Cleantech concrete cuts construction times

Ecolite walls being put into place.

In an effort to reduce waste and cut down on construction time, Ecolite Concrete has combined conventional steel framing with modern lightweight cellular technology to produce concrete walls offsite.

The San Diego company, with its proprietary modeling software, EcoCad, models project plans while the foundation is being laid at the job site. The plans are entered into an enterprise resource planning system that then produces a shop drawing of each wall panel. Once approved, the drawing is transformed into cold-form steel framing members that are snapped into place, connected with screws and outfitted with a high-performance steel lath for strength. Depending on design requirements, the panels are then outfitted with electrical outlets or cross bracing as needed.

Concrete is then poured on the steel frames which are cured on tilt beds that enable easy removal of the panels. Cranes and forklifts take care of the rest at the job site.

The automated steel system is the first of its kind in the United States and is expected to enable the company to double capacity from 2 million to 4 million square feet to 3 million to 6 million square feet of walls. Fabricated at manufacturing plants owned by distributors that license Ecolite’s technology, the walls require minimum maintenance, according to the company.

The wall panels contain no volatile organic compounds and are comprised of 50 percent recycled material, according to Ecolite. The company claims its wall systems have the potential to help builders obtain credits in four categories in the Leadership in Energy and Environmental Design (LEED) ratings system.