Manufacturing Process

The structural framework of all Pacific Star Homes is manufactured using the most modern steel rollforming equipment from the U.S.A., which is controlled by very robust, accurate, and highly detailed software.

1. Step One: Design and Engineering

Working with our team of structural and design engineers in California USA, clients provide basic floor plan and elevation designs to for our initial review.  We then engineer a panelized design of our clients’ homes in a computer file that is then sent to China via Internet.

2. Step Two: Steel Roll Forming

The factory in China receives the computer-generated files for each home from our offices in California, files which are then downloaded into the control systems for the steel roll forming machines.  Using steel coils from 20 to 14 gauge (30 to 68 mil thickness), our electrically driven rollformers then produce specialized “C”-shaped studs that form the basis of our steel framed buildings.  The dimensions and shape of the steel studs (and joists) are tightly controlled by regular quality checks throughout the production process, in accordance with standards mandated by the International Code Council (ICC).  Our two regular steel shapes are 3-1/2” studs and 12” joists; each profile is produced on a separate line of machinery.  The steel studs are pre-punched and cut precisely to the exact length needed for the home, ensuring that there is virtually no waste of steel.

3. Step Three: Frame Assembly

When the steel studs leave the rollformers, they are already pre-cut to exact length and pre-punched for assembly fasteners, as well as for wiring and plumbing.  These studs form the “skeleton” of our homes.  Teams of 4-8 men then assemble these pieces into wall panel frames on flat, square tables, using power and air tools.  Each wall panel is assembled according to individualized diagrams that are created by the design software; these diagrams move with the panel through its entire assembly process.  Once each frame is assembled, it is loaded onto a specialized cart that will carry the panel through the rest of the production steps.  At this stage, each panel is also affixed with a Radio-frequency Identification (RFID) tag, which ensures that all wall panels go to their intended destination.

4. Step Five: Exterior wall assembly

Next, plywood (or OSB) exterior sheathing is screwed to the exterior side of the wall frame over a waterproof barrier, using small power or air tools.  This sheathing keeps the wall perfectly square throughout the rest of the assembly process.  At this stage, a 1” layer of rigid foam insulation may be applied to the sheathing, depending on the insulation needs where the home is to be built.

5. Step Four: Wiring and plumbing

Wiring and plumbing are installed in the wall panel according to diagrams provided by the engineering design files.  Holes are pre-punched, so there is no heavy tool use involved in this step.

6. Step Six: Insulation

Our standard insulation is a soy-based, spray-on, open-cell expanding foam that fills all cavities inside the wall panel.  Blown-in cellulous or fiberglass batting insulation options are also available.

7. Step Seven: Interior wall assembly

Magnesium Oxide board (an environmentally friendly drywall material that is both water-resistant, hypoallergenic, and carries no negative ion charge) is installed by screwing pre-cut sheets onto the steel frame, using small power or air tools.  We have the ability to order very long sheets of this product, which reduces or eliminates seams and joints.

8. Step Eight: Windows, Doors, and Finishes

Windows and Doors are manually installed using complete products ordered from local suppliers.  Wallpaper can even be applied in the factory, if that is the choice of the homebuyer.

9. Step Nine: Floor and Roof Panels

Floor and Roof panels are produced the same way as wall panels, with a special 12” joist profile is used for the framing instead of the 3.5” joist profile used in the wall panels.  Floor and roof panels are then sheathed in a waterproof barrier and plywood or OSB.  Floor and roof panels are also wired, plumbed, and insulated at the factory, in accordance with the design documents.

11. Modularization

In some cases, multiple wall and floor panels will be pre-assembled into components that can be shipped independently.  In these cases, the assembly of these panels will require use of power tools and some heavy lifting equipment.  Final installation of finished items, such as cabinets and decorations, will be performed with power and air tools.  When the finished module arrives on site, it is simply lifted into place with a crane, fastened to the foundation, then wired and plumbed as necessary.  The cost savings and quality control are clear.

12. Loading and transportation

Completed panels are loaded into standard 20’ and 40’ high-cube containers through manual and mechanical means.  Containers are loaded to port by truck or by rail, and then shipped by vessel to USA.

13. Installation

A concrete foundation is prepared at the installation site prior to delivery of the home.  The preparation of all foundations is extremely critical to a satisfactory building, so extra time, money, and attention to detail are spent to ensure that foundations are built within minimal allowable tolerances for deviation.  In most cases, a perimeter foundation forms the support for the floor panels, which are laid down first.  The wall panels are then fastened to the floor, and connected into each other for plumbing and wiring.  The roof trusses are then laid into position and exterior roofing is installed.  Once the structure is stood, all other finishing elements are installed with pre-cut materials, which are shipped in coordination with the panels.

14. Smart Home

Smart Home components are installed into the home on site by our electricians.