Our Product

How the IronFeather Housing System™ Is Built

The IronFeather Housing System™ is a pre-engineered housing system designed specifically for speed, durability, and remote deployment. Every part of the build is designed to reduce moisture risk, shorten construction timelines, and eliminate the common failures seen in traditional and prefab homes.

Read more below to learn about our product.

Off-Site Wall Construction & Remote Shipping

All wall systems are built off-site in controlled conditions, then packed down efficiently for transport. This allows materials to stay dry and protected before installation.
The wall panels are designed to ship easily by truck or ATR aircraft, making them ideal for fly-in and remote communities where logistics are limited.

Once delivered, walls are ready to stand immediately — no cutting, framing, or drying time required on site.

Advanced Insulation for Moisture Control

Instead of traditional fiberglass insulation that sags over time and creates air pockets, IronFeather uses Rockwool and EPP insulation systems.

These materials:

Do not sag or collapse inside walls
Maintain consistent insulation performance over time
Resist moisture retention and mold growth
Improve soundproofing and fire resistance

This design prevents the hidden air gaps that often cause condensation, moisture buildup, and long-term mold issues inside walls.

Interlocking Engineered Truss System

The structural system uses engineered, interlocking trusses that are precision-cut and pre-assembled.
This system is:

Stronger than traditional stick framing
Faster to assemble on site
Compact enough for air transport via ATR aircraft

The truss system locks together cleanly, reducing structural movement and increasing long-term durability in harsh northern climates.

Extremely Fast Weather Sealing

Because the wall system is fully pre-engineered and pre-built, homes can be weather-sealed in less than two weeks.

For a typical 1,200 sq ft home, all exterior walls can be fully installed in less than one working day.
This drastically reduces exposure to weather during construction and allows interior work to begin much sooner than traditional builds.

Steel Siding & Steel Roofing

IronFeather homes use steel exterior siding and steel roofing as standard.

Benefits include:

High fire resistance
Faster installation compared to traditional cladding
Resistance to rot, pests, and moisture
Long service life with minimal maintenanc

Steel exteriors are especially important for wildfire-prone and remote regions where repairs are difficult and costly.

Increased Wall Depth for Higher R-Values

Homes can be built with 2×6 or 2×8 wall systems, increasing overall insulation thickness and R-value.

This improves:

Energy efficiency
Thermal comfort in extreme cold
Long-term heating cost reduction

Wall depth options allow communities to choose the performance level that best fits their climate and budget.

Fire-Resistant, Non-Toxic Interior Wall Panels

Interior walls are not drywall.

Instead, IronFeather uses polyphenolic High-Pressure Laminate (HPL) wall panels, a highly durable architectural material.

These panels are:

Extremely fire resistant
Very difficult to break
100% non-toxic
Non-porous and moisture resistant
Resistant to scratches and impact

HPL panels are made by compressing resin-saturated kraft paper under high heat and pressure, creating a dense, long-lasting surface suitable for demanding environments.

They are available in multiple finishes and designs, allowing for clean, durable interiors that do not degrade like drywall.

Pre-Installed Plexiglass Windows

Windows are pre-installed directly into wall panels before shipping.
This removes the need for on-site window hanging and speeds up full weather sealing.

Instead of traditional glass, IronFeather uses plexiglass glazing, which is:

Virtually unbreakable
Lighter and safer during transport
Resistant to vandalism and impact
Free from costly future glass replacement issues

This significantly reduces long-term maintenance and replacement costs.

Optional Steel Stud Framing

For communities seeking maximum durability, the system offers an optional steel stud wall framing upgrade.

Steel studs:

Add additional fire resistance
Eliminate organic material that supports mold growth
Improve long-term structural stability

This option is ideal for high-risk or high-humidity environments.