Safe Modular Construction with Aerofilm Air Caster Transport
Heijmans and Aerofilm Join Forces for a Flexible, Safe, and Sustainable Modular Construction Solution
Heijmans has established a groundbreaking factory in Heerenveen, the Netherlands for modular construction, where sustainability and innovation go hand in hand. With a unique combination of 2D and 3D building elements, Heijmans has developed a solution that enables carbon-neutral construction while meeting the highest standards in cost-efficiency, safety, and scalability. A key factor in this success was the collaboration with Aerofilm Systems, which introduced air caster technology to move heavy modules effortlessly, flexibly, and safely.
Challenges
Heijmans has established a new factory in Heerenveen, the Netherlands dedicated entirely to modular construction with a unique blend of 2D and 3D building elements. This ambitious project posed a complex challenge: developing a product and production process that is both sustainable and cost-effective. Simultaneously, the factory needed to be flexible, efficient, and, above all, safe for housing production.
To optimize internal logistics, Heijmans partnered with Aerofilm Systems. By leveraging their innovative air caster technology, the heavy 3D modules—each weighing up to 5 metric tons—can effortlessly float on a thin layer of air. This provides a flexible, simple, and reliable solution for internal module transportation.
The safe and efficient system minimizes physical labor and allows precise positioning of the modules, contributing to a streamlined production process. Sustainability was a key consideration, both in material choices and process optimization.
The challenge was to achieve high output—one home per day—without compromising quality or environmental impact. The need for such rapid production was crucial to meet the growing demand for affordable housing while supporting the construction sector’s sustainability goals. It was a first in the Netherlands: designing an entirely new internal logistic process from scratch, requiring an innovative yet thoughtful approach focused on reproducibility and future growth.
Solution
In collaboration with Aerofilm Systems, Heijmans developed innovative skids using air caster technology for moving modules easily and safely. These pallets are equipped with an auto-flow system, making operation extremely simple. The only required actions is connecting an air hose and opening a ball valve. With just one setting, the pallet effortlessly floats, whether empty or fully loaded. Within seconds, the system is operational and ready for use.
The pallets are fitted with six air casters, collectively providing ample capacity to carry the required 5 metric-tons load. Thanks to the air caster technology, the system is not only safe and reliable but also highly cost-effective and flexible. The modular design allows for the quick and easy movement of heavy modules, perfectly aligning with the need for an efficient and streamlined production environment.
The ease of use and reliability of this technology makes it a popular choice among workers. Operators require minimal physical effort to move heavy modules with precision, significantly improving safety and ergonomics. Additionally, the system’s flexibility allows it to be easily adjusted to changing production requirements or future scaling.
By combining Aerofilm’s expertise in air casters with Heijmans’ deep understanding of the construction process, a true team effort has resulted in solutions that perfectly match the builders’ needs while contributing to broader sustainability goals. This synergy has led to an innovative system that enhances productivity and significantly reduces CO2 emissions.
Results
With these results, Heijmans has set a new standard for modular construction in the Netherlands. The combination of sustainability, safety, and ease of use ensures an efficient process that seamlessly aligns with Heijmans’ vision. Thanks to the collaboration with Aerofilm Systems, an innovative solution has been realized that not only optimizes the current production process but also provides room for future growth and further sustainability.
Additionally, the project has demonstrated how innovation can contribute to solving societal challenges such as the housing crisis and climate change. By combining modular and carbon-neutral construction, Heijmans delivers a scalable and affordable solution for creating comfortable and sustainable homes. This makes a significant impact not only in the construction sector but also in shaping a better future for the Netherlands.
Together, Heijmans and Aerofilm have proven that innovative technologies and strategic partnerships are key to successfully tackling complex challenges. The Heerenveen project serves as a prime example of how sustainability and efficiency can lead to structural improvements in the construction industry.
The Aerofilm air caster system helped Heijmans:
- Achieve an efficient production process. Thanks to the air caster system, Heijmans can safely and accurately move heavy modules within seconds, contributing to a daily output of one home.
- Ensure safety and ease of use. Operators experience minimal physical strain and can operate the system easily, regardless of their experience level.
- Promote sustainability and cost savings. The innovative solution supports a carbon-neutral process and lowers overall costs by optimizing time and material usage.
- Enhance flexibility and scalability. The skids provide flexibility to align production with takt times and are prepared for future production growth.
More from Modular Advantage
Resia: Breaking All the Rules
Resia Manufacturing, a division of U.S.-based Resia, is now offering prefabricated bathroom and kitchen components to industry partners. Its hybrid fabrication facility produces more precise bathroom and kitchen components (modules) faster and at lower cost than traditional construction. Here’s how Resia Manufacturing does it.
How LINQ Modular Innovates to Bring Modular To The Market in the UAE and Beyond
LINQ Modular, with an office and three manufacturing facilities in Dubai, is a modular firm based in United Arab Emirates. The company is on a mission: to break open the housing and construction markets in the Gulf Cooperation Council (GCC) area with modular.
ModMax: Redefining Modular Construction with Confidence and Precision
ModMax was born out of frustration—frustration with five persistent pain points in modular construction: Permitting bottlenecks. Production delays. Rigid designs. Disconnect between “the office” and the field. Lack of transparency and communication.
LifeArk: Disaster-Resilient Housing from Recycled Plastic and 100-year-old Technology
Wee compares LifeArk’s housing units to Yeti coolers, as they are built similarly. Each component takes 15 to 20 minutes to manufacture, has an R-value of 40, and includes molded slots and chases for wiring, plumbing, fire sprinklers, and other utilities.
Building the Future of Modular Edge Infrastructure
The edge data center market is expanding rapidly, driven by the surge in AI workloads, IoT adoption, and the need for localized compute power. In these environments, sustainability, scalability, and reliability are non-negotiable. Cooling is among the most complex challenges for operators—and one of the most decisive factors in long-term success.
Accelerating Light-Gauge Steel Construction: A Semi-Automated Digital Workflow for Off-Site Projects
For construction professionals, the message is clear. By adopting semi-automation and digitalization, companies can deliver projects faster, more accurately, and more profitably, while also building stronger collaboration across teams. The approach is not about replacing people with machines, but about empowering people with better tools and processes.
Why Modular Data Centers Are Gaining Momentum
Artificial intelligence, high-performance computing, and edge applications push the limits of traditional “stick-built” data centers. They take years build, often struggle with high density workloads, and aren’t optimized for deployments near end users. Modular data center platforms are purpose-built to address these challenges, offering flexibility and scalability to adapt to evolving technologies, while opening new opportunities for the modular construction industry.
Supply Chain Innovation in Action: 5 Habits Every Modular Leader Should Practice
By applying these principles to supply chain practices — collaborative planning, strategic procurement, scenario modeling, digital tools, and transparent forecasting — construction leaders can build value chains that are not just efficient and agile, but truly innovative.
Exploring the Role of Modular Integrated Construction (MiC) in Advancing Circular City Principles – A Survey of Stakeholder Perspectives
The survey findings highlight the significant potential of Modular integrated Construction (MiC) in advancing the development of circular cities. By reducing costs, accelerating construction timelines, and minimizing waste generation, MiC offers a promising approach to sustainable urban development.
The Use of MS POLYMER™-Based Sealants and Adhesives in Modular Building
These products combine flexibility and elastic recovery with excellent adhesion to different substrates and have already shown their usefulness in traditional construction. Now it’s time for them to be put to use in the modular construction industry.