Final Report Summary - RETROKIT (RetroKit - Toolboxes for systemic retrofitting)
Executive Summary:
RetroKit develops and demonstrates at three building pilots (Spain, Germany and Sweden), multifunctional, modular, low cost and easy to install prefabricated modules in order to significantly increase the EU retrofitting rate and contribute to EU energy reduction commitments. These innovative systems target existing multi-family residential buildings which represent more than 50% of the EU building stock and between 65% and 80% of its energy consumption.
RetroKit project brings the aspect of multifunctional façade and roof elements into the retrofit sector. Special integrated solutions have been developed which are dealing with the aspects of heating, ventilation, cooling, electricity and ICT in a flexible way. The key factors for RetroKit are the window element with a technical box taking in HVAC systems and interfaces for building services (ducting, piping) installed on the existing façade, and façade modules integrating ventilation systems, heat/cold supply systems, piping for heating and cooling, ICT and electricity, and photovoltaic, solar thermal and PV/T collectors into thermal insulation for façade and roofing solutions. To be attractive beyond affordability, multifunctional semi-prefabricated elements are developed which provides an opportunity to retrofit improving aesthetics, comfort, energy performance, and property value at the same time.
Partners investigate and identified negative factors that prevent positive retrofit decisions and the conditions, requirements, information, arguments and human factor aspects for the implementation of the retrofit toolbox. Monitoring and analysis of the results demonstrated the effects of the solutions on the inhabitants. Retrofitting components and technologies have been developed and characterized and tested in lab and real scale environment in parallel to the development of an optimised construction retrofitting processes that minimise intrusion, maximise work to the exterior and cavities of the building, reduce the time and cost of retrofitting, and increase safety. LCA and LCC analyses were also made. The findings are integrated in the RetroKit Toolbox, a real set of modular (semi)prefab solutions, supported by a software enabling decision for retrofitting options. Possible users, barriers, optimal market and marketing strategies have been coupled with an effective route for exploitation of the toolbox. Demonstration activities in Madrid, Frankfurt and Pitea allow for the verification and refinement of the entire RetroKit methodology, several selected developed technological solutions, and the appropriate construction processes.
RetroKit benefits can be seen at different levels:
- at macro-level, by inducing important savings in terms of energy consumption and emissions and by increasing turnover for the benefit of the almost 3 million construction SMEs operating in building renovation with a consequent impact on job creation;
- as buying drivers for the apartment/building owners, as they can have clear economic savings in the energy bills and more attractive higher value properties, while at the same time avoiding the discomforts and burden often associated to retrofitting intervention;
- for the actors involved in the retrofitting supply chain, as new skills and profiles will be required, and new business opportunities can be generated.
Project Context and Objectives:
RetroKit develops and demonstrates at three building pilots (Spain, Germany, Sweden), multifunctional, modular, low cost and easy to install prefabricated modules in order to significantly increase the EU retrofitting rate and contribute to EU energy reduction commitments. These innovative systems target existing multi-family residential buildings which represent more than 50% of the EU building stock and between 65% and 80% of their energy consumption.
RetroKit project brings the aspect of multifunctional façade and roof elements into the retrofit sector. Special integrated solutions have been developed which are dealing with the aspects of heating, ventilation, cooling, electricity and ICT in a flexible way. The key factor for RetroKit is the window element accompanied with a technical box taking in HVAC systems as well as interfaces for building services (ducting, piping) installed on the existing façade.
To develop high technology efficient systems, we have selected and integrated into multifunctional prefabricated modules the most promising retrofitting technologies to include windows, insulation materials, HVAC systems, renewable energy systems and energy supply systems, extensively investigated by our market leaders STO, our research intensive SMEs BGTEC, KOKO and AMS, and leading RTOs FHG, SP, SINTEF and TECNALIA. The modules integrate ventilation systems, heat/cold supply systems, piping for heating and cooling, ICT and electricity, and photovoltaic, solar thermal and PV/T collectors into thermal insulation aimed for façade and roofing solutions.
To be low cost and systemic, we decided to streamline the value chain though prefabricated modular configurations supported decision support system and tool that enable customised production, industrial scale-up, and efficient construction processes adapted to component manufacturers, integrators, installers and contractors. As such, costs in the whole life cycle are decreased: due to easy installation to simple maintenance (pipes on façades are easily accessible from outside), arriving to affordable decommissioning and finally to convenient recycling. Embodied energy is considered.
To be attractive beyond affordability, we aim at multifunctional semi-prefabrication which provides an opportunity to retrofit improving aesthetics, comfort, energy performance, and property value at the same time.
