Inside a high-performance panelization project
How to install a window in a panelized wall with exterior insulation? It’s all in a day’s work for Cape Cod Panel who partnered with Mullen Building and Remodeling on a recent high-performance condo project. Get a behind-the-scenes peek in this tour led by Tyler Grace and Nick Schiffer of the Modern Craftsman podcast.
The takeaway: Panelization helps improve quality control, maximize efficiency, minimize waste, and enable labor to be done in a sheltered, controlled environment. “It really eliminates that ‘hey, we’ll figure it out in the field’ mentality,” as Schiffer said. By reducing the errors commonly associated with field production, it also streamlines the installation process for windows and doors resulting in greater efficiency and accuracy.
Keep reading for three key takeaways from this project and links to resources that could help your next project — whether you’re panelizing or using traditional stick framing.
1) Window installations in walls with exterior insulation require a buck
The 400 Series windows included in this project were installed in walls with ZIP System® Insulated R-Sheathing, which combines sheathing and insulation in one structural panel. This was done because the stretch energy code in the build location of Conway, New Hampshire requires exterior insulation. What that means for window installation is that a buck must be built into the rough opening. The buck connects to the framing and provides the structure needed for mounting the window without compressing the foam insulation layer of the sheathing.
Did you know that we have an installation supplement detailing how to install windows in walls with exterior insulation? We also have a custom installation instruction configurator that allows you to tailor instructions according to your product, project, and more.
2) 3D modeling is the key to reverse engineering the architecture
Panelized walls are manufactured products, which means their design is intentional and tailored to the end user — the crew who will assemble onsite. The modeling that Cape Cod Panel does prior to construction makes it possible to create highly customized wall sections. It also helps them identify potential problems early and implement solutions across the board for improved quality control. One of the particular benefits in this case was that it standardized the nontraditional window installation that was necessary.
Did you know that we provide BIM files for all our products to make modeling easy?
3) Efficiency is an inherent benefit that can improve quality control
Cutting all the framing members at once greatly reduces the amount of waste associated with building a project. In this case, they ended up with a single barrel of scrap wood. Once the studs, header beams, and all the rest of the framing members were cut and labeled, they were organized onto carts by wall section. Then, they were able to build out components at once, including door and window rough openings, before proceeding to assembling the walls.
Did you know all the sizing details you need to prepare your rough openings correctly are easily accessible?
About the Modern Craftsman
Grace and Schiffer are the voices behind the Modern Craftsman, which is a podcast and community network dedicated to promoting excellence, education, knowledge, and respect in the building industry. With their audience of trade professionals, they discuss all aspects of life within the industry and life itself — from mental health to leadership and everything in between. They pride themselves on working with brands and people who strive to make the industry better and advocate for a better life in the trades.
Meet Tyler Grace
Owner of TRG Home Concepts in Medford, NJ, Tyler is an interior remodeling contractor focusing primarily on kitchens, bathrooms, and finish carpentry. His mission is to deliver a quality product to his clients while creating and maintaining value through efficiency and judicious project coordination.
Meet Nick Schiffer
Owner of NS Builders in Boston, MA, Nick leads a team of experienced carpenters, project managers, cabinet makers, and apprentices. He started his business in 2014 and has turned it into one of Boston's most sought-after building companies. Constantly challenging himself and his team, there’s nothing standard about their approach.
Meet Doug Mullen
Doug Mullen was born and raised on Cape Cod and fell in love with construction as a child. He established Mullen Building and Remodeling in 2003 and is a hands-on owner/operator with over 20 years of experience. Mullen Building specializes in custom home building from the ground up, challenging remodels, and improving residential properties — where details matter.
