Nevadan at Work: Building panel developer wants role in ecofriendly projects

Ken Miller spent 10 years developing insulated building panels made with expanded polystyrene and metal frame system that earned him recognition from Popular Science magazine as one of the best 100 innovations in 2009.

Now if he could just turn the innovation into a more profitable business.

Miller and his wife, Alaina, co-founded Ktect Sustainable Building Systems in 2006, manufacturing the panels at a 7,000-square-foot industrial plant at 6012 Topaz St., near McCarran International Airport.

The product was used to build the first platinum Leadership in Energy and Environmental Design-certified medical office in Ogden, Utah, as well as award-winning residential and commercial projects in California, New York and Canada.

"We've got a lot of awards, but not much recognition in Las Vegas," Miller said. "One of the big reasons is we're a small, self-funded company and advertising is expensive."

Ktect panels sell for about $6 a square foot, depending on design and thickness of the wal. Miller said the savings on labor to install the product make it competitive with standard wood framing.

The company is negotiating with major homebuilders in Las Vegas, though none have used the product so far, he said.

Question: What was the concept behind starting your business?

Answer: I researched energy-efficient construction envelopes early in the 2000s, but was unable to find a system that had the energy efficiency and design flexibility I was looking for. After many attempts, I finally was able to find a way to integrate two of the best construction products - light-gauge metal stud framing and EPS - into Ktect Sustainable Building Systems.

Question: Where can we see your work around Las Vegas?

Answer: We built a home in Seven Hills about five years ago and another one in Red Rock (National Conservation Area) about four years ago. It was 4,100 square feet with a 16-foot high garage for the guy's motor home, and it was air-conditioned with 8-inch thick walls. He had a $109 electric bill in July. You can figure at least a 50 percent reduction in energy cost. Wood's not a good insulator. People think it is, but it's not.

Question: Where else is your product used?

Answer: Project Frog used our product in the Golden Gate Bridge visitor pavilion and in (General Electric's) corporate learning center in Crotonville, N.Y. (Project Frog is a San Francisco-based company aiming to revolutionize building by applying technology to overcome traditional construction's inefficiencies.)

Question: How has the downturn in housing affected business?

Answer: The economy downturn has had a negative effect on our business as with most all businesses. Fortunately, since we have business from all parts of the United States and Canada, we have been able to work through the slow economy. And as we are experiencing an increase in inquiries and sales, it is clear that builders, contractors, developers and end-users want to build energy-efficient, ecofriendly, better and more cost-effective. Ktect is exactly what they are looking for.

Question: There are several manufacturers of expanded polystyrene on the market. What's unique about Ktect building panels?

Answer: I used stuff that's very common in the construction industry. Expanded polystyrene has been around for years. We're not reinventing the wheel. We're just reinventing the way it's put together. The EPS used in Ktect Systems is a proprietary blend based on BASF Styropor. This EPS has all sustainable certifications and has no chemicals. Therefore, thermal and sound efficiency never diminish over time. Other EPS products may have chemicals which can diminish performance over time. The metal stud used in Ktect is a proprietary and patented design, not off the shelf. It provides the ultimate in thermal bridging and structural integrity with design flexibility. We also have a proprietary and patented curved wall design.

Question: Have you had any interest from investors in your company?

Answer: We're only so big. We have had offers to buy the company and invest. We have a manufacturer in Brownsville, Texas, and we're in discussions in Seattle.

Question: Do you exhibit at the International Builders' Show that was just here in Las Vegas?

Answer: No, we haven't found it's that beneficial. We're a small company and we're competing against million-dollar companies there. I will tell you we have a tremendous number of people who call us and come to see us during the show.

Question: Do you exhibit anywhere else?

Answer: We'll exhibit at the Green Building show this year in Philadelphia, and at building shows in specific areas of Texas and California. We go to the International Builders' Show to take a look, but we're the only ones with this patented design.

Question: Why aren't we seeing more of this sustainable building product being used?

Answer: The construction industry as a whole can be slow to accept innovation and change, but we are seeing significant attitude change toward acceptance. With construction on the upswing, the request is for a faster, better, energy-efficient, ecofriendly and less expensive way to build.

Question: How can you create demand for the product and increase sales?

Answer: Increased marketing, licensing additional fabricating facilities, along with our humanitarian efforts. That's our No. 1 priority. Public awareness helps create demand.

Contact reporter Hubble Smith at hsmith@reviewjournal.com or 702-383-0491.