Efficient construction processes involve low impact on occupants and lower risk to investors. We are indeed combining the challenge of developing an innovative solution for systemic retrofitting while coping with the pragmatic aspects of construction (corners, connections, thermal bridges, etc.) In order to overcome current barriers for retrofitting, social, technological, industrial, and economic barriers are deliberately treated through the identification of bottlenecks, impediments, and human factors preventing positive retrofit decisions and then by providing the means to overcome them. The result is the RetroKit Toolbox composed of modular solutions and high quality decision support tools that provide information, performance estimates, financial transparency, and design support.
To achieve all of these objectives, our consortium is driven by DRA, the Top 1 European construction company as part of the ACS Group operating world-wide in more than 40 countries, BLATRADEN a highly innovative SME company with long standing experience in prefabrication, STO a technical leader for insulation systems as well as AMS, a research intensive construction SME which has pioneered innovative coatings and plasters to minimise thermal bridges and microbial growth on walls, partitions and air ducts. The project ideas are based on feasibility work performed by FHG, SP, SINTEF and TECNALIA within a joint research programme funded with own resources, which deeply investigated the concept of prefabricated façade systems within the AERTOs ERA-Net framework.
In WP1 (Societal beneficial systemic retrofit) the partners investigate and identified through means of web survey and questionnaires objections, bottlenecks, and impediments that prevent positive retrofit decisions and the conditions, requirements, information, arguments and human factor aspects for the retrofit toolbox in order to be perceived as an attractive solution from the point of view of residents and of decision makers of the construction process (including architects, engineers, builders, authorities, housing owners). Monitoring and analysis of the results demonstrates the effects of the solutions on the inhabitants.
WP2 (Multifunctional and modular retrofitting components and technologies) is a cornerstone of the project and it is dedicated to the development of multifunctional façade retrofitting solutions such as insulation components with integrated air ducts, and multifunctional energy producing façade elements and integrated energy use systems. These new components and systems (with others) have been characterised and tested in lab environment. The WP contains the scientific and technical development of materials and components that form the basis of the prefabricated modules.
WP4 (Effective retrofitting process) integrates the experiences and expertise (mainly) of the consortium retrofitters. The workpackage achieved a study of the construction retrofitting processes in a holistic way and how these processes can be optimised. Then, the optimised construction retrofitting processes that minimise intrusion, maximise work to the exterior and cavities of the building, reduce the time and cost of retrofitting, and increase safety was developed. WP3 (RetroKit Toolbox) is another cornerstone of the project. This workpackage is integrating information provided from WP2 (technologies) and WP4 (processes) to achieve a real toolbox of solutions, supported by a software enabling decision for retrofitting options. Definition of the toolbox has been achieved as well as integration and the decision support system and tools.
WP5 (Market replication) identified possible users, barriers and markets for the Retrokit toolbox. Optimal market and marketing strategies have been coupled with an effective route for exploitation of RetroKit Toolbox. LCA and LCC analyses are terminated, showing the potential benefits of the solutions adopted.
Demonstration activities are described in WP6 (Pilot cases and Demonstration). EMVS provided a large scale building (social housing) for retrofit in Madrid, Spain. ABGNova proposed a German demonstration building in Frankfurt, which renovation in ongoing. The third Demo building is located in Sweden, provided by Blattraden. These case-studies allow for the verification and refinement of the entire RetroKit methodology, several selected developed technological solutions, and the appropriate construction processes.
Testing facilities, which offer state of the art environment control and monitoring capabilities and the ability to integrate and test all RetroKit technical solutions, have been exploited: Fraunhofer facility tested roofs-PV integrated, TECNALIA facility is hosting the dessicant module under development, while SINTEF facility tested a new type of windows integrating PV on glazing.
WP7 (Exploitation, dissemination and stakeholders engagement) was very active as it is demonstrated by the large number of dissemination events sustained by the project. Architectural competition among student has been defined with positive results. Exploitation activities leaded to the definition of 8 Key exploitable results, for which a future path has been drafted.
Lastly, WP8 (Project management) ensured the professional conduct and execution of all project activities. Technical progress and active management of workpackage interdependencies is not business as usual in RetroKit due to the complexity of the challenge at hand, holistic nature of the work to be conducted, and the diverse nature of the consortium.
Project Results:
The multifunctional framing elements – KER #1 – are developed to optimize the integration between the air exchange system and new windows. The new window is equipped with a technical box to improve the air quality and energy saving within the interior environment. The purpose of such element is to exchange heat with the exterior air.
The system has been demonstrated and validated in a relevant and operating environment and its TRL is currently 6 – 7.
Knowledge is jointly owned by BGTEC, Fraunhofer, Kokotas.
