Innovation

Blue Valley Building’s innovation in their main SDG 9, Industry, Innovation, and Infrastructure, is creating new ways in which polymers can be used within construction throughout the whole building process. The primary way in which Blue Valley is doing this is by creating plastic boards that are exceptionally durable and provide excellent insulation. Within the construction industry, innovation is not prioritized very highly. Many methods that were successful 50 years ago in the construction industry are still being used, regardless of their environmental effects. Typically, concrete is heavily used in construction as it is relatively inexpensive and durable, even though it is terrible for the environment. Considering concrete is a non-regenerative product, emitting lots of dangerous chemicals into the air during manufacturing. Blue Valley offers a material that is cheaper than concrete, lasts longer, and provides exceptional insulation; while being 100% recyclable.

David explaining the construction process inside their manufacturing facility

Inspiration

The management team at Blue Valley has decades of experience in the automotive industry and was shocked by the poor productivity and lack of quality control in residential construction. In 2019 the team set out to develop sustainable construction products that would reduce waste and greatly improve productivity. David stated, “I first got into it (polymer engineering) with initially bio-polymers with a perspective of recycling.” The opportunity to develop a recyclable product with lower global warming potential than existing construction materials was very appealing. David also stated that “the recycling program is a disappointment,” adding that the material they use is fully recyclable but is concerned with how much of it is recycled. Sustainability and efficiency for David have always been “the most enjoyable part of the job.”

The other innovation that Blue Valley has been working with is their in-house manufacturing, inspired by all the company originals. As we were interviewing David- we were introduced to Giorgio, a company original whose background is in commercial construction. David stated that working with Giorgio is valuable for the company as commercial construction is much more efficient than residential construction. Having different people involved in the Blue Valley operation allowed all employees to produce a significantly more efficient building process and become more sustainable.

Overall impact

Blue Valley is focused on disrupting an industry dominated by outdated methods by using lean manufacturing principles, off-site manufacturing, and implementing in-process quality controls and advanced materials. Conventional materials, such as the production and use of concrete, are particularly damaging to the environment, making up between 4-8% of global greenhouse gas emissions. Blue Valley is reducing our carbon footprint with each new installation. Prefabricated construction also allows the company to spend as little time as possible on-site, significantly lowering transportation and installation costs.

Short-term impacts include reduced energy bills and more efficient heating and cooling, while long-term is much broader in scale, reducing the total load put on the energy grid. The impact is scalable as more houses are fitted with this insulation, the less energy is needed. With advancements in efficiency, a slight change can significantly impact over time, with something as simple as insulation having great effects.

These methods and materials lead to lower energy costs for the end user and installation costs while reducing carbon footprint as less energy is required in every step process from construction to completion and beyond.

Business benefit

Blue Valley Building specializes in constructing the building envelope in its manufacturing facility. There are many benefits to building it in the facility, such as streamlining efficiency, optimized labor, and reduced environmental implications of working outside (rain, snow, etc.). Not only this, but Blue Valley is a green construction company that has developed durable and sustainable building products that improve construction productivity. Practices like these are exactly what this industry needs, as waste and pollutants coming from construction sites are becoming an ever-growing issue.

Blue Valley Building has been able to follow sustainable practices while also turning a profit. Through methods such as these, Blue Valley is carving a path for others to follow alongside them. These innovations benefit this industry because very few building products have impacted the residential construction market. Blue Valley is demonstrating generating profit while practicing sustainability and efficiency. As this type of building also helps to reduce supply chain issues, it becomes clear that this innovation needs to become a standard practice in residential construction.

Social and environmental benefit

Blue Valley Building is changing the construction game by optimizing the construction process while being a product development company pursuing higher-quality building materials. Their innovation is benefiting society and the environment in many ways. Construction is an industry that has not seen much change over the years, and Blue Valley is stepping up to the plate to create innovations. Through their in-house framing builds, they are streamlining construction, allowing for massive cuts in time spent on site. This process means houses appear quicker with more work going on behind the scenes benefiting society through the increase in housing and a fast-tracked manner.

Blue Valley’s expanded polypropylene (EPP) products improve construction productivity and are an excellent replacement for existing rigid foam and spray foam insulation products. Blue Valley has developed an environmentally friendly 100% recyclable construction system that improves productivity in the field, reducing overall construction costs. The in-house framing is also environmentally conscious as less construction mess is left in communities and is instead dealt with by the building managed and repurposed inside the manufacturing facility company inside their warehouse.

Society is benefiting from Blue Valley's work in economic growth, the innovation of products, and tackling housing. These societal benefits, with the presence of a company pushing sustainability, are all great attributes for a community. An existing attribute that can be easily overlooked is simply the fact that they exist. Their push for innovation towards a more environmentally friendly world is what society needs and drives other companies to follow suit.

Interview

David Calder, Senior Engineering Specialist