Case Study: 
Rethinking Hospital Design: How EIFS Panelization Redefines Speed, Safety, and Precision 
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​Mayo Clinic West Expansion
EIFS and off-site construction methods can drive architectural excellence, enhance operational safety, and deliver on-time, on-budget results in highly complex environments.
Project Overview
In today’s healthcare design, speed, safety, cost control, and future adaptability are critical demands placed on architects and builders. The Mayo Clinic West Expansion in Phoenix, Arizona, offers a clear example of how using Exterior Insulation and Finish Systems (EIFS) through prefabricated panelization can meet—and exceed—these expectations. This case study examines the technical strategies, project innovations, and long-term value delivered by integrating EIFS panel systems into a high-stakes, operational healthcare environment.
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The Mayo Clinic’s Phoenix campus is a flagship facility renowned for innovation in medical care. As patient demand grew, the need for expanded clinical areas and additional hospital capacity became pressing. The West Expansion, completed in 2024, provided this critical space increase while preserving the seamless architectural identity of the existing hospital structures.
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The project’s primary challenge was achieving aesthetic continuity and construction efficiency in an active healthcare environment with tight site access and a non-negotiable need for patient and visitor safety.
Key Project Highlights
Why EIFS and Prefabricated Panelization?
Architects and contractors evaluated traditional field-applied EIFS against a prefabricated panelized EIF system. Prefabrication was selected based on several key advantages:
  1. Cost Control - Prefabricated panels lowered the total installed cost by reducing on-site labor requirements and construction duration.
  2. Accelerated Construction Timeline - Panelization significantly compressed the construction schedule—critical for a hospital that had to maintain full operations during expansion.
  3. Site Constraints and Safety - With limited space for scaffolding and the need to protect pedestrian traffic, prefabrication minimized on-site activities, creating a safer, more controlled work environment.
  4. Architectural Precision - The façade design called for complex reveals, deep window profiles, and two-story panel spans. Prefabrication allowed these features to be executed with millimeter precision in a factory-controlled setting, something difficult to achieve consistently in the field.

Technical Execution and Innovation
The West Expansion’s EIFS façade involved:
  • 1,500 prefabricated panels
  • Panel dimensions: Approximately 24 feet x 15 feet, 24 inches deep with 6 inches of EIFS
  • Unique Features: Two-story spans, sloped windowsills, complex reveals
 
The Digital Building Components team engineered novel framing and support techniques to accommodate the size, weight, and complexity of the panels. Their innovative cold-formed steel design was recognized with the 2023 Cold-Formed Steel Engineers Institute Award for municipal/services excellence.
 
Future-Ready Design
Recognizing the Mayo Clinic’s long-term expansion plans, the panel system was intentionally designed for future vertical and horizontal expansion—demonstrating the adaptability possible with EIFS panelization.

Broader Implications for Architectural Practice
The Mayo Clinic West Expansion highlights several important lessons for the architecture and construction community:
    Challenge                                                  EIFS Panelization Response
    Aesthetic Continuity                                Customizable surfaces and reveal patterns
    Speed of Construction                            Rapid installation with minimal site disruption
    Limited Site Access                                 Reduced need for scaffolding, crane-based installation
    Occupied Facility Constraints                Safer pedestrian conditions, lower noise and dust
    Future Growth Requirements                 Modular, expandable panel design

Incorporating EIFS through prefabrication not only met immediate project goals but also future-proofed the structure, a key consideration for institutional projects under constant pressure to grow and adapt. For architects, this project affirms that prefabricated EIFS is no longer just a technical alternative—it’s a strategic design decision for the future.
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