The partners recognize the potential for applying for a patent on the topic. Still no actions or decision have been made in practical terms, however the innovation is hidden in the products installed so far, therefore the industrial secrecy is preserved.
BGTEC, together with Kokotas will be the producer of the parts. BGTEC will be as well the integrator and the installer of the solution.
Marketing activities will be dedicated to selected arrays of customers, requiring compact and effective solutions.
The business potentially generated is wide, as it can grow in accordance to BGTEC own plans of development.
Regarding the KER #2a, named Prefabricated Insulation panel – Fresh Air Wall (FAW), its development is completed (TRL 7) and the solution can be installed in 1-2 storey buildings. Targeted customers have been mainly identified with housing companies and building owners.
For the general technical approval, the compliance for the fire protection is still necessary, plus large fire tests should be done.
Fraunhofer is the responsible partner for such result, supported by external partners.
Also for the KER #2b – Multifunctional Insulation board - the development has been completed (TRL 7) and the manufacturing is based on usage of mineral wool and steal ducts. There are no problems with fire protection but the solution will be more expensive than the previous one. The general technical approval is still necessary for the production in EPS and plastic ducts. Also for KER #2b customers addressed will be housing companies and building owners.
The responsible partner is STO, supported by Fraunhofer
The KER #2c – ETICS and paintings – is instead already available in the market (TRL 9)
Concerning solutions #2a and #2b, significant business opportunities exist in the market and potential customers are widespread (1% average rate of building retrofitting per year in Europe). However, the real market penetration is related to the compliancy with fire regulation.
Agreement between STO and Fraunhofer should be developed concerning solution #2b.
Market potential is high, and the role of STO can grant an easy access to wide networks.
The KER #4 consists on an integrated façade element including a solar thermal collector and a desiccant module, aimed to provide dry air as an initial step for evaporative cooling systems. The system can be integrated with central air handling units and other HVAC modules, plus its installation is suitable in sun-exposed façades (unobstructed south facing façades).
Currently, development of the KER #4 has achieved a TRL 4: the planned level of 5 has not been reached yet due to the need of re-designing the solution.
The responsible partner of such result is Tecnalia and the initial exploitation strategy foresees the following points:
• (in)Direct involvement in initial experiences
• Need for business development/interaction at building design level (engineering/architecture firms)
• Licensing to third parties: façade manufacturers, lightweight façades, curtain wall systems, etc. (e.g. ASTRAWALL, SCHUCO).
The exploitation of KER #4 aims to address several markets and sectors which can be divided as follows:
• HVAC
o Pre-existing buildings with centralised HVAC systems
o HVAC system installed in roof area
• Climate
o South Europe (or buildings with high cooling loads)
o Need for sun exposed south wall
• Building
o Integration with curtain wall sections
o Overcladding/ façade insulation
The KER #5 provides the following innovative aspects:
• New formulations of nanoparticle’s families
• New “industrialized” (on spot) methods to evaluate their:
o Optical properties
o Physical properties
o Special properties
• Development of a pilot plant producing at semi-industrial scale high performance coatings with advanced fully automated “pre – industrial” methods
The new formulations developed have shown improved properties, such as:
1. IR reflectance – IR absorbance
2. Improve substrate’s porosity
3. Water penetration resistance
4. Hydrophobicity or hydrophilicity
5. Low thermal conductivity
6. Algae growth resistance
7. Anti-bacterial behavior
8. Self – cleaning behavior
9. Acoustic insulation
Initial exploitation strategy for such result foresees the following points:
• AMS’s research results have been exploited for other EU financed project (e.g. CommONEnergy) and used as precursors for further research and development of new innovative multifunctional coatings.
• The results have been presented to clients and partners from the construction industry. The incoming experience resulted from the research was especially useful in order to suggest them innovative retrofitting solutions.
• AMS participated at the fair DesignLab, which took place in Athens last May. Main objective of AMS’s participation was focused on “Innovative Materials in the building sector”. During the fair, results of RetroKit project about new innovative materials have been presented: the audience was enthusiastic with the results based on nanotechnology and interested in the benefits from the use of the innovative materials compared with their cost.
• Several scientific presentations took place from AMS’s scientific staff, giving the opportunity for the exchange of views with academic and research partners and collaborators (National Technical University of Athens, National Center for Scientific Research “Demokritos”).
The potential markets and customers addressed by KER #5 are:
• Professionals of the construction industry (wholesale)
o Technical-Construction Companies for energy efficiency of buildings
o Architects & Designers
o Civil Engineers
Free distribution for testing and fairs is envisaged.
• Consumers (retail sale)
o Paint shops
o E-shops
Targeted advertising strategy will be developed above all for the retail sale.
