GREEN INSTRUCT - Green integrated structural elements for retrofitting and new construction of buildings

EeB.NMP.2013-1 - Energy-efficient Buildings



GREEN INSTRUCT project will develop a prefabricated modular structural building block that is superior to conventional precast reinforced concrete panels by virtue of its reduced weight, improved acoustic and thermal performance and multiple functionalities. The Green Instruct block consists of over 70% of CDW in weight.

Green Instruct project will: (i) achieve sustainability and cost savings through CDW sourced materials and C2C, (ii) develop efficient, robust, eco-friendly and replicable processes, (iii) to enable novel cost efficient products and new supply chains, (iv) develop a building block that renders refurbished or new buildings safe and energy efficient and (v) safeguard a comfortable, healthy and productive environment. They can be achieved by defining the structural, thermal and acoustic performance of our final product to be competitive to similar products in the market. The types and sources of CDW are carefully identified, selected and processed while the supply chain from the sources, processing, fabrication units to assembly site of the whole modular panel will be optimized. The project is guided by a holistic view through building information modelling and optimal overall performance. This includes considering the life cycle analysis, weight, structural performance, thermal and acoustic insulation, connectivity among modular panels and other structural/non-structural components as well as the compatibility of different internal parts of the each modular panel. In order to homogenize the production process, all individual elements are fabricated by extrusion which is a proven cost effective, reliable, scalable and high yield manufacturing technique. The concept, viability and performance of developed modular panels will be verified and demonstrated in two field trials in test cells.


Project Start: 2016 - 0ngoing


Project Coordinator: Brunel University London
Fundacion Cidetec, Acondicionamiento Tarrasense Associacion, National Technical University of Athens - NTUA, Center of Technology Research and Innovation LTD, Exergy LTD, Alchemia-Nova OG - Institute for Innovative Phytochemistry & Closed Loopprocess, Stress Scarl, Universidade de Aveiro, Artia Nano - Engineering & Consulting IKE, NR-GIA Budownictwo SP Z O. O., Collanti Concorde Srl, Cool Haven - Habitacoes Modulares e Eco-Sustentaveis SA, Acciona Infraestructuras S.A.





IMPRESS - New easy to Install and Manufacture PRE-fabricated modules supported by a bim based integrated design proceSS

H2020-EE-2014-2015/H2020-EE-2014-1-PPP G.A. n. 636717


IMPRESS Project - New easy to Install and Manufacture PRE-fabricated modules supported by a bim based integrated design proceSS will develop three different prefabricated panels for buildings:

  • a polyurethane based insulated panel with improved thermal performance and light radiation and
  • a thin, lightweight pre-cast concrete sandwich panel, with optimum thermal and weathering resistance, both of which are suitable for overcladding;
  • a lightweight pre-cast concrete sandwich panel incorporating Phase Change Materials (PCM) to adapt the thermo-physical properties of the building envelope and enable optimum passive heating and cooling benefits, suitable for recladding.

Innovative nano/micro particle based coatings, suitable for 3D printing, will be also developed to achieve anti-corrosion resistance, high mechanical strength, improved solar reflectance, improved ageing resistance and anti-vandalism properties. To create the panels, an innovative manufacturing process will be created that includes Reconfigurable Moulding (RM) techniques, 3D laser scanning and 3D printed technology. In addition, 3D printed microstructured formworks will be developed as permanent external layer for the polyurethane panel to match the existing building aesthetics and provide solar radiation efficiency.

The overall manufacturing process will:

  • allow for mass production of panels, which take into account complex architectural and aesthetic issues,
  • allow for faster production while lowering prefabrication costs 
  • develop new controlled and cost effective solutions.

IMPRESS will also develop a new Iterative Design Methodology, which will incorporate all stages of the Design-Construct-Install-Operate process. This will be integrated with a BIM cloud based database focussing on the interoperability between software tools required for the prefabricated process. Furthermore, new penalty based business models will be investigated.

The final result will be demonstrated on two existing buildings where final as-built product performance will be validated against the initial design.


Project Start: 2015 - Ongoing 


Project Coordinator: Integrated Environmental Solutions
STAM, The Queen’s University of Belfast, Techrete Ireland Limited, STRESS, HYPUCEM, Sirus Aircon, WASP, Geonardo Environmental Technologies, BIESSSE Tape Solutions, Bergamo Tecnologie SPZOO, Tekla Ltd, AH Asociados, Novel Technologies Center, Municipiul Drobeta Turnu Severin, Council of the city of Coventry




ELISSA - Energy efficient lightweight-sustainable-safe-steel construction

EeB.NMP.2013-1 - Nanotechnology for  multi functional lightweight construction materials and components


The project ELISSA - Energy efficient lightweight-sustainable-safe-steel construction, targets the development, testing, assessment and demonstration of nano-enhanced lightweight steel skeleton/dry wall systems with improved thermal, vibration/seismic and fire performance, due to the inherent damping and fire spread prevention properties of carefully preselectedinorganic nanomaterials (aerogels, VIPs, MMTs, CNT) and MEMS. Their implementation,achieved via the development of industrially friendly application methods, will yield new multifunctionalprefabricated elements with improved thermal properties that will be structurally tested andoptimized as load bearing elements, capable of sustaining from weak vibrations up to medium andsevere earthquakes.

