By this time next year, Katerra—a technology startup whose end-to-end business model combines prefabrication, architectural, and construction services primarily for multifamily housing—expects to have six manufacturing plants up and running, including its first mass timber factory, a 250,000-sf building under construction on 29 acres in Spokane, Wash.
That plant, when fully operational in early 2019, will be capable of producing about 4.6 million cubic feet of cross-laminated timber annually. The plant’s size is comparable to CLT factories operating in Europe. “We’re going all in on CLT,” says Trevor Schick, who oversees Katerra’s supply chain, lighting, renovation, and commercial rollout activities.
Katerra’s initial success—it booked $1.3 billion in business last year—and its aggressive growth posture have attracted several high-profile investors, most prominently Japan’s SoftBank, from whose $100 billion Vision Fund Katerra recently raised $865 million in its latest round of financing.
SoftBank is steadily investing in tech-oriented companies that are impacting the built environment. In December, it paid $9.3 billion to acquire a 15% stake in Uber Technologies. It owns the robotics manufacturer and research firm Boston Dynamics. Last summer, SoftBank invested $200 million in the indoor farming enterprise Plenty. And it holds a $4.4 billion stake in WeWork, the cosharing office developer.
TechCrunch reported that the venture-capital world fully expects SoftBank to raise another $100 billion for future investments soon.
In-house design team and consortium
The Menlo Park, Calif.-based Katerra is already among the country’s largest GCs. The housing markets it serves include multifamily, senior and student living, and master-planned developments. Katerra’s largest customer is The Wolff Company, a real estate private equity firm that focuses on the multifamily sector, and whose executive chairman Fritz Wolff was one of Katerra’s Co-founders.
“Having a lead customer is important, given the investment we’re making in factories, IT, and so forth,” says Schick.
Katerra currently produces wall panels, roof and floor trusses, cabinets, and countertops from its factory in Phoenix, which began production in early 2017. That facility features Katerra’s Design Showroom, where clients can view a full suite of products and interior design solutions, including fully finished apartment units made entirely from Katerra-supplied products.
Union Bay South in Carson, Calif., designed by Architects Orange, will offer 357 residential units, with four- and five-story wood framed buildings wrapping two separate concrete parking structures. The building, currently under construction, will include 30,000 sf of retail. Katerra is providing construction, management, and materials. Image: Katerra
Last June, Katerra acquired Nystrom Olson, a boutique architectural studio in Spokane. And six months later, it announced the forming of a design consortium whose members include Michael Green of Michael Green Architecture, a leader in mass timber architectural design; Andrea Leers of Boston-based Leers Weinzapfel Associates, which has also designed buildings using mass timber; Ted Flato of Lake|Flato in Texas; and Joe Greco of Lord Aeck Sargent, a full-service architecture and design firm with six offices.
With Green, Katerra is working on the design and construction of the new Hospitality Center in association with the Community Cancer Fund, Ronald McDonald House and Kootenai Health (Walden House) in Coeur d’Alene, Idaho.
Schick tells BD+C that, aside from the CLT plant in Washington, the other facilities Katerra moves into or builds this year will be conventional wood panel and truss factories. Its next mass timber plant is likely to be located in the Southeastern U.S., although Schick didn’t say when construction for that might start.
Leaning toward mass production
Katerra started as a materials supplier, with sourcing offices in Asia and Mexico. But the company soon realized that it needed a “larger scale” to get its cost model right, says Schick. That meant taking more control over the design, production, construction, and logistics of what it sold.
Technology has been the key to that transformation. Before joining Katerra, Schick spent over 15 years in the electronics industry, most recently as senior vice president at Hewlett-Packard involved in global supply chain and quality. One of Katerra’s Co-founders, Michael Marks, had been CEO of an electronics company now called Flex. A third Co-founder, Jim Davidson, founded Silver Lake, a technology investment firm.
Marks is convinced that building construction would benefit greatly from mass production techniques that are common in electronics and automotive manufacturing. Consequently, Katerra uses a kit-of-parts design system that it combines with prefabricated components production and onsite assembly.
The company’s technology platforms include SAP HANA, a market analytics platform that mines data from real estate and construction; a mobile app that connects its workforce in the field; and industrial IoT tools that optimize jobsite activity and track inventory.
Katerra is building its first mass timber factory, a 250,000-sf building in Spokane, Wash., which will be able to produce 4.6 million cubic feet of product annually. Image: Katerra
Schick says the company currently has 12 multifamily projects under way, ranging from 200 to 400 housing units per project. Sometime this year, he says the company plans to enter the hotel construction sector. Katerra also wants to build schools eventually.