The KER #6 provides the following innovative aspects:
• ICT instrument, and correlated manual (the Tool) that comprises the decision support tool, the methodology and the results of the experience, oriented to ease the best available solutions in response to the actual building refurbishment needs
• To be made available in the form of a web-based ICT tool, to provide data, transparency on payback, guidelines, and design support, according to the experience and the results gathered within the project.
The tool will need 1-2 years after project conclusion to enter the market. DAPP is the responsible partner but the whole RetroKit Consortium is involved.
Different end customers are foreseen in accordance to the finalities and tools quality:
• Building refurbishment companies
• Architects/designers and planners
• Construction Companies
• Building owners willing to get inside to renovation process
The wide span of customers in Europe, associated to the needs felt for retrofitting, make this tool (and the availability online) an interesting asset.
An initial exploitation strategy foreseen the following pathways (in accordance to the customer type) to exploit the tool:
1. Free use of the SW to promote the RetroKit results through an advertising-based model where revenues come from the fees advertisers pay for the access. Money received from advertisers’ fees could help covering costs for hosting and maintaining the website on a commercial server.
2. Freemium proposition for service access to the tool where software is provided free of charge to a large group of users (base version) and revenues come from additional and upgraded features sold to a smaller fraction of the user base (comprehensive version).
3. Pay professional access (annual license fee) through a subscription-based model where users pay a periodic fee (likely annual) for the right to use the software, according to the terms of the agreement signed. Maintenance and support are bundled in the periodic fee and customers get access to the latest versions without having to pay additional upgrade costs.
4. Prefab manufacturers can pay a periodic fee (likely annual) for the right to be listed in the software, according to the terms of the agreement signed.
5. Re-selling of the licenses: the prefab manufacturers pay a big license cost in order to provide customers/partners with the SW free/at lower price.
6. Distribution system: partners can use the normal license to show potential customers how it works and they will receive a fee for every customer acquired.
Finally, the strategy agreed among the partners is drafted in accordance to the following:
• DAPP is the SW owner and is in charge to complete, maintain and upgrade the SW (proprietary code) from the programming and hosting sides
• Project partners (PP) are in charge to update the solutions database and to test the tool
• DAPP and PP can use the SW for free for internal projects
• PP will pay a fee to DAPP when using the SW for commercial purposes under a contract (e.g. customer support)
• Customers that want/need an account will pay the license costs to DAPP
• PP will receive a fee if they provide customer willing to pay license
Three levels of access are planned:
• DAPP: administrator
• PP: power user
• Customer: user
Money coming from the fees will be used to maintain and keep active the SW. About this, partners agreed on the fact that the system is based on trust, hence if nobody pays the fee, the system cannot be maintained.
The RetroKit Methodology (KER #7) will be exploited as a commercial product addressing companies involved in retrofitting apartment buildings.
At project completion such result will reach TRL 9.
In particular, two companies are already interested in exploiting the RetroKit Methodology and they are:
• DWEcoCo: a sustainable design company with architects
• Dragados: a large construction company
DWEcoCo has identified the following market opportunities in Ireland:
• 140,000 apartments in Ireland, about 10% of total dwellings
• Assuming 1% retrofitting rate then 1,400 apts retrofitted pa
• Assume €10,000 deep retrofit cost per apt = €14 M pa
• Consultancy service @ 2% = €280,000 pa income
Dragados found market opportunities in Spain as follows:
• 17 M apartment in Spain
• Assuming 1% retrofitting rate then 170,000 apts retrofitted pa
• Assume €10,000 deep retrofit cost per apt = €1.7 B pa
• 5% of market share for Dragados = € 85 M
DRAGADOS is the exploitable responsible partner for such result, while SP and BLATRADEN are the main contributors. Anyhow, the whole consortium is involved.
Concerning KER#8, partners SEGEL and D'APPOLONIA have both contributed in the work with business modelling as part of the RetroKit project. Both companies may freely exploit the results in any country. The Business Models will be built according to specifics of customers and sectors targeted.
Potential Impact:
RetroKit provides an holistic and systemic approach for the retrofitting of residential multi-storey buildings allowing them to achieve the energy efficiency levels of new buildings.
Holistic because it addresses the whole value chains and components, from decision making to construction processes, from windows to integration of renewable energy systems, from assessment metrics to business models.
Systemic because the approach aligns the stakeholders through the retrofit phases of building assessment, solution design, industrial scale up of developed technologies (manufacturing), and on-site construction processes.
