Plug and Play Modular Façade Construction System for Renovation for Residential Buildings

Abstract

The present paper focuses on the architectural and constructional features required to ensure that building envelope renovation are safe, functional, and adaptable to the building stock, with particular focus on “plug and play” modular facade construction systems. It presents the design of one such system and how it addresses these issues. The outcome of early-stage functional test with a full-scale mock-up system, as well as its applicability to a real construction project is presented. It is found crucial to obtain high quality information about the status of the existing façade with the use of modern technologies such as topographic surveys or 3D scans and point cloud. Detailed design processes are required to ensure the compatibility of manufacture and installation tolerances, along with anchor systems that deliver flexibility for adjustment, and construction processes adapting standard installation methods to the architectural particularities of each case that may hinder its use or require some modification in each situation. This prefabricated plug and play modular system has been tested by reproducing the holistic methodology and new technologies in the market by means of real demonstrators. When compared to more conventional construction methods, this system achieves savings in a real case of 50% (time), 30% (materials) and 25% (waste), thus achieving significant economic savings.

Climate Change Mitigation through Modular Construction

“…Slowing down the resource loop is the CE strategy, which focuses on prolonging the functional lifespan of a product to decelerate the overall consumption of resources [76]. MC contributes to slowing resource consumption by promoting effective refurbishment and maintenance of modules, which helps extend their lifespan [77]. In refurbishment, buildings' outdated and aged components are replaced or renewed through renovation, restoring their serviceability [16].…”

“…In refurbishment, buildings' outdated and aged components are replaced or renewed through renovation, restoring their serviceability [16]. Refurbishing traditionally built structures is difficult as their components cannot be decommissioned without destructive disassembly [77]. However, different components of modular units are easily detachable owing to their adaptable design, which enables the disassembly of units [64].…”

“…MC also allows for the use of optimized windows and doors for superior insulation on a large scale, owing to the standardization of modular units involved, which cannot be replicated in conventional construction due to the high variability in the design of traditionally built structures [35]. Integrating efficient insulation materials such as glass foam, plastic fiber, and expandable polystyrene into MC is easier than in traditionally built structures, improving thermal performance [77]. The quality control in MC garners tighter seals between building components, which prevents energy leakages, further adding to the energy efficiency of modular buildings [74].…”

Off-site prefabricated hybrid façade systems

“…Recently, off-site hybrid prefabricated façade systems, which combine highly efficient insulation façade panels integrated with HVAC and renewable harvesting systems, are an upcoming topic for research, innovation development and policymakers (Du, Huang, & Jones, 2019). Combining innovative HVAC components with renewable energy systems constitutes a cost-efficient all-in-one solution for the renovation of a building towards nearly zero energy building (NZEB) status with significant cost, time, material, and waste savings (Torres, et al, 2021). Several such all-in-one deep renovation façade solutions have been explored and developed within EU-funded research projects demonstrating the extended work done to reach NZEB state after the renovation (D'oca, et al, 2018), such as MORE-CONNECT, BERTIM, E2VENT, iNSPiRe, and 4RinEU.…”

Energy retrofit with prefabricated timber-based façade modules

“…Currently, prefabrication is widely used in new construction, involving prefabricated concrete staircases, windows, partition walls, and other components (Richard, 2005). Today, building façades can also be completely pre-assembled off-site, with a variety of materials, either timber-based (Callegari, Spinelli, Bianco, Serra & Fantucci, 2015;Capener, Burke, Le Roux & Ott, 2014), metalbased (Dannapfel et al, 2019;Torres et al, 2021) or with reinforced concrete (Pittau, Malighetti, Iannaccone & Masera,2017;Salvalai, Sesana & Iannaccone, 2017). Their benefits are widely discussed in literature, including cost, time, human resources, environmental sustainability (Teng, Li, Pan & Ng, 2018), materials, management and planning, and architectural design: compared to in-situ construction, they ensure less dependence on weather conditions, high quality, and fast assembly (Shahpari, Saradj, Pishvaee & Piri, 2020).…”