Amid labor shortages and increasingly tight timelines, developers are turning to prefabrication to accelerate delivery while maximizing cost-efficiency. 

Prefabrication means manufacturing a project’s building components off-site for rapid on-site assembly, from individual wall panels to a building’s entire structure and envelope. The prefab approach is booming, with the global market projected to reach $252B by 2030. 

Wells has provided prefabricated structural and architectural building solutions for decades. The company is seeing a major uptick in prefabrication projects in multifamily and other commercial sectors. Wells Senior Vice President of Project Development Brian Griffis said that while there are many benefits to prefabrication, it’s key to bring in a prefabricator at the beginning of the planning phase to mitigate constructability risks early. 

“The most significant consideration is bringing us — or another prefabricator — to the table early,” he said. “Early involvement eliminates struggles and unknown setbacks that are common with late-stage procurement items when the design is complete and the schedule is set. Completing a design before engaging a prefabricator greatly reduces the potential value and savings that can be realized.”

The Wells team gave a rundown of what builders should look out for, the company's unique approach to prefab, and how it keeps complex projects moving forward. 

Why Site Flexibility Is Critical

Griffis said securing a prefabricator early, while builders still have design flexibility, allows teams to identify structural conflicts. Building components can be value-engineered to comply with site constraints while supporting the design vision. This early design assistance ultimately reduces costs and compresses timelines. 

Early integration also streamlines coordination with other trades, he added. For example, openings for mechanical and plumbing systems can be identified and designed to ensure that components function properly without compromising the building’s structural integrity.

In the multifamily sector, market demands make construction schedules the ultimate deciding factor, Griffis said. Since multifamily fundamentally relies on speed to lease up, prefab compresses the timeline in a way that on-site, traditional construction can't. 

“The introduction of our unitized envelope system, where the panels arrive with the windows already installed, means the building is virtually immediately closed in and interior work can begin sooner,” Griffis said. “Our prefab solutions can reduce the construction schedule up to 40%.”

A Streamlined Approach In Nashville

The Pullman at Gulch Union, a 29-story luxury high-rise building in the heart of downtown Nashville, was on a tight schedule when Wells stepped in to help. 

Wells Preconstruction Manager Ryann Thompson said the company developed a prefabricated building facade system that not only accelerated construction but also reduced structural demands on the building frame. 

“The prefabricated building facade system combined precast concrete, glazing, insulation and structural framing into a coordinated assembly,” he said. “As a result, it improved shipping efficiency, supported predictable tolerances and strengthened the facade quality through the controlled off-site fabrication.”

Though the project was originally designed as a residential tower within a multiphase mixed-use development, the developers decided to shift to luxury condominiums during the design phase. This change required an expedited path to enclosing the building so interior trades could begin work, Thompson said. 

“The prefabricated enclosure approach helped accelerate the dry-in sequence by approximately two to three months compared with a conventional field-installed cladding,” he said. “This acceleration supported earlier occupancy in a competitive urban market.”

Preserving History In Dallas

For Maple Terrace Residences, a 22-story luxury high-rise in Uptown Dallas, Wells aimed to capture a timeless, stacked limestone running bond format to honor the history of the site.

Wells Director of Architectural Systems Marc Angelillo said the team utilized architectural precast panels cast in stacked-stone patterns with a warm, neutral palette. The panels feature a deep charcoal hue at the base that gradually lightens to gray as the tower rises.

The team selected an emulated limestone precast system to achieve the desired texture and warmth while ensuring strict control over long-term performance. The off-site casting let the manufacturer introduce subtle recesses, projections and panel detailing that gave the facade rhythm and variation, Angelillo said.

“The precast panels span floor to floor, leveraging a robust, quiet and efficient building facade system,” he said. “By carefully matching the color and texture of the new architectural precast panels to the original 1920s structure, the new tower complements the historic facade rather than competing with it. Fabricating the panels off-site improved quality control and minimized on-site disruption, delivering consistent, repeatable detailing without sacrificing architectural intent.”

Maintaining Construction Timelines Through Disruptions

Wells Senior Vice President of Project Development Dan Parker explained how Wells helped develop Pop Denver, a five-story, total precast residential space in Colorado with a central courtyard, fitness amenities and integrated parking. The company’s goal was to create a vibrant, functional home for urban residents, where every space felt safe. The general contractor wanted a better way to build than traditional wood or cold-formed steel framing, which brought Wells into the project in a design-build role.

The entire project turned into a challenge as construction started when the global pandemic hit. Yet Wells was well-equipped to pivot despite this challenge.

“Our off-site capabilities let key components get completed safely in a controlled environment, so once foundations were complete, installation could start promptly,” Parker said. “Because so much of the work happened away from the jobsite, a slowdown on-site didn’t mean a slowdown on the build. That controlled setting kept the components progressing and the schedule intact while much of the industry stalled.” 

The site offered no clearance from neighboring properties, requiring the team to use a luffing tower crane to safely maneuver large elements. This precision kept construction on schedule while protecting surrounding spaces.

Precast concrete also saved the timeline when a small fire broke out in the basement during construction, Parker said. Sparks from welders installing a slab edge angle above ignited the foundation waterproofing. Thanks to the fire-resistant nature of precast concrete, the fire was quickly contained. Despite minor smoke damage, the structure was unaffected, and crews went back to work the next day.

“Where traditional materials like stick-built construction might have turned that into a real setback, the precast protected both the project and the timeline,” he said.

Engineering Future Success

By engaging with developers during the initial stages of design, Griffis said Wells aims to leverage its comprehensive expertise to solve structural challenges, navigate disruptions and keep modern builds on track.

“Our team at Wells is composed of a national network of knowledge and experience to guide even the most challenging projects,” he said. “We share the goal with the owner and design team to create aesthetic, efficient and durable spaces that are built to last.”

This article was produced in collaboration between Wells and Studio B. Bisnow news staff was not involved in the production of this content.

Studio B is Bisnow’s in-house content and design studio. To learn more about how Studio B can help your team, reach out to studio@bisnow.com.