RetroKit aim to meet the call targets of 50 kWh/m²/year, the reduction of peak loads, and a reduction of 30% energy consumption with respect to new building standards by developing new retrofitting systems based on prefabricated elements has been almost achieved. Last post project refinements consist in an industrialization of some of the technologies developed and the mass production will reduce the current prototype production costs.
A payback close to 7 years was made possible through the project approach to develop prefabricated multifunctional retrofitting solutions. Business models accounts for benefits not only directly related to energy saving but also on the avoided impact of the traditional retrofitting systems and tool, not used in RetroKit due to the technologies prefabrication.
Benefits can be seen at different levels:
- at macro-level, by inducing important savings in terms of energy consumption and emissions and by increasing turnover for the benefit of the almost 3 million construction SMEs operating in building renovation with a consequent impact on job creation;
- as buying drivers for the apartment/building owners, as they can have clear economic savings in the energy bills and more attractive higher value properties, while at the same time avoiding the discomforts and burden often associated to retrofitting intervention;
- for the actors involved in the retrofitting supply chain, as new skills and profiles will be required, and new business opportunities can be generated.
RetroKit target is the 10 million multi-family residential buildings built from 1945 to 1980, which are supposed to require a general maintenance and refurbishment and where energy-efficiency measures could provide added value at a reasonable extra cost.
Starting from the difference in thermal transmittance before and after retrofitting intervention and the heating degrees hours for the building location, assumed in central Europe, the total energy saving that can be obtained with intervention on the envelope only is about 4,2 billions kWh per year if the new retrofitting solution is applied in 5% of the target buildings, leading to almost 1 Mton of CO2 saved.
Considering an average energy cost of 0,12 €/kWh27 between 2010 and 2030, this energy savings corresponds to an overall saving of about 500 M€, considering the expected market penetration of 5%.
RetroKit followed approach will result also in an increase of turnover for the whole European construction sector, through new investments which couple structural retrofitting to energy efficient solutions. Assuming that a standard intervention with the RetroKit approach over the whole building combines the solution for the outer envelope, the total investment costs (including installation) can be estimated as 120 €/m2 in total. With these numbers and assuming again a penetration rate of 5% within 5 years after the end of the project, this will result in an increase of turnover and additional investments for the construction sector of almost 4 billion €.
This market share will have a positive impact also on job creation as it includes effects on the volume of construction works, effects on the volume of jobs related to the components manufacturing and to the façade assessment and many others. The additional investments can be compared to the turnover and employment of the construction industry, where 14,9 million operatives generate a total turnover of 1173 billion €28, corresponding to a turnover of 78 k€/y per employee. It can be assumed that the share of material costs for the proposed retrofitting process is a factor of 2 higher than conventional construction activities.
Thus, an additional 150 k€/y invested into energy-savings packages would generate one new position. Therefore additional investments of 4 Billion € would roughly correspond to 27000 additional new jobs in the construction and installation industries across Europe.
To get continuous feed-back from the market and other stakeholders, it is of great importance to disseminate public results from the project. The project partners in RetroKit have disseminated actively on a national, as well as international, level.
A number of 101 separate dissemination activities have been carried out within the project since the project started in September 2012.
The RetroKit partners has mostly made oral presentations of the project at both scientific events as well as to wider publics. The project has also mainly been included in newsletters and at the project partner’s websites. In addtion to that RetroKit Newsletters has been issued and sent to almost 1000 contacts and afterward published on the project website.
The RetroKit project partners have arranged and participated at seminars on national as well as international level.
Among many others, the partners have disseminated RetroKit at:
• BAU 2013 and 2015 in Munich, Germany;
• The 35th AIVC Conference in Poznań, Poland;
• Clima 2013 in Prague, Czech Republic;
• The project has also been presented in a PhD Course at Luleå University of Technology in Sweden;
• ABGNova has a permanent exhibition about RetroKit at Sophienhof, in Frankfurt.
At a national level the project partners have arranged and participated at 8 seminars with national stakeholders.
Finally a design contest for architect students was set up. The main objective was to involve and engage young architects in the innovative and energy efficient RetroKit concept, hence a design contest for architect students was run autumn semester 2015 and spring semester 2016. The contest was developed by DWEcoCo and EMVS, with support from SP.
The competition was made as a student task in a course at the universities in Alcalà de Henares and Dublin, and was in that way not an open competition.
All students’ projects can be viewed in a book at the website: http://www.retrokitproject.eu/wp-content/uploads/2016/06/RetroKit-Design-Project__Compressed.pdf
DWEcoCo introduced the design project to the students in the Masters in Sustainable Design programme with the RetroKit project as a source of information. Through a combination of seminars on retrofitting and the sustainable design of buildings and design workshops focused on design concepts and solutions for a selected apartment building in Dublin.
