Vol. 3 No. 2

Research Articles

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

Published 2026-05-08

  • Patrick Daly
    • ,
  • Gallego P

Patrick Daly
Technological University Dublin image/svg+xml

Gallego P
Technological University Dublin image/svg+xml

Abstract

Prefabricated, panelised over-cladding façade systems are promoted as a means of accelerating the decarbonisation 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 the implementation of modular retrofit systems and the practical evaluation of design for disassembly across all levels and within real-world contexts.

Keywords

Design for Disassembly, Circularity, Prefabrication, Modular Systems, Retrofit, Architectural Technical Design.

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Author Biography

Patrick Daly

Patrick is full time lecturer researcher in the School of Architecture Buildings and Environment at Technological University Dublin. Patrick has a background in Architectural Technology and Project Management and in design technology education, and has two master’s qualifications in Architecture / Environmental Studies (MSc AEES) and in Research Methods and Sustainability (MSc Research Built Enviro), and is currently a PhD candidate.

He has participated in several European research projects including being Principle Investigator.

STRIVE – EPA funded study into Hemp Lime as a potential construction material in Ireland

CONCERTO – Technical advisor and consultant to the Irish energy authority on the HOLISTIC Dundalk 2020 Sustainable Energy Zone

IEE – Bioregions – toward developing a sustainable bioregion and sector in the midlands of Ireland.

FP7– Rockwood – promoting sustainable development of SRC in Ireland

H2020 – Drive 0 – demonstration low carbon deep energy retrofit via modular circular solutions.

Current - Interg NW  Circ Reno – Supporting development of agri crop biobased solutions and supply chains in Ireland – focused on modular retrofit.

He has published several journal papers, a book chapter, and numerous conference papers and articles.

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