Megapanel Mania: Prefabricated Exterior Wall Assemblies

Prefabrication of exterior wall systems and assemblies is a growing trend in the construction industry. There are many terms used to describe this process (panelized, modularized, unitized, etc.) and the definition and scope of prefabrication can be as unique as the project itself. For many projects, the exterior walls are anticipated to be panelized or unitized from the start as is often the case with precast concrete panels and aluminum-frame curtain wall systems. However, sometimes modularization is proposed by the construction team after design is complete as a means of expediting the schedule, addressing site access constraints and/or lowering project costs. The presenters will describe different types of panelized exterior wall assemblies and will present a case study regarding a 10-story, 700,000 square foot healthcare facility that utilized megapanel exterior wall construction. The change to a panelized approach occurred after the design was complete, resulting in challenges associated with continuity of air, water and thermal control layers, particularly at the interface conditions.

Learning Objectives:

• Understand various exterior wall prefabrication techniques and several advantages and drawbacks of panelized construction.
• Demonstrate an understanding of building science and the impacts of megapanel joinery and transitions with respect to building enclosure performance and continuity of air, water, thermal and vapor control layers.
• Appreciate challenges associated with integrating exterior wall and roof construction in panelized assemblies.
• Describe building enclosure quality assurance and quality control efforts that can be performed in the prefabrication facility, for mock-ups and at the construction site.

Presenters: Sarah Sinuses, PE, Senior Associate, Wiss, Janney, Elstner, Patrick Reicher, SE, REWC, REWO, Principal, Raths, Raths, & Johnson Inc

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