The building in Dublin; Glovers Court, is of a similar type to the focus of the RetroKit project. Plans of the building were made available to the students in a CAD format so that they could focus their efforts on the design of suitable retrofit solutions using the RetroKit Toolbox.
Ten students completed the project with various innovative ideas for the building in Dublin, with focus on energy efficiency and attractive design for the residents.
EMVS introduced the RetroKit project as a source of information, to university students at the 4th Year course on Innovation & Sustainability, at the School of Architecture at Alcala de Henares University. The students developed their projects while going through a combination of seminars on retrofitting and the sustainable design of buildings and design workshops focused on sustainable and bioclimatic design concepts and solutions.
18 students from different countries, grouped in eight different teams completed the project with various innovative ideas for the buildings in Spain & Greece, with focus on energy efficiency and sustainability.
In a first phase, each group chose an existing building, analyzed climate and performance and proposed a retrofitting solution, based on RetroKit developments. The second part consisted of designing a new build small industrialized extension with RetroKit products as well.
The definitive updated list of Key Exploitable Results (KERs) and their characterization were agreed among partners during the exploitation strategy seminars and following updates occurring along the course of the entire project.
Eight Key Exploitable Results has been identified, 6 related to products, 2 related to services:
1 Multifunctional framing elements (BGTEC);
2 Integrated façade elements (FHG) – This KER is split in three sub-KER;
3 Envelope integrated solar thermal and PV (STO);
4 Renewable prefabricated cooling systems (TECNALIA);
5 Novel high reflectance and/or insulating coatings (AMS);
6 Decision Support System (DAPP);
7 RetroKit retrofitting methodology (DRA);
8 RetroKit business model (SEGEL).
For each of the KERs the following analyses have been performed. First of all a characterization of the result is provided with all the necessary information to describe and contextualize the KER, then a PESTLE Assessment has been performed which collect the impact on and influences of the external factors. Then a simple Business Model has been drafted to evaluate the impact of the internal factors influencing the exploitation strategy and the potential commercial path.
An Evaluation of the possible risks is performed as well, together with an analysis of the patents and publications landscape, in order to allow partners to understand the potential room for patenting and to identify the competitors and similar solutions.
Finally an Exploitation route is provided, encompassing the role of the partners into the exploitation of the result, their exploitation claims and future activities to be done to completely achieve the necessary conditions to enter the market.
List of Websites:
www.retrokitproject.eu
Andrea Ferrari (coordinator)
andrea.ferrari@dappolonia.it
D'Appolonia S.p.a.
Via San Nazaro 19
16145 Genoa
Italy
Phone: +39 010 3628148
RetroKit develops and demonstrates at three building pilots (Spain, Germany and Sweden), multifunctional, modular, low cost and easy to install prefabricated modules in order to significantly increase the EU retrofitting rate and contribute to EU energy reduction commitments. These innovative systems target existing multi-family residential buildings which represent more than 50% of the EU building stock and between 65% and 80% of its energy consumption.
RetroKit project brings the aspect of multifunctional façade and roof elements into the retrofit sector. Special integrated solutions have been developed which are dealing with the aspects of heating, ventilation, cooling, electricity and ICT in a flexible way. The key factors for RetroKit are the window element with a technical box taking in HVAC systems and interfaces for building services (ducting, piping) installed on the existing façade, and façade modules integrating ventilation systems, heat/cold supply systems, piping for heating and cooling, ICT and electricity, and photovoltaic, solar thermal and PV/T collectors into thermal insulation for façade and roofing solutions. To be attractive beyond affordability, multifunctional semi-prefabricated elements are developed which provides an opportunity to retrofit improving aesthetics, comfort, energy performance, and property value at the same time.
Partners investigate and identified negative factors that prevent positive retrofit decisions and the conditions, requirements, information, arguments and human factor aspects for the implementation of the retrofit toolbox. Monitoring and analysis of the results demonstrated the effects of the solutions on the inhabitants. Retrofitting components and technologies have been developed and characterized and tested in lab and real scale environment in parallel to the development of an optimised construction retrofitting processes that minimise intrusion, maximise work to the exterior and cavities of the building, reduce the time and cost of retrofitting, and increase safety. LCA and LCC analyses were also made. The findings are integrated in the RetroKit Toolbox, a real set of modular (semi)prefab solutions, supported by a software enabling decision for retrofitting options. Possible users, barriers, optimal market and marketing strategies have been coupled with an effective route for exploitation of the toolbox. Demonstration activities in Madrid, Frankfurt and Pitea allow for the verification and refinement of the entire RetroKit methodology, several selected developed technological solutions, and the appropriate construction processes.
