In our smart factory, H-shaped steel components weighing 30 tons are undergoing final quality inspection through automated production lines. These "steel building blocks" will be transported to a new energy vehicle battery factory site 500 kilometers away within 48 hours. As a leader in the prefabrication of domestic steel structures, we have solved the industry pain points of "long construction period, high cost, and high quality fluctuations" in traditional factory construction with a full industry chain prefabrication model of "standardized design, factory-based production, and modular assembly." The Ruifute New Energy Project it undertook, created a record of "completing the main construction of a 150,000 square meter factory building in 90 days", which is 60% faster than traditional concrete structures and 23% cheaper.
Prefabrication: Reconstructing the time rules of factory construction
- A process revolution from "cast-in-place" to "factory-intelligent manufacturing"
In factory construction, "time is money". In traditional methods, on-site construction is often delayed due to weather, labor, and other factors, resulting in delayed production and capital backlog. XTD Steel Structure's prefabricated structure has revolutionized this problem. It uses modular design to complete the prefabrication of standardized steel structure components through automated assembly lines in the factory, and then assembles them on site in a "building blocks" style, which greatly shortens the construction period.
Our prefabricated structure system first introduces revolutionary innovation from the design end. For example, in a project for a certain automobile manufacturing plant in Jiangsu last year, the BIM system optimized the design plan in just one week, compressing the original 12-month construction period to 6 months. More importantly, intelligent manufacturing is fully adopted in the production process: the factory is equipped with an automated welding robot production line and high-power CNC flame, plasma, and laser precision cutting machines, while the accuracy can still be controlled at the millimeter level. This new manufacturing method is 5 times more efficient than traditional manual welding.
- Modular design realizes an efficiency revolution
The key to modular prefabrication is "standardized integration", which decomposes the factory into standard modules, each of which integrates the steel structure frame, roof system, wall enclosure, and pipeline interface. We have established a comprehensive component library, covering all parts from steel beams, steel columns, to fences. The transportation of modular steel components is very convenient. They are generally packed and loaded as a set, so it only takes a short time to arrive at the site. During the installation process, workers will use high-strength bolts for quick connection to avoid a lot of on-site welding, which can save a lot of man-hours.
The entire process achieves process reengineering by moving the most complex and time-consuming construction links (such as structural assembly, enclosure installation, and pipeline pre-buried) to a factory with a controlled environment. The work on site is therefore greatly simplified, focusing on the hoisting and positioning of the modules and the tightening of bolts. This model of deep factory integration and efficient on-site assembly constitutes an efficiency revolution in modular prefabrication, with standardization, factoryization, and assembly at its core. It not only greatly shortens the overall construction period and improves the controllability of construction quality, but also significantly reduces the intensity of on-site operations and the impact on the surrounding environment. In essence, modularization is like assembling high-quality "building blocks" in advance in the factory, and only needs to be quickly combined and connected when arriving at the construction site, which completely changes the traditional linear construction model.
Built to last: steel's inherent century-long performance
- Material revolution consolidates the structural foundation
Factory construction is not a "one-time investment" but an investment in a century-old foundation. Traditional factories often have short lifespans and high maintenance costs due to material degradation and design defects. The prefabricated structure revolution uses steel as its "backbone" and ensures its durability through advanced technology. Steel itself has high strength and corrosion resistance. XTD Steel Structure further uses high-performance alloy steel and cooperates with precision manufacturing technology to give prefabricated components advantages such as ultra-long lifespan and earthquake and explosion resistance.
- Precision manufacturing ensures a century of accuracy
The core advantage of factory prefabrication lies in the quality control that can be controlled throughout the process: each steel component must undergo 12 quality inspection processes before leaving the factory, including 3D laser scanning (accuracy ±0.3mm), ultrasonic flaw detection (defect recognition rate 99.8%), and paint film thickness detection (error ±5μm). The "millimeter-level precision revolution" begins in the factory. The modular core of the steel structure plant lies in its ultimate pursuit of precision manufacturing and system integration. Through the standardized process of deep prefabrication, the overall settlement stability and structural deformation control of the plant have reached an unprecedented level, far superior to traditional concrete frames that rely on on-site operations. This excellent structural integrity is the fundamental guarantee for supporting the rigid demand for ultra-stable production environment in cutting-edge fields such as semiconductor lithography, precision instrument research and development, and spacecraft assembly.
