Project Overview

- Client: Cushman & Wakefield

- General Contractor: Schuchart

- Location: Boise, Idaho

- Building Type: Commercial (Single-Story Bank)

- Size: 5,000 sq. ft.

- Fabrication Site: St. Peters, MO

- Construction Timeline: 2 months fabrication + 4-day on-site install

- Time Saved:  Approx. 10 weeks

- Estimated Cost Savings: $100,000 (anticipated)

- Man Hours Saved: Approx. 400

Background & Context

In Boise’s harsh winter conditions, speed was critical. The sooner the NER (electrical) room is operational, the faster the bank could open its doors. With a pressing need to beat the weather and stay on schedule, the project team turned to prefabrication for a faster, more efficient solution.

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Design & Planning

Why Prefabrication?

- Speed to market

- Cost savings

- Minimized site congestion

- Weather mitigation

- Material waste reduction

Prefabricated Elements:

- 1 fully wired & plumbed NER Room Pod

- 2 complete Bathroom Pods

- 30 exterior wall panels with multi-finish façade (ACM, metal siding, stucco)

Design Process:

- VDC (Virtual Design & Construction) enabled full 3D modeling

- BIM-driven coordination for architecture, MEP, and logistics

- Digitally-generated Bill of Materials (BoM) reduced material waste to near zero

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Fabrication & Assembly

Off-Site Manufacturing:

- Prefab components built in a controlled environment in St. Peters, MO

- Transported via truck & trailer to Boise

On-Site Installation:

- All prefabricated elements installed in just 4 days

- Minimal equipment used (mobile crane, scissor lift)

- Exterior wall panels installed in tilt-up style - eliminated need for long-term scaffolding

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Schedule & Efficiency

Time Saved:

- 2 weeks saved through prefabrication

- Additional 2 weeks saved via pod installation (NER & bathrooms)

- Total timeline reduction of 10 weeks compared to conventional methods

No Delays:

- Installation went according to plan

- Eliminated weather-related delays on the exterior

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Cost Implications

- Labor Efficiency: Reduced need for on-site crews

- Waste Reduction: Near-zero material waste

- Back-End Cost Savings: Accelerated schedule saved overhead costs

- Estimated Savings: $100,000 (preliminary estimate)

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Challenges & Solutions

Key Challenges:

- Precise tolerances required by the National Financial Institution

- Complex MEP coordination

- Schedule logistics

- Transportation constraints

Solutions:

- Extensive pre-planning & digital QA/QC documentation

- CNC milled drywall and plywood enabled accurate electrical box placement

- Deviation reports ensured layout precision post-steel erection

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Sustainability & Solutions

- Reduced On-Site Impact

- Zero Material Waste (via BoM-driven procurement)

- Enhanced Quality Control: Fabrication in controlled setting with documented QA/QC processes

- Energy Efficient Construction Process

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Outcomes & Lessons Learned

Project Wins:

- Entire exterior and pod installation completed in 4 days

- Avoided winter weather delays

- Accelerated project turnover

- Set a benchmark for future National Financial Institution prefab builds

Key Takeaway:

Prefabrication enabled rapid construction with zero compromise on quality, all while navigating weather risks, tight tolerances, and high-performance standards. The collaboration and digital tools ensured that this project was not only faster—but smarter.

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