Technologies changing how projects get built

MCS Influencer John Kenney says contractors who master both the old and the new will win complex, high-value work. 

One of the biggest game changers is the integration of robotics, automation and AI into fabrication. Automated roll forming, laser cutting, robotic welding and AI-powered seamers are improving precision, reducing waste and speeding up production. In metal construction, that means fewer fit-up issues in the field and tighter tolerances as you deliver panels and components.  

AI-driven tools also enter seam and panel alignment. Seamers that use sensors to monitor alignment and adjust on the fly reduce mistakes. That kind of control is a significant advantage when tight tolerances make all the difference in high-end architectural builds.  

When you bring that capability in-house or partner with fabricators who use it, your field installation becomes smoother, faster and more predictable. 

Digital modeling and data: BIM, IoT and smart buildings 

Another area with major upside is Building Information Modeling (BIM), but it has been pushed further into the installation phase. When your design, fabrication and field teams all work from the same 3D model, clash detection improves and prefabrication becomes more reliable. As metal systems grow in complexity — curved panels, custom trims, multiple roof planes — you need those models to stay accurate. 

Beyond BIM, IoT sensors and embedded monitoring are finding their way into metal building systems. Sensor networks inside wall or roof panels can track structural movement, temperature gradients, moisture intrusion or expansion and contraction over time. Over the years, that data has become predictive maintenance gold, not just reactive repair.  

Being able to monitor their envelope in real time is a powerful selling point for building owners, and as a contractor, offering those features gives you a differentiator. 

Advanced materials and smart coatings 

Materials are evolving, too. New alloys, composite metals and advanced coatings are pushing performance boundaries. Think panels that resist corrosion better in harsh environments, lightweight alloys that cut structural demands or coatings that self-heal minor scratches.  

Then there are “smart” coatings that shift reflectivity or thermal behavior in response to temperature changes, helping reduce heating and cooling loads. These may not be mainstream yet, but as climate-controlled design becomes more important, they’ll have real demand in metal envelope systems.  

If you can stay in touch with what’s happening in materials science and test a few pilot projects, you’ll build knowledge ahead of the competition. 

Prefabrication and modular construction 

Prefabrication has been with us for a while, but what’s new is pushing more module-level work off-site. Whole wall or roof sections delivered nearly ready to install reduce field labor, speed up schedules and improve quality control. That model works well in metal systems because many components are repetitive and connectable. 

Combine modular building with shop robotics, laser cutting and CNC forming, and you start moving toward a lean, almost factory-like approach to site installation. 

Digital twins and lifecycle analytics 

One of the more futuristic but increasingly fundamental concepts is the “digital twin.” You create a complete digital replica of the building envelope, then monitor it through sensors, field input and performance data. That twin helps predict deterioration, schedule maintenance or simulate design changes. Contractors who offer the digital twin as part of the handoff to the client deliver value beyond just installation. 

Because the data lives beyond your field team, it opens the door to long-term service contracts, envelope monitoring and reliability warranties backed by real data. 

Drones, AR and field intelligence tools 

On the jobsite, drones equipped with LiDAR or thermal sensors are becoming more common. They can help scan complex roof geometry, detect panel misalignments or find hot spots in coverage. That gives you an aerial perspective you can’t match from the ground. 

Augmented reality (AR) tools, such as glasses or tablets, overlay digital models on a physical view. These tools help installers see where panels go, how trim meets or where hidden fasteners reside, reducing guesswork and rework. 

How to adopt without breaking yourself 

You don’t need to adopt every new tool at once. Be selective. Start with one area where you’re already struggling-field fit-up, fabrication accuracy or quality control — and pilot a new technology there. Partner with a fabricator, test a robotic seamer or try AR for one roof. As you see results, expand them. 

Track your improvements, less waste, fewer callbacks, faster installations — and use those metrics when selling your projects. The data becomes proof that you’re investing in excellence, not gimmicks. 

Also, remember training and team readiness. Technology is only as good as the people who use it. Get buy-in, allocate time to training and involve your best foremen in the decision-making process. 

If you succeed in blending experience-based practices with these emerging technologies, you won’t just keep up, you’ll lead. The metal building world is evolving, and contractors who master both the old and the new will win complex, high-value work.