Alexander Construction

What did this project set out to measure?

This study documents frame installation performance during Alexander Construction’s first build using the Truss House portal frame system in Napier, Hawkes Bay. The purpose was to capture real-world metrics, identify learnings, and establish a worst-case baseline to inform future builds. All findings are supported by timestamped photographic evidence captured on site.

What were the key results?

Active framing time (lift → plumb → brace): 136.25 minutes (2 hours 16 minutes) for all 31 frames across 28 lifts.

Total elapsed time (first frame lifted → last frame installed): 305 minutes (5 hours 5 minutes). This broader window includes natural pauses, crane repositioning, site coordination, and learning moments typical of a first-time system.

These results demonstrate high installation efficiency even on a first build, strong repeatability once the sequence was established, and a clear distinction between active labour time and overall site time — critical for realistic programme planning.

How was the data captured?

The study measured frame installation activities only:

• Lifting portal frames from the stack using a HIAB crane
• Placing the portal on the foundation/bearers in the correct position
• Plumbing, levelling, fixing, and temporary bracing

Excluded: installation of strongbacks, interior wall nogging, subfloor installation, follow-on trades or fit-out works.

Data capture used timestamped photos at each stage (lift, set in place, plumbed and braced). Durations were calculated directly from photo metadata — no retrospective estimates applied.

Context and clarifications

• This phase occurred over two days
• This was a first build, with learning intentionally prioritised
• These results should be considered a worst-case timing baseline
• No optimisation strategies had yet been implemented

Nothing observed would slow future builds. All learnings point toward further time reductions.

What did the team learn?

Several practical improvements were identified for future builds, spanning preconstruction planning, crane capacity, crew sizing, and pre-installed components:

• A preconstruction meeting between fabricator (PFTL), site team, and client to agree delivery and portal-stacking methodology would reduce on-site handling and repositioning
• A larger, more powerful HIAB would reduce handling time and improve control of larger frames
• Comparison between three and four people on site showed minimal speed difference — the system scales well with smaller crews
• Pre-installed cleats on bearers significantly improved efficiency; engineered brackets sent ahead of delivery would reduce on-site decision-making further

On-site collaboration

On the second day, Pohutukawa Frame and Truss was represented on site by Myles Whitcher, who confirmed frames were received as expected and identified additional ways to optimise packaging, sequencing, and on-site usability for future deliveries. This direct loop between fabrication and installation is a key strength of the Truss House system.

Overall assessment

Frame installation was fast, controlled, and repeatable. On-site complexity was reduced. Learning outcomes were clear and actionable. No issues were identified that would inhibit scale or repeat use. With lessons learnt applied, future builds are expected to be faster, smoother, and even more predictable.

Closing note

It has been a genuine pleasure working alongside Alexander Construction on the first phase of the first build. The openness of the team on site, combined with a willingness to test, learn, and refine, created a strong foundation for success. This study represents the starting point, not the ceiling, of what this partnership can achieve.

Pam Aitken Impact Lead at Truss House