New Easy to Install and Manufacture PRE-Fabricated Modules Supported by a BIM based Integrated Design ProceSS

Project Information

IMPRESS

Grant agreement ID: 636717

DOI

10.3030/636717

Project closed

EC signature date 11 May 2015

Start date 1 June 2015

End date 31 May 2019

Funded under

• SOCIETAL CHALLENGES - Secure, clean and efficient energy

Total cost

€ 6 041 474,28

EU contribution

€ 4 493 099,74

Coordinated by

INTEGRATED ENVIRONMENTAL SOLUTIONS LIMITED
United Kingdom

Periodic Reporting for period 3 - IMPRESS (New Easy to Install and Manufacture PRE-Fabricated Modules Supported by a BIM based Integrated Design ProceSS)

Reporting period: 2018-05-01 to 2019-05-31

Summary of the context and overall objectives of the project

Buildings dated between 1950 and 1975 were constructed in an era where energy efficient performance was not a critical part of the design. Many of these buildings now require the retrofit of exterior pre-fabricated concrete panels, and an opportunity exists to ensure this occurs utilising the latest technologies to improve energy efficiency. IMPRESS has leveraged on the potential of offsite manufacture for prefabrication by developing a new range of easy to install panels. Three different prefabricated panels for buildings have been developed: (i) a polyurethane based insulated panel for overcladding (ii) a thin, lightweight pre-cast concrete sandwich panel for over-cladding; (iii) a lightweight sandwich panel incorporating Phase Change Material, for re-cladding. Innovative nano/micro particle based coatings, suitable for 3D printing, have also developed to achieve anti-corrosion resistance, high mechanical strength, improved solar reflectance, and improved ageing resistance. To create the panels, an innovative manufacturing process has been created that includes Reconfigurable Moulding (RM) techniques, 3D laser scanning and 3D printed technology. The overall manufacturing process allows allow for mass production of panels, increases the speed of production and gives new controlled and cost effective solutions. Improved methodologies and systems have been created and the project has produced decision support tool for the design stage of renovation to allow the end user to choose which re-cladding/over-cladding option is suitable for their building. A new BIM based Iterative Design Methodology has been produced which incorporates all stages of the design - install - operate process, and has been integrated in an online management platform as well as backed by a cloud based BIM database focussing on the interoperability between software tools required for the prefabricated process. The final results were demonstrated on two buildings where final as-built product performance was evaluated and the software and methodology assessed.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

Work Package 1
The following panels were extensively researched, tested and iteratively developed in the lab environment so that they were ready for the test and full scale demos:
• Hybrid Polyurethane Panels for over cladding
• A high performance concrete panel for over cladding
• A high performance concrete sandwich panel with phase change materials for re cladding

Work Package 2
The precasting process was defined and optimised and a 3D laser scanning technique was defined and applied to the existing façades. This allowed the design of necessary equipment and formwork for producing pre-casted elements both standard and customised, as well as the design and build of the reconfigurable mould coupled with 3D printing technologies.

Work Package 3
The activities included investigating innovative installation techniques for fixing the panels to the existing façade. Anchors for panels based on double sided adhesive tapes were tested but found to be not suitable for the application. New metallic anchors for the panels were also designed, but due to legislative requirements they could not be used. Existing market solutions were therefore employed and user-friendly installation guidelines were created.

Work Package 4
In-depth stakeholder analysis was conducted and the baseline of existing collaborative methodologies was established. This informed the development of the IMPRESS methodology which was specific to the prefabricated renovation process. This was then joined with the latest BIM protocols to create iBIM: a BIM based methodology specific to IMPRESS and the prefabricated renovation process. It includes communication mechanisms and energy management skills for the stakeholders and ensures energy design is included early in the design process and carries through to the operation of the building. A penalty based business model as well as an auditing procedure was also developed as part of the methodology to ensure that all stakeholders are responsible for the final product performance.

Work Package 5
The following software tools were developed:
• A Decision Support Platform that allows the end user make an informed decision as to which prefabricated panel option they wish to install that best suits their individual requirements.
• An Online Management Platform that allows all stakeholders to engage
• An interoperable data exchange server which allows all software tools and data within the prefabricated panel renovation process to communicate and exchange data with each other.
These tools were extensively testing within the project and externally via the Advisory Panel.

Work Package 6
The demo site envelopes were assessed and the 3 panels were tested on separate test facades in Naples and at Techrete’s outdoor facility in Balbriggan in order to assess energy performance and behaviour under real conditions. The final panels were then installed on the two different types of demo buildings in Romania and Ireland for a large scale demonstration. The performance of the panels was demonstrated through the use of sensors and data loggers at the demos sites for as long as possible, as well as detailed modelling using IES VE. The methodology and software tools were also assessed in terms of their benefits as part of this work package.

Work Package 7
The dissemination of the project and results occurred through:
• Publication of academic and industry papers
• Attendance at conferences and events
• Promotion on the project website and social media pages
• Newsletter updates, e-bulletins and blogs
• Workshops to engage with academic and industry stakeholders
• Two External Advisory Panels

Standardisation activities occurred as well as the development of exploitation plans to maximise market uptake after the project.

Work Package 8
This comprised five main activities:
• Administrative, Financial, Quality Assurance and Risk Management
• Periodic Progress Verification Assurance
• Decision making and conflict resolution
• Scientific and technological management
• IP generation and management
There was regular contact with EC officers and there have been Consortium meetings every 6 months and number of Amendments required for the project during its duration.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

Reduction in total buildings (primary) energy consumption – the results for precast sandwich panels in both recladding and over cladding U-Values of 0.14 and 0.15 respectively. Simulations showed that the application of the recladding panels to the Coventry demonstrator could result in an energy saving could be 8% per year. For the Hypucem panels, the U-Value of the external walls would reduce from 1.54 to 0.19 W/m2K, and the energy saving on the Severin demonstrator could be 22% per year.

Reduction of renovation operations and installation time - It has been concluded that a time reduction of entire process can be reduced more than 30% in comparison with standard practises. Further to this, it was concluded in the assessment of the methodology and software tools, that if followed, potential time savings could be greater than 30% across the design, manufacture and installation process.

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