Banner Boswell Case Study

Project Overview

The project at Banner Boswell Medical Center in Sun City, Arizona was part of a $106 million expansion to the exisiting hospital facility, including a new emergency department and patient tower. The medical facility had not undergone this large of a renovation in 30 years. The new ED increased capacity from 42 to 56 beds, allowing the department to care for up to 60,000 ED patients annually, representing a 25% increase. Construction of the six-story, 322,000-square-foot patient tower began in YEAR and was completed in 2021. The tower’s first floor opened in late 2020 and contains the main lobby, gift shop, retail pharmacy, admitting desk and chapel. The five floors above the main lobby are designed as connecting shelled spaces, reserved for for future inpatient rooms.


One of the innovative cost-and-time-saving measures deployed on the Banner Boswell project involved the use of prefabricated interior and exterior wall panels. The panels were constructed offsite by The Berg Group and delivered to the job site for installation, saving approximately three months of construction time. In addition, the use of prefabricated wall panels allowed for enhanced safety precautions during the COVID-19 pandemic because the nature of prefabrication installation allowed for adequate social distancing and fewer people on-site.

“We are thrilled about the extra capacity that will serve the growing needs of the community for generations to come. This new ED and patient tower lobby will truly transform our Boswell campus and create a welcoming experience given the new entrance”


Each of the 625 exterior stone veneer panels, known as “Banner Block” – average size weighing nearly 10,000 pounds and measuring approximately 8-feet-tall by 30-feet-wide, and weigh approximately 2,400 pounds. he heaviest 16-feet-tall by 33-feet-wide – The Berg Groups construction crew hoisted the panels into place and secured the exterior wall system to the steel structure.

Approximately 125 of the prefabricated wall panels are interior partition walls placed inside the ED. All electrical, plumbing, and medical gas piping required for these walls were installed prior to their arrival on site. This process minimized installation labor and waste, increased productivity, and reduced safety risk and costly site cleanup.

Project Details


  • Sun City, AZ


  • McCarthy Builders, HMC Architects 


  • 2021

Total Contract:

  • $106MM


  • 322,000 square feet (new tower)
  • 6 stories
  • 429 beds
  • 2,578 employees


  • Drywall
  • EIFS
  • Exterior Panels
  • Framing
  • Paint
  • Prefabricated Patient Headwalls
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