Panelized Systems

Flat-Packed Precision. On-Site Speed.

Panelized 2D modular systems deliver factory-fabricated wall, floor, and roof panels as flat-packed assemblies. Shipping efficiency is maximised — up to 3x more building area per truck versus volumetric modules — while still capturing 40–60% of construction value in the controlled factory environment.

Technical Specifications

Panelized System Performance Data

Factory-built panels with site assembly. All load-bearing elements engineered to Eurocodes. Cladding, windows, and services coordination pre-planned at BIM level.

ParameterSpecificationStandard / Notes
Frame MaterialCold-formed steel (S350GD+Z) or engineered timber (C24, GL24h)EN 1993-1-3 / EN 1995-1-1
Panel TypesExternal wall, party wall, floor cassette, roof cassetteLoad-bearing and non-load-bearing
Factory Completion40–60%Structure, sheathing, insulation, windows, door blanks
Site Assembly Rate80–120 m² of wall per crew per day4-person crew, crane-assisted for floor cassettes
Maximum Panel Dimensions3.0m × 12.0m (wall); 4.0m × 12.0m (floor)Transport-limited; stacked on A-frames
Shipping EfficiencyFlat-packed: 3x building area per truck vs volumetricReduced transport cost per m², fewer deliveries
Acoustic — AirborneDnT,w + Ctr ≥ 45 dB (party wall)BS EN ISO 16283-1
Acoustic — ImpactL'nT,w ≤ 62 dB (floor cassette)BS EN ISO 16283-2, resilient layer
Fire Resistance60–120 minutesBS EN 13501-2, Type IIA/IIB construction
Thermal TransmittanceU = 0.15–0.18 W/m²KBS EN ISO 6946
Building HeightUp to 6 storeys (timber); up to 12 storeys (steel)Higher with hybrid structural frame
Typical Programme8–12 weeks factory + 6–14 weeks site14–24 weeks total; depends on cladding scope
Panelized 2D wall panels being assembled on site with crane, showing flat-packed delivery efficiency
How It Works

Factory Precision, Site Assembly

Panelized systems strike an optimal balance between factory quality control and on-site flexibility. Panels arrive pre-cut, pre-insulated, and pre-sheathed. Site crews erect the structural enclosure in days rather than weeks, then complete MEP first fix, plasterboard, and finishes using conventional techniques — but starting from a dimensionally perfect shell.

  • Steel or timber frame — choose the right material for your project
  • Windows and external doors pre-installed in wall panels at the factory
  • Service zones pre-formed: conduit routes, back boxes, plumbing chases
  • Cladding support rails factory-fixed, reducing working-at-height site time
  • BIM model drives every panel: 10,000+ components digitally coordinated before fabrication
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Advantages

Why Choose Panelized

Lower Transport Cost

Flat-packed panels ship up to 3x the building area per truck compared to volumetric modules. For projects with long logistics distances or constrained site access, panelized systems dramatically reduce the transport cost per square metre — often the deciding factor for regional and remote projects.

Design Flexibility

Because MEP and finishes are completed on site, panelized projects accommodate design changes later in the programme than volumetric. Room layouts, service routes, and finish specifications can be adjusted after panels are erected — valuable for tenant-fit-out phases and speculative developments where the end user is not yet known.

Hybrid-Compatible

Panelized systems combine seamlessly with volumetric modules in a hybrid approach. Use volumetric for kitchens, bathrooms, and plant rooms (wet, service-intensive spaces) and panelized for bedrooms, living areas, and corridors (dry, flexible spaces). One BIM model coordinates both systems — single-source design responsibility.

Rapid Enclosure

A trained 4-person crew erects 80–120 m² of external wall per day. A 4-storey, 2,000 m² building can be structurally enclosed and weather-tight in under 3 weeks. This compresses the programme's critical path, unlocks earlier MEP and finishes start dates, and reduces the site's exposure to weather risk during the most vulnerable construction phase.

Method Comparison

Panelized vs Volumetric vs Traditional

Selecting the right system depends on project typology, site constraints, logistics, and budget priorities. This comparison is based on a 4-storey, 3,000 m² office building.

MetricPanelized (2D)Volumetric (3D)Traditional
Factory Completion40–60%80–95%<5%
On-Site Labour (person-hours/m²)8–124–618–25
Transport Cost (relative)LowHighN/A
Total Programme Duration14–24 weeks16–28 weeks36–52 weeks
Design FlexibilityHighModerateVery High
Weather DependencyModerateVery LowHigh
Quality ConsistencyGoodExcellentVariable
On-Site Crane Time2–4 weeks1–2 weeksContinuous
Best ApplicationOffices, schools, low-rise residential, retailHotels, student housing, hospitals, high-rise residentialOne-off bespoke, complex geometry
Capital Cost (relative to traditional)90–100%95–105%100% (baseline)
0Max Factory Completion
0Panel Erected Per Day
0Shipping Efficiency vs Volumetric
0Max Programme Duration

Explore Panelized for Your Project

Tell us about your project and we will assess whether panelized, volumetric, or a hybrid approach delivers the best value — with quantified cost, programme, and quality trade-offs for each option.

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