufactured from .95 mm thick G550 steel carries a 50 Year structural warranty. A range of MMC Modular designs are included in the attached schedule. With over 30 years of international building experience, MMC Modular guarantees predictable outcomes and dependable results. We’re redefining the construction of modular buildings with the latest light gauge steel technology and building processes to meet our client’s needs.

Page 5

!

Page 6

AUSTRALIAN MODULAR HOUSING OVERVIEW One of Australia's most recent construction trends is the preference for modular construction techniques. Off-site construction methods like modular construction include building prefabricated modules in a factory setting before transporting them to the job site. Prefabricated (Modular) building systems and construction hold a high potential to improve the efficiency and performance of the Australian construction industry in a more sustainable sense. With the market just opening up in the building industry, generating trust and investments in the technology, the market is open to ample opportunities and can witness substantial growth in the coming years. The Australia Prefabricated Buildings Market size is estimated at A$16 billion in 2024, and is expected to reach A$19.5 billion by 2029, growing at a CAGR of 4.93% during the forecast period (2024-2029). Increasing demand for new homes is driving the market. and is primarily driven by the demand for low to mid-rise residential buildings, project homes, and public housing. Increasing awareness about the benefits of prefabricated buildings, such as reduced material waste and less disruption to the surrounding environment, is driving market growth. The adoption of prefabricated solutions in Australia has increased significantly over the past few years. Industry associations and institutions in Australia are launching campaigns to create awareness about the benefits of the prefabricated industry. Leading figures in the Australian industry have recognised the productivity and efficiency gains that advanced manufacturing techniques can offer. Due to various causes, including a tight labor market, rising input costs, and increased demand due to government incentives, the construction and building industries have experienced significant price inflation in most states. However, the problems mentioned above are beginning to affect all types of construction. The cost rises traditionally started in residential construction. The adoption of prefabricated solutions in Australia has increased significantly over the past few years. Industry associations and institutions in Australia are launching campaigns to create awareness about the benefits of the prefabricated industry. Many public spaces in Australia, such as new railway stations, police stations, healthcare facilities, and community centres, are now being built using volumetric modular construction and other prefabricated methods with the assistance of the Australian government. The prefabrication construction market in the country is estimated to witness growth.

Page 7

MODFLOOR All modular houses and buildings are manufactured on either a steel or timber chassis designed to enable the finished building (dwelling) to be transported to site by truck then craned into position. Some buildings comprise multiple modules complexed onsite. The use of timber for the manufacture of chassis is declining due weight of the finished product, speed of assembly and the need for qualified carpenters to manufacture. Traditionally, steel chassis have been manufactured from “hot rolled or structural steel” The components of the chassis are then usually welded together to create a torsionally strong chassis. This type of chassis usually requires heavy steel “skid beams’ to support and brace the structure. MODFLOOR completely eliminates heavy hot rolled steel beams, is up to 1/3 cheaper, lighter, stronger, does not require any measuring, cutting or welding and offers Australia’s only corrosion warranty for modular floor systems. Modfloor can be designed to suit virtually any type of foundation system with up to 18 metre lengths and 5.3 metre widths available.! Components are manufactured to exact lengths in the factory eliminating waste at the point of assembly.!! Modfloor technology allows modular builders to customise floor panels with less flex and deflection and independent testing has proven the strength and righty of the system. LINK TO INDEPENDENT TEST REPORT !Pre-punched service holes allow builders to install plumbing, electrical services even air conditioning ducts in the floor during manufacture rather than onsite. Speed of assembly is proving to be a key motivator for manufacturers looking to speed up production and meet demand. LINK TO ASSEMBLY VIDEO The video below of a ample 12 metre x 4.5 metre chassis was assembled in under two hours by three unskilled workers with no previous experience.

Page 8

MODFLOOR -V- TRADITIONAL STEEL CHASSIS TRADIONAL STEEL CHASSISMODFLOORWEIGHTIndividual components and the finished chassis are heavy with some individuals components requiring forklifts or overhead cranes to move components around the factory floor.Manufactured from light gauge steel (LGS). Finished chassis are generally 30% to 40% lighter and individual components can be man handled.WET AREA STEP DOWNSIncluding wet area step-downs is complex and difficult to achieve due to the supporting structureEasy to achieve and can be set from mom to 50mm and can be bevelled to provide for flow to drains. Designed and manufactured though a computer-based system ensuring unprecedented accurate dimensions.ASSEMBLYChassis assembly require experienced and high cost welders. Components need to be measured, cut and welded often combination with multiple brackets. Location of each joist to be measured the joists welded to perimeter frame.Modfloor is delivered ready to assemble. No measuring or cutting and can be assembled with a screw gun and a clamp by general hands. No welding required. Joists simply connect to bearers into pre-punched tabs with Tek Screws that positively locate the joists and completely eliminates measuring, cutting and welding.#FAST ASSEMBLYRequires either several welders to manufacture in one day or multiple days to assemble a typical chassisFast assembly with a 12 meters x 4.5 metres typical chassis assembled in under three hours by unskilled labourSTRENGTHChassis strength relates to the deflection of the chassis during transport. Typical deflection rates are 15mm to 20mmIndependent testing confirms nominal deflection rates at a maximum of 4mm eliminating internal repairs after deliverySERVICE HOLESNot possible with traditional chassisPre-punched service holes allow builders to install plumbing, electrical services even air conditioning ducts in the floor system during manufacture rather than onsite saving time and money. WASTEOn-site waste requires disposalZero on site wasteFREIGHTOutsourced pre-built chassis incur heavy freight costs due to wide load restrictions and escort costsNo special transport requirements and Modfloor is shipped flat packed ready for assemblyCORROSION PROTECTIONManufactured from galvanised steel which needs repainting where welded as welding destroys galvanisingManufactured from Envirosteel GIX with 5-7 times more corrosion protection that galvanise steel. No wielding, so no repainting.REUSABLE LIFTING BRACKETSSingle use lifting brackets welded into the chassis adding complexity and cost and sacrificing strengthReusable lifting brackets combine transport tie-downs reducing costs and manufacturing time.

Page 9

STEEL FRAME AND TRUSS PRODUCTS Cadsteel continues to manufacture high quality cold-formed steel frames and trusses. The product is non-combustible and can withstand fires, hurricanes, and high winds. Cold formed steel is a termite, mould, and rot-proof solution and is the most recycled material on Earth. The ease of prefabrication and mass production, fast and easy erection, and installation of Cadsteel Frames and Trusses substantially speeds up construction time. Cadsteel cold formed steel members are fabricated to exact standards and are accurate to within 1.6 mm, allowing even complicated designs to be constructed more easily and with less waste than with traditional materials.

Page 10

C-SPAN C-SPAN is a light-weight flooring system designed to replace web or timber joists. Manufactured utilising our “state of the art” rollformer the system comprises both joists and perimeter frame with the joists sitting at the same level as the perimeter, achieving a full load transfer for multi-level dwellings providing strength and reliability. C-Span joists are pre-punched with service holes to provide sufficient space for electrical, plumbing and air-conditioning services within the joist. Manufactured from cold rolled galvanised steel and comprises a C section joist and a perimeter section that incorporates a tab to which the joists are fastened through pre-punched holes. C-Span trucks are fitted with HIAB cranes with substantial reach so that product can be delivered to site, usually without the additional cost of crane hire.

Page 11

MMC MODULAR DESIGN SAMPLES

Page 12

Page 13

Page 14

Page 15