Cost-effectiveness reconstruction: value creation throughout the life cycle
Cost is a key consideration in factory construction. Traditional methods rely on manual labor and waste materials, resulting in high costs, but XTD Steel Structure's prefabricated structure revolution has achieved amazing cost advantages through scale and lean operations. This benefit is not a simple "price reduction", but a systematic value optimization: costs are reduced by 30-40%, while improving comprehensive performance, thereby reconstructing the "economic dimension" in productivity.
- Short-term costs: the double bonus of speed and efficiency
Prefabricated construction achieves significant cost efficiency through the time-cost divergence effect: in the Zhenze smart factory project, the production efficiency of prefabricated components is 5 times higher than that of traditional manual processing, and the production cost per ton of components is reduced by 18%; the on-site construction period is shortened by 40%, directly reducing explicit costs such as labor and machinery rental by 22%, and avoiding hidden losses caused by delays in construction period (such as equipment idle fees, delayed production capacity benefits, etc.).
- Long-term value: green cycle and intelligent operation, and maintenance
The steel recycling economy system enables a 95% steel recycling rate when the factory is demolished, which is an overwhelming advantage over the 8% recycling rate of concrete structures. Taking a 100,000 square meter factory as an example, the steel structure solution can reduce construction waste by 12,000 tons, which is equivalent to reducing the landfill volume of three standard swimming pools.
Technical breakthrough: solving three core problems of prefabricated steel structures
- Node connection: from "welding dependency" to "quick assembly"
"Rapid assembly" is not just a construction method; it represents an efficient, reliable, and future-oriented construction philosophy. When we replace the complicated on-site manual work with modular precision factory manufacturing, and replace the fiery hammering of welds with the precise bite of bolts, the rise of "rapid assembly" becomes clearer, more efficient, and more stable. In a medical device smart factory project, the installation of 2,000 nodes was completed in only 15 days, which is 25 days shorter than the traditional process, and avoids the safety risks caused by high-altitude welding.
- Fire protection and thermal insulation: from "single material" to "complex function"
The fire resistance limit is increased from 1.5 hours of traditional materials to 3 hours, while the thermal conductivity is as low as 0.013W/(m・K), which is 30% more energy-efficient than rock wool boards. In a lithium battery production base, this material not only meets the fire protection requirements of Class C workshops, but also reduces the energy consumption of workshop air conditioning by 25%, saving a lot of electricity costs every day.
- Industry revelation: from "builder" to "value definer"
Prefabricated steel structure is redefining the value coordinates of factory construction - it is not only an innovation in the way of construction, but also a revolution in the organizational form of productivity. When the hard texture of steel is combined with the flexible production of intelligent manufacturing, and when the green concept is integrated into every weld, XTD Steel Structure is writing not only the speed record of factory construction, but also the footnote of the era of China's manufacturing industry moving towards high-end development. In the construction services in countries along the "Belt and Road", our prefabrication solution speeds up by more than 50% compared with the local traditional construction method, becoming a new business card for China's infrastructure technology exports.
Are you ready to complete your factory construction with XTD Steel Structure?
As the industry leader, we always adhere to quality and innovation. Choosing XTD Steel Structure means choosing a new way of building prefabricated factories that is efficient, durable, and economical. From large domestic manufacturing bases to key overseas projects, we are everywhere, using our strength to build a solid foundation for every building.
With more than 20 years of deep technical accumulation, we always provide customers with efficient, high-quality, and environmentally friendly factory construction solutions with the full industry chain prefabrication model of "standardized design, factory-based production, and modular assembly". Contact us and work together to create a brilliant future for industrial buildings.
