The estimated daily output of the production line is between 600 and 1000 m² of living space.

This figure is influenced by a variety of factors and may vary depending on operational conditions and project-specific requirements.

Key factors affecting production capacity include:

• The level of automation selected during equipment configuration. Higher levels of automation typically lead to greater speed and consistency of output;
• The qualification and experience of personnel, including both production workers and technical staff;
• The complexity of architectural and layout solutions. Standardized, repeatable designs can be produced more quickly than unique or customized configurations;
• The type of production flow: in serial production, where identical modules or panels are manufactured in sequence, output is at its highest. In single-unit or small-batch production, time is required for reconfiguration, coordination, and preparation, which reduces daily output;
• The logistics setup on site: efficient material supply, uninterrupted dispatch of finished products, and well-organized use of storage and auxiliary areas all contribute to higher productivity;
• The scope of finishing work performed at the factory. If a significant portion of interior work (electrical, plumbing, tiling, painting, etc.) is carried out in-house, this may reduce daily capacity — especially during the initial phase of process adoption.

As a result, the stated capacity range reflects a realistic and achievable output, assuming proper production management, skilled personnel, and efficient site logistics.

The automation level of the production line can reach up to 90%, depending on the equipment configuration, selected technological layout, project budget, and the production priorities set by the client.

Modern systems allow for automation of most key stages of the production process, including:

• raw material preparation, dosing, and feeding,
• mixing and transport of the mix,
• internal movement of semi-finished elements between zones,
• packaging of finished products,
• and continuous automated monitoring and control of all major operations.

It is especially important to highlight that all critical technological units that affect the stability and quality of the final product are fully automated.

This includes equipment responsible for precise dosing, uniformity of the mix, maintaining correct processing parameters, consistent geometry of the products, and stable packaging.

Such automation ensures high repeatability, minimal defect rates, consistent product quality, and real-time control over all critical variables.

Certain areas — particularly those related to finishing work, visual quality checks, custom adjustments, and equipment maintenance — still require the involvement of skilled personnel.

The actual automation level depends on:

• the nature and scale of production,
• the need for flexibility and frequent reconfiguration,
• and whether finishing operations are included as part of the in-factory process.

The maximum achievable automation level is determined individually — based on the technical goals of the project, the available investment, and the desired level of operational independence.

The recommended production facility area required for the installation and efficient operation of the equipment is approximately 13,000 m².

The exact area requirements will be determined upon finalizing all project parameters. Several factors may influence the final calculation, including:

• Local regulatory requirements, such as occupational safety standards, fire protection regulations, and sanitary norms;
• Structural characteristics of the building, which depend on the selected equipment capacity, the level of automation, and the type of internal logistics (e.g., use of overhead cranes, conveyor systems, or warehouse equipment). Key parameters include ceiling height, number and placement of load-bearing columns, floor load capacity, availability of natural or artificial lighting, ventilation, and technological openings such as gates, ducts for utilities, and service channels;
• The presence and layout of auxiliary spaces required to support daily operations. These may include:
  • changing rooms and sanitary facilities for workers,
  • dining or break areas,
  • offices for administrative and technical staff (e.g., shift supervisors),
  • workshops or rooms for technical maintenance teams (e.g., electricians, mechanics),
  • spare parts and tool storage,
  • staff rest areas or utility rooms.

It is also important to consider whether these auxiliary spaces will be integrated into the main production building or located separately on the adjacent premises, as this will significantly impact the total area required.

Auxiliary Areas for Raw Material Storage

The size of auxiliary areas, such as the storage zone or building for raw materials, requires additional coordination and planning. The optimal storage area depends on several factors, including the volume of stock to be maintained, the distance to suppliers, delivery frequency, and supplier reliability.

For example, if suppliers are located far from the facility or have long lead times, it may be necessary to maintain a larger inventory. Conversely, if reliable, just-in-time delivery is guaranteed, a smaller storage area may be sufficient. Other considerations may include local logistics infrastructure and on-site handling capabilities.

Finished Product Storage Area

The finished product storage area, often referred to as a dispatch yard or holding area, is used for the temporary placement of panels and modules before they are delivered to the construction site.

