Background & Project Overview

In response to a growing need for enhanced women’s healthcare services, the VA Hospital in Iowa City embarked on a vertical expansion of its existing Building 50. This project added two new floors—a third and fourth—on top of the existing two-story Women’s Health Clinic, doubling the building’s usable space by adding approximately 20,000 square feet (10,000 SF per floor).

Because the building below was actively occupied during construction, minimizing disruption, water intrusion risks, and on-site congestion was critical. Prefabrication—specifically a StoPanel system—was selected early in the design phase to address these constraints and improve the efficiency and quality of the build.

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Design & Planning

To support the prefabricated approach, Building Information Modeling (BIM) and Virtual Design & Construction (VDC) tools were used extensively during the design phase. This allowed for seamless panelization planning and precise coordination with the existing structure.

Three types of StoPanel prefabricated wall systems were utilized:

- StoPanel MVES: Featured thin brick finishes to match the existing exterior.

- StoPanel Classic NExTci: Included Sto’s Strike Defense system for a durable, woodpecker-resistant EIFS finish.

- Sto Backup Panel Assemblies: Designed specifically for stair towers to later receive linear metal as a field-applied finish.

This systemized planning ensured compatibility between new and old components and optimized the exterior design for off-site fabrication.

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Fabrication & Assembly

All panels were fabricated in TJ Wies Prefab Innovation Center ensuring consistency and high-quality assembly in optimal conditions. Once completed, the panels were shipped to the Iowa City jobsite via truck and trailer.

The constrained site logistics required a highly coordinated delivery and installation process, with a “one-in, one-out” trailer system and use of a 100-ton crane to hoist the panels into place. Despite the complexity, the full panel installation was completed in just 10 days—a testament to the effectiveness of prefabrication.

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Schedule & Efficiency

One of the most significant benefits of using prefabricated panels was the ability to enclose the building in just 10 days, which accelerated the overall construction timeline. This rapid enclosure was especially valuable for the hospital, as it allowed interior work to begin much sooner than would have been possible with traditional methods—minimizing disruption to ongoing operations and reducing exposure to weather-related delays.

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Cost & Operational Benefits

While prefabrication introduced a modest increase in upfront costs, it significantly reduced overall project expenses & exposures by:

- Reducing on-site labor requirements at an active hospital facility

- Eliminating prolonged on-site crew presence at an active hospital facility

- Avoiding water damage risk to active medial areas

- Enhancing building quality & eliminating any rework of on-site trade damage

The labor efficiencies and faster project timeline ultimately created a cost-effective solution that outperformed traditional methods.

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Challenges & Solutions

Several common prefabrication challenges arose, including:

- Tight tolerances

- Transport limitations

- Design coordination across disciplines

- Managing mid-project changes

These were addressed through rigorous planning, ongoing communication, and close collaboration between TJ Wies, the general contractor, MEP contractors, and the design team. Detailed BIM modeling played a crucial role in aligning the new construction with the existing structure, ensuring precise integration and avoiding misalignments or rework.

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Sustainability & Quality

Prefabrication supported the project’s sustainability goals by:

- Reducing material waste

- Minimizing energy use on-site

- Limiting environmental disruption at the hospital

The quality of construction exceeded expectations, especially when compared to the existing field-built portions of the facility. Fabricating in a climate-controlled environment with proper lighting resulted in more precise assemblies and fewer post-installation issues.

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Conclusion

The VA Hospital Building 50 Vertical Expansion project is a showcase of how modern prefabrication methods, when paired with digital design tools and tight team collaboration, can transform complex medical construction. For TJ Wies Contracting, this project not only demonstrated the value of prefabricated StoPanels but reaffirmed their leadership in delivering high-performance building envelope solutions with speed, precision, and confidence.

Outcomes & Lessons Learned

The prefabrication strategy produced strong, measurable results:

- Schedule reduction: 2 months saved on enclosure

- Labor efficiency: Fewer workers needed on-site

- Quality gains: Enhanced finish and consistency

- Cost control: Reduced long-term expenditures

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Overall, the primary benefit of using finished panels in a hospital vertical construction project is the significant reduction in water intrusion risk. Even minor water damage that renders a patient room or other medical space unusable can result in hundreds of thousands of dollars in damages. Additionally, the hospital may lose tens of thousands of dollars or more in canceled procedures, along with the substantial opportunity costs associated with operational disruptions and adjustments to lower-floor activities.

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