RetroKit benefits can be seen at different levels:
- at macro-level, by inducing important savings in terms of energy consumption and emissions and by increasing turnover for the benefit of the almost 3 million construction SMEs operating in building renovation with a consequent impact on job creation;
- as buying drivers for the apartment/building owners, as they can have clear economic savings in the energy bills and more attractive higher value properties, while at the same time avoiding the discomforts and burden often associated to retrofitting intervention;
- for the actors involved in the retrofitting supply chain, as new skills and profiles will be required, and new business opportunities can be generated.
Project Context and Objectives:
RetroKit develops and demonstrates at three building pilots (Spain, Germany, Sweden), multifunctional, modular, low cost and easy to install prefabricated modules in order to significantly increase the EU retrofitting rate and contribute to EU energy reduction commitments. These innovative systems target existing multi-family residential buildings which represent more than 50% of the EU building stock and between 65% and 80% of their energy consumption.
RetroKit project brings the aspect of multifunctional façade and roof elements into the retrofit sector. Special integrated solutions have been developed which are dealing with the aspects of heating, ventilation, cooling, electricity and ICT in a flexible way. The key factor for RetroKit is the window element accompanied with a technical box taking in HVAC systems as well as interfaces for building services (ducting, piping) installed on the existing façade.
To develop high technology efficient systems, we have selected and integrated into multifunctional prefabricated modules the most promising retrofitting technologies to include windows, insulation materials, HVAC systems, renewable energy systems and energy supply systems, extensively investigated by our market leaders STO, our research intensive SMEs BGTEC, KOKO and AMS, and leading RTOs FHG, SP, SINTEF and TECNALIA. The modules integrate ventilation systems, heat/cold supply systems, piping for heating and cooling, ICT and electricity, and photovoltaic, solar thermal and PV/T collectors into thermal insulation aimed for façade and roofing solutions.
To be low cost and systemic, we decided to streamline the value chain though prefabricated modular configurations supported decision support system and tool that enable customised production, industrial scale-up, and efficient construction processes adapted to component manufacturers, integrators, installers and contractors. As such, costs in the whole life cycle are decreased: due to easy installation to simple maintenance (pipes on façades are easily accessible from outside), arriving to affordable decommissioning and finally to convenient recycling. Embodied energy is considered.
To be attractive beyond affordability, we aim at multifunctional semi-prefabrication which provides an opportunity to retrofit improving aesthetics, comfort, energy performance, and property value at the same time.
Efficient construction processes involve low impact on occupants and lower risk to investors. We are indeed combining the challenge of developing an innovative solution for systemic retrofitting while coping with the pragmatic aspects of construction (corners, connections, thermal bridges, etc.) In order to overcome current barriers for retrofitting, social, technological, industrial, and economic barriers are deliberately treated through the identification of bottlenecks, impediments, and human factors preventing positive retrofit decisions and then by providing the means to overcome them. The result is the RetroKit Toolbox composed of modular solutions and high quality decision support tools that provide information, performance estimates, financial transparency, and design support.
To achieve all of these objectives, our consortium is driven by DRA, the Top 1 European construction company as part of the ACS Group operating world-wide in more than 40 countries, BLATRADEN a highly innovative SME company with long standing experience in prefabrication, STO a technical leader for insulation systems as well as AMS, a research intensive construction SME which has pioneered innovative coatings and plasters to minimise thermal bridges and microbial growth on walls, partitions and air ducts. The project ideas are based on feasibility work performed by FHG, SP, SINTEF and TECNALIA within a joint research programme funded with own resources, which deeply investigated the concept of prefabricated façade systems within the AERTOs ERA-Net framework.
In WP1 (Societal beneficial systemic retrofit) the partners investigate and identified through means of web survey and questionnaires objections, bottlenecks, and impediments that prevent positive retrofit decisions and the conditions, requirements, information, arguments and human factor aspects for the retrofit toolbox in order to be perceived as an attractive solution from the point of view of residents and of decision makers of the construction process (including architects, engineers, builders, authorities, housing owners). Monitoring and analysis of the results demonstrates the effects of the solutions on the inhabitants.
WP2 (Multifunctional and modular retrofitting components and technologies) is a cornerstone of the project and it is dedicated to the development of multifunctional façade retrofitting solutions such as insulation components with integrated air ducts, and multifunctional energy producing façade elements and integrated energy use systems. These new components and systems (with others) have been characterised and tested in lab environment. The WP contains the scientific and technical development of materials and components that form the basis of the prefabricated modules.
