The Power of Pre-Framed Wall Panels in Modern Construction
Pre-framed wall panels are transforming construction by reducing labor, improving efficiency, and minimizing delays. Unlike traditional on-site framing, which requires manual assembly and is subject to weather conditions, these panels are built in a controlled factory environment and delivered ready for installation. This process cuts framing time by up to 50%, enhances quality control, and provides a more cost-effective and reliable solution for builders.
What are Pre-Framed Wall Panels?
When constructing a building, walls need to go all along the perimeter and inside of the structure. The exterior walls give something to put your roof on and keep the elements out. Exterior wall panels are typically framed with 2x6 studs and covered with plywood or OSB. Interior walls are typically framed with 2x4 studs.
In traditional construction, walls would be built on site and set in place by framers. The walls are framed in lengths that make sense to stand up on the job site. Framers either need to lift the walls from a horizontal to a vertical position or use jacks to put them up.
Pre-framing walls entails building the wall panels in a controlled factory environment using an exterior and interior plan provided by the builder. The panels are then taken out to the job site in sections and set in place with a crane, reducing the amount of time to put up walls by 50%.
Key Benefits of Using Pre-Framed Wall Panels
A Smarter Approach to Construction Planning
Traditional on-site framing follows a familiar timeline: planning, construction, and move-in. While this process offers flexibility, it often leads to inefficiencies. Planning is sometimes rushed, leaving unresolved details that must be addressed during construction. This can result in last-minute decisions, unexpected delays, and increased costs. Framers may have to make adjustments on-site without full coordination with the builder, leading to inconsistencies and wasted materials. These inefficiencies not only extend project timelines but also drive up labor and material costs and create logistical challenges.
With pre-framed wall panels, the process shifts to a more structured approach. The planning phase is longer and more detailed, ensuring that every element is accounted for before construction begins. Once the panels arrive on-site, the build moves forward quickly and efficiently. Since the walls are pre-measured, pre-cut, and designed to fit seamlessly, the construction phase is much shorter, reducing waste and minimizing costly errors. This approach results in a faster, more predictable build, allowing projects to be completed on schedule while improving overall quality and cost efficiency.
Build More Homes Faster
When you frame a project on site, your lumber company drops off materials a few days before they are needed. Framers receive a pile of plywood or OSB, boxes of nails, hangers and hardware. We assume that all of this is dropped off before they are needed, but it can occur where the framer arrives at the site and the materials have not yet been delivered. During the few days before the walls are built, all the lumber and hardware is exposed to the elements, which can reduce the quality of dimensional lumber and risk theft of the material.
The lumber company will usually drop the materials in the driveway due to its easy access for a big truck. Depending on where the work needs to be completed, the framers may need to move the materials by hand or forklift to the jobsite. For example, when framers are working on an L shape house with the living space behind the garage, it takes a significant amount of time and energy to move those materials to where they belong.
When you pre-fabricate wall panels, the framers will receive their material for the floors ahead of time. Once their floors are installed, your panel manufacturer will bring the wall panels out on a truck exactly when they are needed and at the precise size needed. Since they are made in a controlled factory environment, they will be dry and ready to install. When practical, we use a boom truck to place the wall panels in place, saving the time of moving the materials. Once the walls are in place, they are generally ready for roof trusses the next afternoon.
Due to the speed of pre-fabrication, contractors can complete more projects during the year. Framing crews could get their projects done in 20% less time, which means that you could have enough time to do 2-3 more builds during the year. If you're a homeowner, you can be in your home sooner and it will cost you less using wall panels than framing on site.
Increased Safety for Workers
On site, builders will frame a wall panel on the ground before standing it up vertically in the place it needs to be. Framers could also use jacks to raise wall panels, but these can break, fall and cause serious injury.
“I don't know how many times I've been out on a job site measuring for roof trusses or some other reason, and they're like, ‘Hey, come over here and help us stand this wall.’ And the framers are out there with this wall that's 30 feet long and weighs a couple of thousand pounds. They need some help because they've got three or four guys out there to stand that thing up. Boy that is hard on the back.” - Chad Johnson, President of Truss Components of WA
Overall, framing walls on site is a lot of strain on the body and could be the cause of a potentially serious injury.
