Inside Modular Explores the Role of CFS in Modular Construction

Introduction 

In a recent episode of Inside Modular: The Podcast of Commercial Modular Construction, host John McMullen spoke with Andreas Kilander, Offsite and Modular Manager at FRAMECAD. During their discussion, Andreas shared insights into his journey in modular construction, FRAMECAD’s evolution over the years, and the growing role of cold-formed steel (CFS) also known as light gauge steel (LGS) and steel framing in the industry. Here’s a closer look at their conversation and key takeaways.

Andreas Kilander’s Journey to FRAMECAD 

Originally from Sweden, Andreas moved to Australia 12 years ago to work in manufacturing and mechanical design. His career took a pivotal turn in 2015 when he was asked to develop the concept for a modular construction business in Sydney. This led to his role at Interpod, one of Australia’s largest modular bathroom manufacturers. As a FRAMECAD technology user, Andreas eventually transitioned to the company in 2021 to help clients establish their CFS manufacturing operations. 

What is FRAMECAD? 

FRAMECAD specializes in end-to-end technology solutions for designing and manufacturing cold-formed steel structures. Their system includes design and engineering software, roll-forming equipment, and building components. Andreas used the analogy of a “3D printer for building structures,” enabling precise and efficient production.   

Today, FRAMECAD operates in 120 countries, with over 1,000 active systems producing wall frames, trusses, floor joists, and modular bases. “While many of our clients are in modular construction, our technology is used across a wide range of sectors, including residential, commercial, and industrial construction,” Andreas noted. 

The Evolution of FRAMECAD

Founded in 1987 in New Zealand, FRAMECAD initially provided building systems to the Pacific Islands. In the 1990s, the company began specifying machinery but relied on external manufacturers. Recognizing the need for software integration, FRAMECAD developed its own software and, by 2005, started designing and manufacturing its own machines in its Auckland factory - a practice it continues today. Over the years, FRAMECAD has significantly advanced its building systems, with its software evolving from a design tool to a comprehensive manufacturing suite. 

How the FRAMECAD System Works 

FRAMECAD follows a streamlined design, manufacture and build process: 

• Design: Clients use FRAMECAD software to create and optimize designs, generate CNC codes and prepare digital assembly instructions. 

• Manufacture: The roll-forming machines produce pre-punched steel members with connection points, ensuring precision and ease of assembly. 

• Build: Panels are organized for efficient assembly, with some manufacturers integrating the entire process within their production lines. 
  
  

Advantages of Cold-Formed Steel 

CFS offers numerous benefits over traditional materials: 

• Efficiency: Faster production and streamlined workflows. 

• Durability: Resistant to fire, pests and extreme weather. 

• Precision: Automated processes minimize errors. 

• Reduced Waste: Continuous roll-forming reduces material cut-offs. 

• Storage Efficiency: Steel coils require significantly less space than timber. 

• Supply Chain Control: Manufacturers can produce frames on demand. 

CFS is ideal for low-rise and mid-rise buildings (up to 8 stories), with hybrid methods allowing for taller structures. 

Industry Trends in Steel-Based Modular Construction 

Andreas explained the shift toward cold-formed steel in modular construction continues to gain momentum. Companies that previously assembled CFS manually are now investing in automated systems and more fully steel-based modules are being built, replacing previous hybrid designs with welded structures or concrete bases. Another key trend he mentioned is vertical integration, with developers and builders establishing their own manufacturing capabilities. 

Challenges and FRAMECAD’s Solutions 

Setting up a new CFS manufacturing operation involves challenges beyond design and production, including: 

• Scheduling and resource management 

• Material traceability and compliance 

• Inventory management 

• Project tracking and delivery 

To address these, FRAMECAD developed FRAMECAD NEXA, the first production management platform designed specifically for the CFS industry. This software provides end-to-end visibility, from design to installation. 

Best Practices for Handling CFS 

Andreas shared practical tips for working with CFS: 

• Keep wall sizes manageable for manual handling. 

• Use zoning functions in FRAMECAD software to optimize manufacturing and assembly sequences. 

• Take advantage of pre-punched service holes for plumbing and electrical installations. 

• Display assembly instructions on a large screen for better visibility on the factory floor. 

Future of CFS Modular Construction 

Looking ahead, Andreas expects growth in three key areas: 

• Accessory Dwelling Units (ADUs): Driven by increasing housing demand. 

• Affordable Housing: Governments are investing in faster, cost-effective building solutions. 

• Prefabricated Fit-Outs: Prebuilt drywall and interior elements are becoming more common, with stricter regulations requiring detailed as-built drawings and material traceability. 

FRAMECAD at World of Modular 

FRAMECAD will be exhibiting at MBI’s World of Modular event in Las Vegas in April 2025, where Andreas looks forward to engaging with clients and attending breakout sessions on industry insights. 

What’s Next for FRAMECAD? 

FRAMECAD will continue investing in research and development, with a focus on enhancing its software and expanding FRAMECAD NEXA. Client-driven innovation remains a priority, ensuring that their technology evolves to meet the needs of modular manufacturers worldwide. 

As modular construction continues to evolve, FRAMECAD’s integrated approach to cold-formed steel manufacturing is shaping the industry’s future. With ongoing advancements in automation, software integration and production management, CFS is becoming a dominant material in offsite construction. For those considering modular building solutions, FRAMECAD’s expertise offers a compelling path forward. 

Listen to the full podcast interview here. For further reading visit Myths about Modular Construction, Permanent vs Non-permanent and Prefabrication and Modular Construction. 

To discuss more about LGS modular construction, book a meeting with Andreas Kilander from his calendar below.