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A2P1102

Panelizers & Unitizers: Prefabrication in Modern Building

Panelizers and unitizers

Setting the Stage for Modern Construction

Within the ever-evolving landscape of construction, the demand for efficiency, quality, and sustainability has never been greater. To address these needs, innovative construction methods such as prefabrication has emerged, revolutionizing how buildings are assembled. Understanding prefabrication and all that it encompasses is essential for navigating the complexities of modern building projects and making informed decisions that meet specific project goals.

Defining Unitizers and Panelizers

Unitizers and panelizers are integral components in modern construction, revolutionizing how buildings are assembled. Historically, the construction industry has undergone significant evolution, with these technologies emerging to address challenges related to efficiency, quality, and sustainability.

Unitizers

Unitization refers to the process of creating larger, fully assembled sections or “units” of a building that are constructed off-site and then transported to the construction site for installation. These units may include walls, floors, or even entire rooms, with elements like insulation, windows, and mechanical systems pre-installed. The main advantage is the speed of on-site construction since entire sections are already built and ready to be connected. This significantly enhances installation efficiency and reduces the need for extensive on-site labor. Considering the ongoing labor shortages, this is particularly crucial.

Panelizers

Panelization involves creating smaller, flat components such as wall panels or roof panels in a factory setting. These panels are then transported to the project site, where they are assembled into a watertight and airtight building envelope. The rapid assembly of panels — often completed in days rather than months — offers substantial time savings and cost reductions associated with project management and overhead. Furthermore, panelized systems ensure a high-quality enclosure that aligns with high-performance construction standards, such as net-zero or Passive House, enhancing durability and energy efficiency.

Industry Impact; Construction Efficiency

The integration of unitizers and panelizers in modern construction not only addresses long-standing productivity issues but also aligns with evolving market demands for speed, quality, and sustainability.

panelizers and unitizers: prefabrication in the built environment

A significant challenge facing the construction industry today is the shortage of skilled labor. Factors such as an aging workforce, decreased enrollment in vocational training programs, and increasing project demands contribute to this issue. Labor shortages can lead to delays, increased costs, and compromises in the quality of work.

Unitizers and panelizers offer effective solutions to mitigate these labor challenges. By allowing for the pre-assembly of components, unitizers reduce the amount of labor required on-site. This means that fewer skilled workers are needed to achieve the same level of productivity, which is crucial given the current labor market.

Panelized construction also allows for quicker assembly on-site. With factory-made panels, the complexity of on-site work is minimized, enabling less experienced labor to participate in the installation process without sacrificing quality. Moreover, much of the work done in a controlled factory environment ensures higher standards of quality control, reducing the potential of errors that could arise from inexperienced labor.

Seamless Integration with Systems: GreenGirt CMH and SMARTci

The GreenGirt CMH continuous insulation and SMARTci building enclosure systems enhance the performance of prefabrication methods. GreenGirt CMH provides thermal breaks and robust cladding support in wall systems, combining the corrosion-resistant properties of fiber-reinforced polymers with the structural resilience of metal components for effective insulation and reliable load distribution.

The SMARTci building enclosure system integrates seamlessly into prefabricated wall panels, offering efficiency and ease of installation. By fully integrating composite metal hybrid Z-girts with custom-profiled rigid-board insulation and pressure seals, the SMARTci system creates an air- and water-tight building enclosure with a smooth drainage plane. This significantly reduces installation time, as materials arrive ready for placement.

These integrated systems improve thermal performance and streamline installation, enabling builders to achieve higher energy standards and better sustainability outcomes.

Real-World Application

Embassy Suites by Hilton, Madison, WI

The Embassy Suites by Hilton in downtown Madison features a nine-story structure with 262 rooms, part of the Judge Doyle Square redevelopment aimed at enhancing connections between the Capitol and the Monona Terrace Community and Convention Center.

This project utilized panelization with cold-formed structural metal panel walls manufactured by BLUvera, ensuring high structural strength and thermal efficiency. The use of a panelized system allowed the building to reach a watertight state in days instead of months.

Video source: Mortenson Construction

Precise layout planning ensured safety and quality while eliminating the need for additional on-site material storage. The unique non-square shape of the building required careful panel placement to achieve the desired curvature, showcasing modern construction techniques.

By installing the GreenGirt CMH continuous insulation system, the project benefited from improved energy efficiency and structural integrity. The system’s ease of installation and compatibility with various insulation materials allowed for a streamlined construction process. Production began promptly upon order receipt, with a dedicated logistics team ensuring timely delivery of materials.

Looking Ahead in Construction

As evolution continues in the construction industry, the adoption of mechanisms like unitization and panelization plays a significant role in addressing the challenges of today’s construction sector. By leveraging systems like GreenGirt CMH and SMARTci in prefabrication, construction teams can significantly enhance efficiency and streamline operations. These systems facilitate quicker assembly and integration, reducing reliance on extensive on-site labor. As the industry continues to evolve, adopting these innovative methods will set new standards for quality and sustainability, ultimately leading to a more efficient construction process.

If you’re interested in learning more about GreenGirt CMH continuous insulation and SMARTci building enclosure systems, please visit our website or call us at 269-355-1818.