Flexibuild™: near-site manufacturing for mission-critical building envelopes
Kosha Construction Systems is building Flexibuild™, a deployable micro-factory that keeps envelope decisions adaptive deeper into construction—without changing GC means-and-methods or expanding the project insurance boundary.
We are a platform company, not a contractor
Problem (Why this matters now)
Modern mission-critical delivery forces major building envelope and interface decisions 18–30 months before commissioning - even as key variables remain unresolved:
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Power interconnection timing
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Cooling architecture + rack density (AI-driven)
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Equipment lead times + scope changes
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Approvals / regulatory and community constraints
When late changes occur, today’s systems translate them into redesign, rework, and schedule slips—destroying value on revenue-sensitive projects.
Design + envelope freeze (too early) → uncertainty resolves (during construction) → redesign + re-procurement cycles → critical-path delays and penalty exposure.
Solution (What Flexibuild™ is)
Factory-grade output without moving the jobsite. Flexibuild uses robotic additive placement inside a deployable, controlled micro-factory—relocating envelope manufacturing into the near-site logistics zone: close enough for short-haul, crane-servable delivery, but operationally separate from the active construction site.
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Flexibuild includes
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Deployable near-site micro-factory in industrial parcels / IBZs
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ACC (Accelerated Concrete Curing): target ~28 days → ~7 days to handling strength
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QA release gates + traceability + inspection packet (“permission artifacts” that scale)
What changes for GCs
Who builds building envelopes—and where and when envelope manufacturing happens.
What does not change for GCs
GC sequencing, site safety perimeter responsibility, and the project insurance boundary.
How it works (Deployable micro-factory + release logic)
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Material in
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Robotic additive concrete envelope panel fabrication
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ACC (controlled curing)
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Post-process (fire retardant / EMI shielding)
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Installation-ready panel out
QA release gates (permission-first)
Hold points tied to measurable thresholds (go/no-go)
Traceability: batch tracking + dimensional logs + nonconformity report workflow (NCR)
Inspection packet designed for DOB/FDNY + special inspections
Underwriter-ready checklist and risk allocation map
Kosha does:
manufacture near-site panels, control curing + treatments, enforce QA release, and deliver installation-ready units
Kosha does not:
act as GC, manage site logistics, assume EOR responsibility, or expand the project insurance boundary.
NYC-first (Why NYC)
NYC is the permission market: if Flexibuild is accepted in NYC, the insurance, inspection, siting, and regulatory pathway creates artifacts that become reusable precedents for faster expansion elsewhere.
Flexibuild is designed to deploy in industrial parcels / IBZs, enabling near-site production while keeping manufacturing operationally separate from the jobsite.
NYC precedent → Northern Virginia scale
Differentiation (The “missing middle”)
NYC is the permission market: if Flexibuild is accepted in NYC, the insurance, inspection, siting, and regulatory pathway creates artifacts that become reusable precedents for faster expansion elsewhere.
Flexibuild is designed to deploy in industrial parcels / IBZs, enabling near-site production while keeping manufacturing operationally separate from the jobsite.
Flexibuild repositions manufacturing close enough to respond to change, but far enough to preserve schedule certainty and insurability.
Pilot we’re seeking (bounded scope)
We’re seeking a bounded NYC pilot within one of three NYC-legible archetypes
Success metrics
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Early-age threshold achievement (handling readiness)
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Dimensional tolerance + repeatability
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Inspection packet acceptance
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Install cadence without disrupting GC workflows
If you’re delivering a colocation/interconnection expansion or complex upgrade in the NYC area, we’d like to discuss a bounded pilot scope
Team + Advisors
Aparna Sundaram — CEO & Co-Founder
Sustainable infrastructure finance, building performance, capital discipline, underwriting alignment.
Motti Lerer — CTO & Co-Founder
Construction execution, additive manufacturing, manufacturing workflow design under real-world constraints.
Advisors (institutional readiness)
Labor & employment (union/non-union) • Financial/tax governance • Strategic finance & scaling
Kosha’s Mission
To embody layered, humane, and adaptive systems for how the world is built.