33rd Annual Conference of the International Group for Lean Construction (IGLC 33) - Osaka and Kyoto, Japan - 2025

https://doi.org/10.24928/2025/0289

Lean in Action: BZI’s Innovation Process for Steel Erection

Adam Hoots1, Corinne Nalder2, James Jeffs3, Shima Clarke4 & Alex Henry5

1PhD Candidate and Instructor, Clemson University, Clemson, SC, USA [email protected], https://orcid.org/0000-0002-0383-8437
2Project Engineer, Clayco, Reno, NV, USA [email protected], https://orcid.org/0009-0000-5302-6253
3Project Executive, Building Zone Industries (BZI), Cedar City, UT, USA [email protected], https://orcid.org/0009-0007-8933-4638
4Professor and Interim Associate Dean of the College of Architecture, Art, and Construction, Clemson University, Clemson, SC, USA [email protected], https://orcid.org/0009-0006-4962-5089
5Project Manager, Industrial Project Innovation (IPI), Greenville, SC, USA [email protected], https://orcid.org/0009-0001-1851-8866

Abstract

The steel erection sector of the construction industry continues to wrestle with persistent challenges, including safety concerns, workforce inefficiencies, and hesitance toward adopting new practices. This study explores how Building Zone Industries (BZI) aligns Lean Construction principles with innovative solutions to overcome these constraints efficiently and effectively. This case study of BZI's innovation process highlights two examples of unique, innovative, and proprietary BZI tools: the Unilink and Wide Swivel Carriage, both custom-designed to address the specific needs of a mega industrial manufacturing plant. These technologies were conceived from direct communication in the field, brainstorming, and testing. Central to BZI’s approach is the culture of innovation which is focused on safety. Their core values drive the innovation process, which rapidly transitions ideas from conceptualization to deployment as examined in their innovation process. The findings highlight the role of collaborative leadership, workforce engagement, and iterative design in overcoming traditional barriers to Lean adoption. The study highlights the scalability of BZI’s methods offering a replicable framework for integrating Lean practices across the broader architecture, engineering, and construction sector. By advancing both theory and practice, this study provides actionable insights for driving innovation and efficiency in steel erection.

Keywords

Lean Construction, Steel Erection Innovation, Waste Reduction, Continuous Improvement, Workflow Optimization

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Reference in APA 7th edition format:

Hoots, A., Nalder, C., Jeffs, J., Clarke, S. & Henry, A.. (2025). Lean in Action: BZI’s Innovation Process for Steel Erection. In Seppänen, O., Koskela, L., & Murata , K. (Eds.), Proceedings of the 33rd Annual Conference of the International Group for Lean Construction (IGLC 33) (pp. 258–269). https://doi.org/10.24928/2025/0289

Shortened reference for use in IGLC papers:

Hoots, A., Nalder, C., Jeffs, J., Clarke, S. & Henry, A.. (2025). Lean in Action: BZI’s Innovation Process for Steel Erection. IGLC33. https://doi.org/10.24928/2025/0289

 

Founded in 1993, the IGLC is an international network of researchers from practice and academia in architecture, engineering, and construction (AEC) who feel that the practice, education, and research of the AEC industry have to be radically renewed in order to respond to the global challenges ahead.

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