A Physical Audit of DfD Performance in a Panelised - Modular Construction System

Abstract

Prefabricated, panelized over-cladding façade systems are promoted as a means of accelerating the decarbonization of existing building stock while enabling circular construction practices. Although pilot projects have demonstrated the technical feasibility of this approach, significant challenges remain in defining and measuring circularity - disassembly performance in practice. This study investigates the application of prefabricated and modular systems in deep energy retrofit projects, with particular emphasis on integrating circularity principles - advanced design for disassembly (DfD) within the design and construction process. The paper outlines the rationale, methodology, and findings from a detailed physical audit assessing DfD performance in a pilot mock-up of a modular circular wall panel developed for retrofit within an Irish social housing demonstrator under the Drive 0 project. A novel DfD audit method was employed to evaluate actual disassembly and reassembly performance. Results indicate that DfD principles were largely successful in practice, with substantial potential for reuse and reassembly of elements, components, and materials across multiple levels of the construction hierarchy. Only minor damage and limited material loss, primarily associated with jointing systems, were observed. The mock up and audit also identified opportunities for system refinement to enhance disassembly efficiency, alongside broader architectural and technical improvements. Furthermore, the findings correlate with and provide validation for an innovative design-stage assessment method for disassembly. Overall, the research contributes to the growing body of knowledge on circular construction, addressing key gaps related to empirical physical validation of design for disassembly in case practice, holistic and hierarchical design for disassembly methodology advancement and validation, empirical design and prototyping of modular circular retrofit application, benchmarking to standards and other demonstrators.