The required size of this area depends on several factors, including the logistics strategy — whether the products will be shipped directly from the production line or stored on-site for a certain period.

Additional influencing factors may include the delivery schedule to construction sites, the available transportation fleet, the frequency of shipments, on-site loading efficiency, and the potential need for staging multiple orders simultaneously.

Proper planning of this area ensures smooth dispatch operations and helps prevent bottlenecks in production flow.

Worker Welfare and Support Facilities

A dedicated area should be allocated for worker welfare, including changing rooms, dining spaces, restrooms, and other necessary amenities.

The size and configuration of this zone depend on local labor regulations and health and safety standards, which may stipulate minimum space per worker, hygiene requirements, and facilities for personal storage, rest, and sanitation.

Additional factors include the total number of shifts, the peak workforce size, gender-specific accommodation needs, and whether the facility will operate year-round or seasonally.

The estimated installation period for the production line is 30 to 45 calendar days from the moment the site is ready and the equipment has arrived on location.

The actual timeline may vary depending on several key factors, including:

• The readiness of the production facility, such as foundations for equipment, availability of utilities (electricity, water, ventilation), and general infrastructure;
• The complexity and scope of the equipment package — more advanced or large-scale setups typically require longer installation and commissioning times;
• The level of automation and the number of integrated control systems;
• On-site logistics, including crane access, storage space, reliable power and water supply;
• The coordination between the installation team, the client, and third-party contractors responsible for construction and utility connections;
• Weather conditions, especially if parts of the work must be carried out in open or partially enclosed areas.

The stated timeframe includes:

• mechanical assembly and interconnection of system components,
• connection to utility networks,
• commissioning, calibration,
• and initial test production runs.

If the site is well-prepared in advance, installation can be completed closer to the lower end of the range (around 30 days). If the facility requires additional adaptations or if there are delays from third parties, the schedule may extend toward 45 days or slightly beyond.

The estimated number of production personnel required per shift is approximately 50 to 70 people.

The actual staffing needs will depend on several factors. One of the key aspects is the qualification level of the workers and the skills they acquire throughout the work process.

During the initial phase of launching production and fine-tuning all technological processes, a larger workforce may be required. However, as experience grows and processes are optimized, the number of operators can generally be reduced.

Another significant factor influencing workforce size is the level of automation and the specific configuration of the selected equipment. The higher the degree of automation and the more integrated the production processes, the lower the need for manual labor and support staff.

The complexity of the project and its specific technical requirements also play an important role. Special attention should be given to panel finishing and especially to volumetric modules.

The number of workers needed for operations such as window and door installation, interior finishing, painting, plumbing, and tiling in sanitary areas depends on both the scope of work performed at the factory and the qualification level of the personnel.

If the project includes extensive finishing work at the production site, it may be necessary to engage skilled specialists or provide additional training.

Depending on the project delivery model, it is also possible to involve temporary workers or subcontracted teams for specific tasks.

It is important to emphasize that even with a high level of automation, no production line operates entirely without human involvement. Automated systems still require monitoring, adjustments, quality control, and regular maintenance. In addition, certain tasks — particularly those related to finishing and material handling — may still involve manual labor, depending on the design and requirements of the project.

At the same time, it is worth noting that labor costs represent a relatively small portion of the total cost per square meter, especially when the production line is operating at high capacity.

Even if the actual number of workers slightly exceeds initial estimates, this will have minimal impact on the final unit cost due to the overall efficiency and productivity of the system.

The total installed power capacity required for the production line is estimated at approximately 300–400 kW.

This is a preliminary figure and is subject to adjustment as the project specifications are finalized.

The actual power demand will depend on the selected equipment configuration, the level of automation, the capacity of individual processing units, and the design of internal logistics systems — such as the use of conveyor belts, overhead cranes, and automated control systems.

The final power requirement will be determined after all technical specifications, layout arrangements, and infrastructure needs are confirmed.

It is also essential to take into account additional power loads, including:

• lighting,
• ventilation,
• air conditioning systems (if required),
• pumping and water treatment units,
• compressed air systems,
• and other facility-wide infrastructure components.