Depending on the site conditions, your panel supplier may set pre-fabricated wall panels in place with a boom truck, preventing extra lifting, labor and motion while still getting all of the parts where they belong. It's safer because all of the weight is being carried by the boom truck. If using the boom truck is not practical, the walls can still be moved to place by hand. They are going to be in smaller sections than what would typically be framed on site, so they are lighter and easier to move around.
Less Waste, More Cost Savings
In traditional framing, the material dropped off by the lumber company is in random lengths. Framers will need to cut off parts they don’t need, resulting in expenses paid to haul it away. Each framer builds a house slightly differently, resulting in a possible variance of supplies needed. Your material list might have too much material, which means you're going to have returns. You could have too little material, resulting in delays and extra expenses to get new material.
With pre-fabricated panels, all of the materials in the wall panels are carefully optimized. The sheathing is nested into pieces so that the manufacturer uses each sheet of material efficiently. Wall panel manufacturers produce very little waste in the plant. On site there is practically zero waste.
Reduced Dependence on Skilled Labor
In today's labor market, finding people with framing experience is difficult and experienced framers are expensive. With the pre-fabricated wall panels, less skilled labor is needed on site. With an experienced carpenter on site, framers can lead a crew of a few inexperienced framers and have a project completed well. Expenses will be saved for the contractor and the home owner.
The Installation Process: What Builders Can Expect
Delivery & Site Preparation
Ahead of delivery day, a layout with the location and labeling for all of the wall panels is provided to the framer. Each label corresponds to a wall panel, showing exactly where they go.
We build our wall panels about an eighth of an inch shorter than what they are specified on the plans to allow for slight variances in material sizes and accuracy of floor framing. It's a good idea to make sure that you are using a tape measure as you set the wall panels out. One of the common pitfalls with using wall panels is not using a tape measure and setting everything end to end to end. If this happens to you, don’t hesitate to call your wall panel manufacturer so they can direct you on how to correct the length.
Pre-fabricated wall panels loaded onto a Truss Components of WA truck.
Setting the Wall Panels
On delivery day, the boom operator will offload the wall panels in bundles close to where they are going to be used. If conditions allow, we will individually set the exterior wall panels in place, allowing on site laborers to receive them and brace them in place. Interior wall panels, which don't have plywood or OSB on them are much lighter. They can be set inside the building on the floor, close to where they will be used. The laborers on site will move the individual walls to where they go, stand them up and brace them.
Integration with Other Building Components
A major advantage of using wall panels is that the manufacturer designs a complete package with the wall panels, floor trusses and roof trusses. On the plans, the studs align so plumbing and other obstructions that need to go through the walls would be matched up with the floor below and roof above. You are working with the same designer throughout your project with one set of plans. It greatly reduces the possibility of one design system not fitting or working well with another.
Common Questions & Misconceptions
Are Pre-Framed Wall Panels Only for Large Commercial Projects?
No! Your project is a great candidate for wall panels. We have supplied wall panels successfully for everything from garages to multi unit apartments, town home complexes, dormitories, commercial buildings and individual residences of all different sizes. Any project is just made up of a lot of small parts, whether big or small.
Do Pre-Framed Wall Panels Limit Design Flexibility?
There are some situations where wall panels may not be the best solution, but that's pretty rare. When we do run into that, we are happy to say what sections should be panelized or framed on site. Where there is a section that should be framed on site, we can design and pre-cut all of the framing parts for that section and deliver them to the job site with instructions on how they go together. It makes framing of those sections much faster with less waste.
How Do Pre-Framed Wall Panels Perform in Different Climates?
Regardless of where you are, wall panels make the framing process faster. If you are in a dry climate, the wall panels are going to make that framing process quick and you will be able to move on to the next set of trades and get your project done faster. If you're in a wet climate, those wall panels are going to help the project go more quickly, reducing the amount of water that can get to the wood. When it comes time to move on to insulation or drywall, there's going to be less effort necessary to make the product dry enough to move on to the next trades.
Conclusion
The transition to pre-framed wall panels is a significant step toward faster, safer, and more efficient construction. By reducing material waste, minimizing the need for skilled labor, and ensuring precise assembly, these panels streamline the building process while maintaining structural integrity. As the demand for smarter construction solutions grows, pre-framed wall panels are proving to be a key innovation for modern building projects.