The new nanomaterial enabled multi-functional steel/dry wall elements of ELISSA will reach the highest achievable degree of energy efficiency, safety and sustainability for steel lightweight buildings through:

  • Ensuring efficiency and structural integrity under thermal, dynamic and fire loads (due to nanomaterial properties, MEMs and design concept).
  • Saving materials, energy and time during construction in terms of envelop and steel frame materials (pre-fabricated elements) and due to construction concept (prefabricated lightweight with multi-functional envelops-resilient construction that doesn’t need repair in case of lower seismic action).
  • Saving energy during building operation due to materials (multi-functional elements with suitable insulation)
  • Being economic (re-usable materials, flexibility in architectural design, optimized production logistics-construction-use chain).

Duration: 3 years (2013-2016)


Project Coordinator: National Technical University of Athens

Knauf Gips KG, STRESS, FARBE S.p.A., WÖLFEL Beratende Ingenieure GmbH + Co. KG, Bayerisches Zentrum fuer Angewandte Energieforschung e.V. (ZAE Bayern), University of Ulster, Häring Nepple AG, Università Degli Studi Di Napoli Federico II, Knauf s.a.s., VA-Q-TEC AG



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DApHNE - Development of adaptive production systems for eco-efficient firing processes

FP7-FoF.NMP.2012-1,Adaptive production systems & measurement and control equipment for optimal energy consumption and near-to-zero emissions in manufacturing processes. G.A. n. 314636


The project DApHNE - Development of adaptive production systems for eco-efficient firing processes, was set up to explore energy-saving solutions for the ceramics, glass and cement industries by substituting high-temperature heating with microwave technology.

Project partners developed smart monitoring and control solutions to provide real-time information on energy consumption and product quality on the basis of key performance indicators. They designed, tested and demonstrated solutions based on the self-adaptive control of a high-temperature microwave system and the active control of production lines, which incorporated the proposed microwave solutions.

Researchers first produced a lab-scale prototype and then a semi-industrial prototype with two different modules for processing five target materials: ceramic frits, clinker, slag cement, metakaolin and glass. The challenge was to reduce energy consumption by 40 % whilst achieving high productivity with less environmental impacts by reducing process emissions to below prescribed limits.

Work conducted by DAPHNE is particularly relevant to energy research, smart energy networks, and energy efficiency and saving. As well as reducing the need for energy it also encourages recycling, reducing demands for raw materials and their transport, and lower carbon dioxide emissions.

The project's outcomes will therefore help to bring about a radical reduction in total energy demand, thereby supporting the European Strategic Energy Technology Plan and the Energy Efficiency Plan 2011.


Duration: 3 years (2012-2015)


Project Coordinator: KERABEN
AIDICO, NTUA, ASCEM B.V., CEMEX RESEARCH, UNIVPM, TU BAF, AGORIA, IST IPA-FRAUNHOFER, STRESS, Técnicas Reunidas, Santos Barosa – Vidros S.A., FLO-IR,  MUEGGE Tu Bergakademie Freiberg, Universitat  Politecnica de Valencia, ICV CSIC, IFT Tecnico Lisboa, Ceinnmat


Awarded by the European Commission




BIOCORIN - New biocoating for corrosion inhibition in metal surface




The project BIOCORIN - New biocoating for corrosion inhibition in metal surface, aims at developing a green alternative to the coatings and solutions used up to date for MIC corrosion protection and prevention in infrastructures. As the concept of the project is the identification of anti-fouling microorganisms, their later integration in a sol-gel coating and finally the monitoring of the coating performance, latest technologies, solutions and methods related to those fields will be analysed.

This sol-gel coating would be used to protect steel structures (viaducts, railways, steel structures in ports, airports, gas pipes, etc.) aiming at increasing their life by 30%. The demonstration activities are being carried out in 3 sites: 

  • Harlingen Harbor (The Nederlands - marine environment)
  • Gijón Harbor (Spain – marine environment)
  • Shore area of Bagnoli-Coroglio (Napoli, Italy – marine and land environment)


Duration: 3 years (2012-2015)


Project Coordinator: ACCIONA Infraestructuras 



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