A comprehensive energy assessment will be conducted during the detailed engineering phase, ensuring that all project and operational conditions are fully considered.

The production process requires approximately 55 tons of water per day.

This figure may vary depending on the complexity of the project — such as the thickness of exterior walls, the number and thickness of internal partitions, the quantity and size of window and door openings, and other structural parameters. The main water demand is associated with foam concrete production, while a smaller portion is used for equipment cleaning.

Water consumption for cleaning depends largely on the continuity of the production process: frequent starts and stops may require more frequent washing and rinsing cycles. Therefore, it is essential to ensure a stable and sufficient water supply, and to consider options for additional water delivery, if needed.

The estimated daily cement consumption is around 120 tons, but this figure can vary significantly depending on a range of factors.

Key variables influencing cement usage include:

• Actual production volume – the higher the daily output, the greater the total cement consumption;
• Complexity of architectural and structural design, including wall thickness, number and configuration of partitions, monolithic inserts, and integrated utility elements;
• Cement quality – fresh, high-grade cement with strong binding activity allows for reduced usage without compromising strength. In contrast, aged or improperly stored cement with reduced reactivity may require higher dosages;
• Concrete mix formulation – different strength classes, density, and durability requirements (e.g., frost resistance) demand varying cement-to-aggregate ratios;
• Extent of in-factory finishing and casting work – if internal elements such as partitions, floors, or sanitary zones are cast directly at the plant, additional cement will be required;
• Level of process control and dosing accuracy – well-calibrated dosing systems help minimize material overuse and ensure consistent quality;
• Seasonal conditions – adjustments to the mix may be needed during hot, cold, or humid weather, which can impact daily cement consumption.

Therefore, the figure of 120 tons per day reflects an average estimate based on full-capacity operation under standard conditions, but actual consumption may be lower or higher depending on project design, raw material quality, and operational factors.

The structural framework in LGSF systems (Light Gauge Steel Framing) is made from galvanized steel coils, known for their high strength, corrosion resistance, and dimensional stability.

The most commonly used material is Zn275-coated steel, with a strength grade of S350GD, in accordance with the international standard EN 10346:

• Zn275 indicates a zinc coating mass of 275 g/m² (total for both sides),
• S350GD signifies a minimum yield strength of 350 MPa, making the steel suitable for structural load-bearing applications.

The steel is supplied in coil form and then slit into strips of the required width, followed by roll-forming into LGSF profiles.

In many cases, steel suppliers offer coil slitting as an additional service, which simplifies logistics and speeds up implementation.

However, upon request, our company can also supply coil slitting equipment as part of the production line package.

Depending on project requirements, structural loads, and engineering design, the thickness of the steel may vary, typically within the range of 0.8 to 1.5 mm.

Additional highlights:

• The steel complies with European and international standards (EN 10346 / ASTM A653 / GOST 14918),
• The zinc coating provides long-term corrosion protection across various climate conditions,
• Coils can be supplied in different widths, depending on the profile configuration and project needs.

The use of cold-formed galvanized profiles ensures a lightweight structural system, high precision assembly, fast installation, and strong resistance to environmental impacts, while keeping maintenance costs to a minimum.

Foam concrete, standard grade D200 (density: approx. 200 kg/m³)

As a rule, the panels and modules are filled with foam concrete of standard D200 density, which offers excellent thermal and acoustic insulation, dimensional stability, and a lightweight structure while maintaining sufficient strength and form integrity.

When using a high-quality protein-based foaming agent along with specially developed chemical additives, it is possible to reduce the material density without compromising its key performance characteristics. Such formulations are used in exceptional cases, for example, when minimizing structural weight is a critical design requirement.

All essential components — foaming agent and chemical additives — can be supplied by our company as part of the equipment package. This ensures consistent and reliable quality, full compatibility with the production line, and repeatable results.

These components have been developed by our team based on global best practices and advanced technological insights, specifically tailored for non-autoclaved foam concrete systems.

Upon request, the technology can be adapted to meet the specific needs of the project, including adjustments in material density, composition, and consistency.

In addition to equipment and materials supply, we provide training for the client’s technologists and carry out on-site calibration and process setup on the installed production line to ensure a stable and efficient launch of operations.