Better buildings, fewer jobsite headaches, and a serious rethink of how we put everything together.
Construction has a strange relationship with inconvenience. We complain about missing workers, wasted materials, weather delays, and schedules that read like a creative writing assignment. Then we start the next project using almost exactly the same process.
At some point, “that’s how we’ve always done it” becomes an expensive subscription nobody remembers signing up for.
That is why panelization deserves a serious conversation. Moving portions of wall, floor, and roof construction into a controlled manufacturing environment creates opportunities to make building more predictable. Components can arrive measured, assembled, labeled, and ready for a planned installation sequence. Depending on the system, insulation and other envelope components can come with them.
The appeal is easy to understand. The execution takes more thought. People like Charles Leahy of Eco-Panels and Gregory J. Leja of Gorilla Composites are contributing different—and useful—ideas about how much a panel can actually accomplish.
First, Let’s Get the Vocabulary Straight
“Panelized modular construction” gets used as though it describes one product. It doesn’t. Panelization and volumetric modular construction belong to the broader offsite construction family, but they deliver different things.
Volumetric modular construction delivers three-dimensional building sections. Panelization delivers two-dimensional components that assemble into a building. The two can also work together.
Even within panelization, the differences are substantial. An open wood-framed wall panel leaves much of the enclosure work for the site. A closed panel can incorporate insulation and additional layers before shipment. Structural insulated panels, commonly called SIPs, combine structural facings with an insulating core. Other composite panels use different core materials and structural arrangements.
The Department of Energy describes SIPs as prefabricated structural elements used in walls, ceilings, floors, and roofs. They are one category within a much larger panelized construction landscape.
That distinction matters when somebody promises faster installation or lower labor costs. A truckload of framed walls and a truckload of integrated envelope panels don't leave the same amount of work for the builder.
The Opportunity Is Real. The Boom Needs Context.
Before we declare that panelization has taken over construction, let’s check the numbers.
NAHB’s October 2026 analysis of Census data found that modular and panelized methods together accounted for approximately 3% of completed U.S. single-family homes in 2025, unchanged from 2023 and 2024. Of roughly 30,000 homes in that combined category, approximately 16,000 were panelized or pre-cut. NAHB also notes that broader industry definitions yield higher panelization estimates.
Those figures don't capture every commercial, industrial, or institutional application. They do, however, challenge the idea that growing attention automatically means widespread adoption.
I see opportunity in that gap. Builders can recognize a problem long before they change purchasing habits, train their crews, or persuade their project partners to try a different approach. Panelization still has to earn those changes through completed projects and repeat orders.
A market forecast cannot install a wall. A prepared crew with the right system can.
Charles Leahy: Make the Envelope Work as a System
Charles Leahy, founder of Eco-Panels, has focused attention on the relationship between building performance and construction complexity.
In Bill Murray’s January 2026 Offsite Innovators interview, Leahy emphasized that insulation, air sealing, windows, ventilation, and HVAC sizing need to work together. He argued that a high-performing building depends on the completed assembly, not an impressive specification for one component.
As he put it: “people do not live in a panel — they live in an assembly of panels.”
That observation gets to the heart of panelization. Every connection becomes part of the product. Corners, openings, roof transitions, and foundation interfaces must carry the performance the panel promises.
Eco-Panels uses an injected closed-cell polyurethane foam core, integrated cam-lock connections, and a one-piece corner panel. The company presents these features as ways to combine structural and insulating functions, simplify assembly, and reduce thermal interruptions at corners. These are manufacturer-described features and benefits; the design and completed installation still determine project performance.
Leahy’s contribution is especially relevant to builders facing a complicated sequence of envelope tasks. Each added layer brings installation details, scheduling requirements, and another chance to miss something. Combining functions can make the process easier to manage when the system is properly designed.
In the same interview, he advised planning ahead and resolving details before construction. That is probably less exciting than a wall going up in a time-lapse video, but considerably more useful when the truck arrives.
Gregory J. Leja: Rethink What the Panel Is Made Of
Gregory J. Leja brings another dimension to this discussion through Gorilla Composites, where the company identifies him as CEO and CTO.
His published background includes adhesives, resin systems, structural honeycomb, manufacturing plant design, and composite processing. The company credits him with continuing to develop honeycomb cores, curing systems, laminating processes, and assembly methods. That experience connects materials development to the practical question of how to manufacture a product repeatedly.
Gorilla Composites describes its current panel technology as a structural composite system using a proprietary honeycomb core bonded to skins. It says it focuses on strength-to-weight performance, manufacturing flexibility, and applications in housing, ADUs, and other manufactured products. This differs from the foam-core approach associated with conventional SIPs.
For builders and manufacturers, that opens a useful line of questioning. What functions can the engineered panel perform? Which skins fit the application? How will connections, penetrations, finishes, and repairs work?
Leja’s contribution highlights the importance of considering the materials and manufacturing process together. Developing a promising panel also means developing a dependable way to produce, handle, and assemble it.
