IMPRESA HOUSE: PANELISATION IN EVOLUTION

Established in October 2016, Impresa House has carved a respectable niche for itself in the local construction space, built on an ethos of leveraging the modern panelised technologies that have long led the way in the construction sector in Europe.

Designing in Australia to meet local standards, the company uses leading edge European technology such as CNC (Computer Numerical Control) equipment from German giant Weinmann. Manufactured offsite at Impresa’s own plant to increase construction efficiencies, the resulting panelised building system is highly efficient and sustainable, as well as adaptable to a wide range of processing options, enabling a wide range of end-uses.

Impresa House CEO Sean Morley believes panelised systems represent the forefront of what the pre-fab industry can offer the construction sector. “Our products offer a very high level of quality in terms of structural, thermal and acoustic properties and are designed specifically for the harsh and demanding Australian climate.”

“There are some companies working with a volumetric approach but our experience shows that panelisation is one of the most efficient and cost effective ways to deliver buildings. We use high tech machinery to create solutions that are not only efficient to build but, because of the thermal insulation techniques we use, also create energy efficient homes that are healthier and more cost effective to live in and run than conventionally built homes.”

“There are some companies working with a volumetric approach but our experience shows that panelisation is one of the most efficient and cost effective ways to deliver buildings. We use high tech machinery to create solutions that are not only efficient to build but, because of the thermal insulation techniques we use, also create energy efficient homes that are healthier and more cost effective to live in and run than conventionally built homes.” Sean Morley, CEO – Impresa House.

A significant part of the company’s commitment to its output lies in continually improving its processes, he adds. Hailing from a distribution and logistics background, Morley says his minimal prior exposure to the construction sector has in fact proven an advantage.

“I think one of the benefits I’ve brought to this business is a different way of seeing things. For example if you’re working with traditional construction professionals, their approach is to see significant delays as commonplace; but my approach is to continually ask why. We have a lean manufacturing system in place at Impresa which is all about optimising every step of the process.”

Technology including BIM plays an important role, he says. Impresa House’s manufacturing is also almost totally automated. “We employ around 18 to 20 people who operate different zones at our plant, with around three people working per zone.”

Equipped with state-of-the-art Weinmann machinery, Impresa’s 16,000 square metre plant in Derrimut on the outskirts of Melbourne operates two shifts a day, with an output of 350-500 homes per year depending on the size and design of the constructions.

“Our main process is around making panelised walls. This is highly automated, with cutting completed by machine; framing follows, with OSB bracing and fixing applied manually. External cladding can also be adding inside the plant if required.”

Impresa House has designed its own software that works in parallel with the machining process and is able to track each panel through their system and calculate the time it takes to produce each one.

“At full capacity we’re using 20 workers. Our aim is to produce 150 square metres a shift. Currently we’re sitting at around 110 square metres.”

As well as wall panels, the plant also produces floor and roof cassettes using a more manual process.

Impresa House also recently added a window production capability to the plant, where a range of windows are now produced, including high spec models such as European style tilt and turn windows.

“The ability to make our own windows has been really critical to our success, giving us real control over the process. Our windows are typically aluminium framed, double glazed. Essentially they’re a very high quality window at a very competitive price.”

While working on continual improvement in terms of lean production output, Morley says the company is also constantly striving for improvement in other areas.

“For example we’re currently working on creating our own system of transport using custom designed trucks. We’ve used A-frame and vertical stacking trucks but we’re now looking at an entirely new system.”

Aside from clearing its own self-imposed hurdles, the company faces wider industry challenges at a sectoral level; however Morley believes collaboration between industry players including Impresa House will create a unified voice for the nascent industry.

“The ability to make our own windows has been really critical to our success, giving us real control over the process. Our windows are typically aluminium framed, double glazed. Essentially they’re a very high quality window at a very competitive price.” Sean Morley, CEO – Impresa House.

“As just one example, certification is a huge issue. Traditionally full certification has to happen on site, so a new way of thinking about certification to deal with products that are largely created offsite has to be found. Another area where challenges exist is education. We believe the emergence of new dedicated courses, like the recently added Panelised Building Construction Skill Set course at Chisholm Tafe, is really helping create the prefab subcontractors of tomorrow, but more needs to be done in this space. Another area is of course finance; there’s still a long way to go in terms of providing clear pathways for lending to developers and homeowners in the prefab space.”

“Finally it’s also very much about educating consumers and homeowners. For our part, Impresa House’s aim is to produce a better quality house at an affordable price. Our system produces a higher quality build with greater precision, meaning greater sustainability and eco-friendly elements. The result is a more energy efficient house that is designed the way the client or end-user wants it, essentially a quality home that is greener cleaner and cheaper to run.”■