FFG Project Prefab.Facade

Prefab.Facade – Improving the performance of recyclable, serially prefabricated facade elements

The construction sector is responsible for a significant proportion of raw material consumption, CO₂ emissions, and waste generation worldwide. Around 34% of global CO₂ emissions and 32% of energy consumption are attributable to the construction and operation of buildings. Existing buildings with poor energy efficiency in particular offer great potential for significantly reducing energy consumption through renovation. At the same time, the integration of resource-efficient and recyclable construction methods, combined with automated manufacturing, opens up the possibility of reducing raw material consumption and environmental impact and creating new economic prospects for the construction industry.

The research project “Prefab.Facade – Performance enhancement of recyclable, serially prefabricated facade elements” pursued the goal of creating the basis for the development and large-scale implementation of modular timber frame systems for renovation that can be manufactured as part of a prefabrication process. The focus was on achieving the highest possible degree of prefabrication, a continuous digital process chain from planning to production and assembly, and the ecological and economic optimization of the systems.

Several innovative approaches were investigated in the project. These included digital inventory using laser scanning and drone photogrammetry, the development of an optimized layer structure for the facade, and the automation of production through the use of industrial robots. Two 1:1 scale prototype walls were constructed in the laboratory and used for practical testing. This allowed assembly processes with facade elements to be tested, assembly systems and efficient connection techniques between the modules to be investigated, and measures to minimize thermal bridges to be evaluated. In addition, jointless, rear-ventilated plaster facades and various facade claddings were tested for their practical suitability.

The results show that modular facade systems can achieve significantly higher recyclability and lower environmental impact than conventional composite thermal insulation systems. Serial prefabrication shortens construction times, reduces personnel costs, minimizes weather-dependent work, and increases the quality of execution. At the same time, precise digital inventory and a continuous process chain enable efficient planning and implementation. A targeted choice of materials helps to significantly reduce environmental impacts.

Overall, the research provides valuable insights into the optimization of construction processes and the further development of sustainable, resource-efficient facade systems. The project thus makes an important contribution to promoting the circular economy and achieving climate neutrality in the construction industry.