That does not make every composite panel suitable for every building. It does expand the choices worth evaluating. A panel’s structural capability, thermal performance, and fire performance are separate questions, each requiring evidence for the proposed assembly.
The Labor Conversation Needs an Upgrade
Panelization can move repetitive work into a factory and reduce certain site tasks. But “less onsite labor” needs a more thoughtful explanation than “we won’t need skilled people.”
Someone still has to translate the design into manufacturing information. Someone checks dimensions, manages production, controls materials, and verifies quality. At the site, people still need to understand layout, lifting, bracing, connections, and weather protection.
As skills shift, training has to follow.
I would rather see a company explain exactly how a new employee learns to assemble and inspect its system than announce that almost anybody can do it. Clear instructions, practiced procedures, and accessible supervision make a system more approachable. Assuming that a simpler product makes training unnecessary creates a different kind of labor problem.
This also creates an opportunity for younger workers. Well-organized production and assembly work can offer visible progression: learn a task, demonstrate competence, understand the quality checks, and move to the next responsibility. That is a stronger invitation than handing somebody a tool and hoping they figure out the industry.
Quality Control Starts Before the Truck Leaves
A factory provides useful conditions for repeatability. Workstations can be organized around defined tasks. Materials can be protected. Checks can happen at planned stages. Document problems before components disappear behind finishes.
Still, a factory can repeat a mistake extremely efficiently.
The value comes from the quality system operating inside the building: approved drawings, controlled revisions, material checks, inspection records, and clear responsibility for correcting defects.
For SIP construction, Pacific Northwest National Laboratory’s Building America guidance stresses detailed plans, coordination with trades, trained installers, accurate foundations, protected storage, and properly sealed seams. It also emphasizes checking air sealing before finishes conceal the connections. Those details illustrate how factory preparation and field execution depend on one another.
The last panel leaving the factory is a milestone. The assembled building meeting its requirements is the result that matters.
Faster Walls Need a Faster Overall Plan
Panel erection videos are satisfying. By lunchtime, a building seems to appear where there was only a floor that morning. It's easy to see why people share those clips.
But the project schedule includes design, approvals, manufacturing, foundations, shipping, assembly, utilities, finishes, and inspections. Saving time at one stage helps only if the next stage is ready.
Consider a hypothetical project that saves eight days erecting its enclosure but waits ten additional days for a missing approved detail or an unavailable trade. The installation crew may have performed beautifully while the overall project gained nothing.
My advice is to build the schedule backward from occupancy. Identify what controls each handoff, and make the panel package fit that sequence. Confirm who unloads it, where it goes, what equipment is required, and which crew follows.
Speed becomes commercially useful when it carries through the project.
Different Buildings Need Different Answers
The opportunity extends beyond detached houses, but the requirements change with the building.
For a residential developer, repeatable details and an efficient envelope may lead the discussion. A school addition may place greater emphasis on limiting activity around an occupied campus. An industrial project may require specific durability, span, or environmental performance. Multifamily and institutional buildings introduce their own combinations of fire, acoustic, accessibility, and service requirements.
These are applications to evaluate individually. Success in a small house does not establish suitability for a multistory apartment building or a school.
The supplier should help the design team identify the applicable test reports, engineering, installation requirements, and approval pathway early. That conversation makes adoption easier.
Nobody needs to discover during procurement that the exciting panel presentation skipped the assembly their project actually requires.
Follow the Cost All the Way Through
A panel quote can look expensive beside a lumber package when the two include different amounts of work.
The comparison needs a consistent finish line. Include what remains for framing, insulation, sheathing, connections, lifting, installation, and weather protection. Account for design and engineering, freight, crew training, and any project-specific requirements.
Then measure the outcome. How many labor hours were used? What was discarded? What needed correction? How quickly did the enclosure become ready for subsequent work?
Waste reduction deserves the same honesty. Organized cutting and material handling can reduce offcuts and damage, but moving waste into a factory does not make it disappear. Material choices, manufacturing scrap, transport, durability, and end-of-life options all belong in the environmental assessment.
“Factory-built” tells us where something happened. The records tell us whether it happened more efficiently.
Gary’s Observation
What interests me about panelization is the chance to execute construction more consistently.
Charles Leahy’s work puts attention on integrated envelope performance and assembly details. Gregory J. Leja’s work brings composite materials and manufacturing processes into the conversation. Their approaches differ, giving the industry more than one direction to explore.
We should welcome that variety while asking practical questions. Show us the approved details. Explain the training. Account for the remaining site work. Track the completed cost and performance.
Panelization does not need another promise that every building will suddenly become cheap, fast, and effortless. It needs more projects where the people doing the work can say the process made sense—and where the owner can see the benefit afterward.
That is the kind of progress I can get behind. Give a capable crew a well-designed system, settle the decisions before production, and let the results do some of the talking.