As for projects using mass timber, Schick believes that demand among developers, contractors, and cities can only go up. He notes that the International Code Council has a vote scheduled for April to amend the 2021 International Building Code to allow for the use of CLT for buildings up to 18 stories. (Currently, CLT is limited in the U.S. to buildings no higher than six stories.)
In Washington State, ESB Bill 5450, which has passed both chambers of the legislature and is on the governor’s desk to sign, creates a section in the state statute defining qualifying mass timber products. It also directs the State Building Code Council to adopt rules for the use of mass timber in residential and commercial building, consistent with application national and international standards.
Katerra is already doing fire, earthquake, and wind sheer testing of CLT panels that it can make on its 60-foot-long by 12-foot-wide press.
Related Stories
Multifamily Housing | Feb 21, 2023
New multifamily housing and mixed-use buildings in Portland, Ore., must be ready for electric vehicle charging
The Portland, Ore., City Council recently voted unanimously to require all new residential and mixed-use buildings to be ready for electric vehicle charging. The move amends Portland’s zoning laws to require all new multi-dwelling and mixed-use development of five or more units with onsite parking to provide electric vehicle charging infrastructure.
K-12 Schools | Feb 18, 2023
Atlanta suburb opens $85 million serpentine-shaped high school designed by Perkins&Will
In Ellenwood, Ga., a southeast suburb of Atlanta, Perkins and Will has partnered with Clayton County Public Schools and MEJA Construction to create a $85 million secondary school. Morrow High School, which opened in fall 2022, serves more than 2,200 students in Clayton County, a community with students from over 30 countries.
Museums | Feb 17, 2023
First Americans Museum uses design metaphors of natural elements to honor native worldview
First Americans Museum (FAM) in Oklahoma City honors the 39 tribes in Oklahoma today, reflecting their history through design metaphors of nature’s elements of earth, wind, water, and fire. The design concept includes multiple circles suggested by arcs, reflecting the native tradition of a circular worldview that encompasses the cycle of life, the seasons, and the rotation of the earth.
Multifamily Housing | Feb 16, 2023
Coastal Construction Group establishes an attainable multifamily housing division
Coastal Construction Group, one of the largest privately held construction companies in the Southeast, has announced a new division within their multifamily sector that will focus on the need for attainable housing in South Florida.
Senior Living Design | Feb 15, 2023
Passive House affordable senior housing project opens in Boston
Work on Phase Three C of The Anne M. Lynch Homes at Old Colony, a 55-apartment midrise building in Boston that stands out for its use of Passive House design principles, was recently completed. Designed by The Architectural Team (TAT), the four-story structure was informed throughout by Passive House principles and standards.
Contractors | Feb 14, 2023
The average U.S. contractor has nine months worth of construction work in the pipeline
Associated Builders and Contractors reports today that its Construction Backlog Indicator declined 0.2 months to 9.0 in January, according to an ABC member survey conducted Jan. 20 to Feb. 3. The reading is 1.0 month higher than in January 2022.
Contractors | Feb 13, 2023
Webcor names Matt Rossie CEO
Matt Rossie, the President and Chief Operating Officer at San Francisco-based general contractor Webcor, assumed the responsibilities of Chief Executive Officer effective January 1.
Office Buildings | Feb 12, 2023
Smyrna Ready Mix’s new office HQ mimics the patterns in the company’s onsite stone quarry
Designed by EOA Architects to showcase various concrete processes and applications, Smyrna Ready Mix's new office headquarters features vertical layering that mimics the patterns in the company’s stone quarry, located on the opposite end of the campus site. The building’s glass and concrete bands are meant to mirror the quarry’s natural contours and striations.
Multifamily Housing | Feb 10, 2023
Dallas to get a 19-story, 351-unit residential high-rise
In Dallas, work has begun on a new multifamily high-rise called The Oliver. The 19-story, 351-unit apartment building will be located within The Central, a 27-acre mixed-use development near the Knox/Henderson neighborhood north of downtown Dallas.
Sustainability | Feb 9, 2023
New guide for planning, designing, and operating onsite water reuse systems
The Pacific Institute, a global nonpartisan water think tank, has released guidance for developers to plan, design, and operate onsite water reuse systems. The Guide for Developing Onsite Water Systems to Support Regional Water Resilience advances circular, localized approaches to managing water that reduce a site’s water footprint, improve its resilience to water shortage or other disruptions, and provide benefits for local communities and regional water systems.