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.

Single-task construction robots (STCRs) have become a popular research topic for decades. However, there is still a gap in the ubiquitous application of STCRs for onsite construction due to various reasons, such as cost concerns. Therefore, cost–benefit analysis (CBA) can be used to measure the net economic benefit of the STCRs, compared to traditional construction methods, in order to boost the implementation of STCRs. This paper presents a simple and practical framework for the economic evaluation of STCRs and conducts a case study of a cable-driven facade installation robot to verify the method. The results show that the cable-driven robot for facade installation is worth investing in in the UK, as well as in the majority of G20 countries. Furthermore, other socioenvironmental implications of STCRs and the limitations of the study are also discussed. In conclusion, the proposed method is highly adaptable and reproducible. Therefore, researchers, engineers, investors, and policy makers can easily follow and customize this method to assess the economic advantages of any STCR systems, compared to traditional construction technologies.

Engineer-to-order manufacturing, characterized by highly customized products and complex workflows, presents unique challenges for warehouse management and operational efficiency. This paper explores the potential of a digital twin as a transformative solution for engineer-to-order environments in manufacturing companies realizing prefabricated building components. This paper outlines a methodology encompassing users’ requirements and the design to support the development of a digital twin that integrates Internet of Things devices, Building Information Modeling, and artificial intelligence capabilities. It delves into the specific challenges of outdoor warehouse optimization and worker safety within the context of engineer-to-order manufacturing, and how the digital twin aims to address these issues through data collection, analysis, and visualization. The research is conducted through an in-depth analysis of the warehouse of Focchi S.p.A., a leading manufacturer of high-tech prefabricated building envelopes. Focchi’s production processes and stakeholder interactions are investigated, and the paper identifies key user groups and their multiple requirements for warehouse improvement. It also examines the potential of the digital twin to streamline communication, improve decision-making, and enhance safety protocols. While preliminary testing results are not yet available, the paper concludes by underlining the significant opportunities offered by a BIM-, IoT-, and AI-powered digital twin for engineer-to-order manufacturers. This research, developed within the IRIS project, serves as a promising model for integrating digital technologies into complex warehouse environments, paving the way for increased efficiency, safety, and ultimately, a competitive edge in the market of manufacturing companies working in the construction industry.

The transition towards a Circular Economy (CE) in the construction sector is essential to achieving sustainable, inclusive smart cities. This study examines the integration of CE principles into construction policies across four key global contexts: the European Union (focusing on Italy and Germany), the United States, and Japan. Through a comparative policy analysis, the research identifies best practices, implementation barriers, and the role of digitalization in advancing CE strategies. In Europe, CE is embedded in policy frameworks such as the Green Deal and the New Circular Economy Action Plan, driving the shift toward sustainable urban development. The United States, while in the early stages of CE adoption, is fostering circular initiatives at local levels, particularly in waste management and building deconstruction. Japan’s policy landscape integrates CE within a broader strategy for resource efficiency, emphasizing technological innovation. The findings highlight the necessity of a research-driven approach to inform policies that leverage digital tools, such as Building Information Modeling and Digital Product Passports, to enhance material traceability and urban circularity. This study contributes to the global effort of designing smart cities that are not only technologically advanced but also environmentally and socially sustainable through the adoption of CE principles in the built environment.

To assist the sustainable development of the building sector, designers require tools illustrating the most viable design options. This paper, starting by presenting the opportunities and limitations of the Life Cycle Assessment (LCA) methodology and Digital Product Passport (DPP) instrument when applied to Custom Modules for Curtain Walls, proposes a Semantic Data-driven Framework to facilitate the design of low-carbon and circular façade modules. Based on literature and the practical outcome of the H2020 project Basajaun, this framework integrates computer-aided technologies that manufacturing companies commonly employ to automate an efficient sustainability assessment process using primary data. This solution innovates industrial process management and architectural design and supports the creation of greener products. It also facilitates the output of documents supporting end-of-life scenarios. The development methodology involves investigating required quantitative project data, environmental factors, and circularity information, as well as the definition of flowcharts for the Life Cycle Inventory, extending a best practice for the façade module’s DPP. Furthermore, the methodology implicates data collection and IT implementation and organisation. This is through the definition of an ontology conceived for interconnection between digital systems. The findings shall contribute to implementing the LCA and DPP practices for custom prefabricated façade modules and suggest areas for further development. Challenges include obtaining and sharing data on environmental impacts and circularity, but involving stakeholders and addressing technical limitations can improve sustainability.