While Sears had stolen the spotlight on precut technology, their lesser-known rival, Aladdin Homes, helped usher in prefabrication, but not initially. For many years, Aladdin fought the concept of pre-assembling parts of homes in their factory, asserting that their precut packages took...

As discussed in this issue’s article, “Growth and Accolades for Component Manufacturers,” Carolina Truss Systems (CSS) has been celebrated for its latest expansion plans in Virginia. As announced, CSS is investing at least $5.5 million to establish a new manufacturing facility...

As we start 2025, we have surpassed the 125th year of offsite wall technology, so it seems fitting to return to the beginning and describe its early progression. Surprisingly, this includes the Ready-Frame® technology that is currently being marketed by Builders FirstSource, as well as the...

In 1990, when Dickie Vail traveled from his shuttered Virginia plant to his job interview in Burlington, NC, he didn’t have much going for him. He was 35 and broke, and he was meeting Carroll Shoffner, a 57-year-old mega-millionaire who owned over a dozen highly efficient truss plants....

Handling studs and plates to build walls is easy, but handling oversized sheets of OSB and sheathed wall panels is not. Fortunately, two inventors in the Midwest have lightened the load. Automated Sheathing Saw: Since he began his career at Monet DeSauw 30 years ago, David Ohnesorge has been...

George “Sid” Ketchum, cofounder of the Wood Truss Council of America (WTCA), and an exceptionally generous man, passed away peacefully on November 11, 2024. Sid had a long and distinguished career in the truss business, beginning in 1973 when he took over PDJ Components, a...

During the challenging 1980s, gutsy cousins Larry Rogers and Dickie Vail tackled truss plant ownership. Larry put his savings on the line in 1981 and with an SBA loan began Rogers Manufacturing Co. (RMC), not far from where he had worked in northeast Louisiana. Dickie relied mostly on backing...

Plate markers, single tool bridges, and automated saws were just a few of the enhancements that filtered into wall panel shops at the Millennium. Their adoption was quickened by the consolidation of component manufacturers (CMs) and by the increasing pressure on all CMs by busy builders....

One of the strangest twists of fate in the truss business was initiated by Larry Rogers, and fortunately it boosted his career and that of his replacement, Dickie Vail. Out of this occurrence, both men launched successful startup companies. However, there was also a flood and more than one...

Toll Brothers imported an automated panel line commensurate with their luxurious homes, or so they expected. Perhaps because the European economy was ailing in the early 1990s, Randek from Sweden, like the Makron company from Finland before them, offered Toll an excellent deal. But Randek was an...