Nails. 10,228 of them, made in Denmark*. Each one driven home with the right pressure to the right depth in the right location, which means the structural frame performs exactly the way it was designed and engineered. We can say this because our walls and floors are manufactured at Brockport Home Systems, one of the world’s most advanced indoor automated assembly plants for home building. Brockport's technologies have been developing in Europe for the past 60 years, first in Scandinavia and more recently in Germany and the UK.
* There are 10,228 nails in a typical 3150 sq. ft. home, (excluding roof trusses and sheathing).
It begins with design
At Brockport, all the systems in the home—structural, electrical, plumbing, heating and ventilation—are fully rendered in 3D to make sure they work together without conflict. The digital renderings become the instructions that direct our precision manufacturing process, governing how materials are fit together and how they’re joined, glued, nailed, stapled, and cut.
We build the floors and walls as panels in a controlled environment, with quality checks at every stage. Our use of automated construction means we can select more durable materials and fabricate larger, more stable panels. As they come off the line, we load the panels onto special flatbed trailers in the order they’ll be needed.
By changing the way roofs are built, we can compress the timelines even further. Using custom flatbed trailers, we’re now able to put a roof together on site at ground level at the same time the walls are being framed - more control, increased safety. At the right time the assembled roof is carefully lowered in place, ready for shingling. As we bring this new technology online, we’ll be able to frame, roof, and seal a house in 2 days, start to finish.
The benefits are enormous. Automated assembly using premium materials leads to greater accuracy, fewer joints, and a more stable building. Achieving a closed-in house in less time means interiors are less likely to get wet, reducing the risk of damage and mold. Integrated design of all domestic systems virtually eliminates on-the-fly troubleshooting by contractors, minimizing deficiencies and repairs. There’s less waste of material—a bonus to the environment. The construction site is cleaner and safer. Installation of flooring and cabinetry is smoother. Delays occur far less frequently. And there’s the biggest benefit of all. A home to be proud of, built to last.