WP4 (Effective retrofitting process) integrates the experiences and expertise (mainly) of the consortium retrofitters. The workpackage achieved a study of the construction retrofitting processes in a holistic way and how these processes can be optimised. Then, the optimised construction retrofitting processes that minimise intrusion, maximise work to the exterior and cavities of the building, reduce the time and cost of retrofitting, and increase safety was developed. WP3 (RetroKit Toolbox) is another cornerstone of the project. This workpackage is integrating information provided from WP2 (technologies) and WP4 (processes) to achieve a real toolbox of solutions, supported by a software enabling decision for retrofitting options. Definition of the toolbox has been achieved as well as integration and the decision support system and tools.
WP5 (Market replication) identified possible users, barriers and markets for the Retrokit toolbox. Optimal market and marketing strategies have been coupled with an effective route for exploitation of RetroKit Toolbox. LCA and LCC analyses are terminated, showing the potential benefits of the solutions adopted.
Demonstration activities are described in WP6 (Pilot cases and Demonstration). EMVS provided a large scale building (social housing) for retrofit in Madrid, Spain. ABGNova proposed a German demonstration building in Frankfurt, which renovation in ongoing. The third Demo building is located in Sweden, provided by Blattraden. These case-studies allow for the verification and refinement of the entire RetroKit methodology, several selected developed technological solutions, and the appropriate construction processes.
Testing facilities, which offer state of the art environment control and monitoring capabilities and the ability to integrate and test all RetroKit technical solutions, have been exploited: Fraunhofer facility tested roofs-PV integrated, TECNALIA facility is hosting the dessicant module under development, while SINTEF facility tested a new type of windows integrating PV on glazing.
WP7 (Exploitation, dissemination and stakeholders engagement) was very active as it is demonstrated by the large number of dissemination events sustained by the project. Architectural competition among student has been defined with positive results. Exploitation activities leaded to the definition of 8 Key exploitable results, for which a future path has been drafted.
Lastly, WP8 (Project management) ensured the professional conduct and execution of all project activities. Technical progress and active management of workpackage interdependencies is not business as usual in RetroKit due to the complexity of the challenge at hand, holistic nature of the work to be conducted, and the diverse nature of the consortium.
Project Results:
The multifunctional framing elements – KER #1 – are developed to optimize the integration between the air exchange system and new windows. The new window is equipped with a technical box to improve the air quality and energy saving within the interior environment. The purpose of such element is to exchange heat with the exterior air.
The system has been demonstrated and validated in a relevant and operating environment and its TRL is currently 6 – 7.
Knowledge is jointly owned by BGTEC, Fraunhofer, Kokotas.
The partners recognize the potential for applying for a patent on the topic. Still no actions or decision have been made in practical terms, however the innovation is hidden in the products installed so far, therefore the industrial secrecy is preserved.
BGTEC, together with Kokotas will be the producer of the parts. BGTEC will be as well the integrator and the installer of the solution.
Marketing activities will be dedicated to selected arrays of customers, requiring compact and effective solutions.
The business potentially generated is wide, as it can grow in accordance to BGTEC own plans of development.
Regarding the KER #2a, named Prefabricated Insulation panel – Fresh Air Wall (FAW), its development is completed (TRL 7) and the solution can be installed in 1-2 storey buildings. Targeted customers have been mainly identified with housing companies and building owners.
For the general technical approval, the compliance for the fire protection is still necessary, plus large fire tests should be done.
Fraunhofer is the responsible partner for such result, supported by external partners.
Also for the KER #2b – Multifunctional Insulation board - the development has been completed (TRL 7) and the manufacturing is based on usage of mineral wool and steal ducts. There are no problems with fire protection but the solution will be more expensive than the previous one. The general technical approval is still necessary for the production in EPS and plastic ducts. Also for KER #2b customers addressed will be housing companies and building owners.
The responsible partner is STO, supported by Fraunhofer
The KER #2c – ETICS and paintings – is instead already available in the market (TRL 9)
Concerning solutions #2a and #2b, significant business opportunities exist in the market and potential customers are widespread (1% average rate of building retrofitting per year in Europe). However, the real market penetration is related to the compliancy with fire regulation.
Agreement between STO and Fraunhofer should be developed concerning solution #2b.
Market potential is high, and the role of STO can grant an easy access to wide networks.
The KER #4 consists on an integrated façade element including a solar thermal collector and a desiccant module, aimed to provide dry air as an initial step for evaporative cooling systems. The system can be integrated with central air handling units and other HVAC modules, plus its installation is suitable in sun-exposed façades (unobstructed south facing façades).
Currently, development of the KER #4 has achieved a TRL 4: the planned level of 5 has not been reached yet due to the need of re-designing the solution.
The responsible partner of such result is Tecnalia and the initial exploitation strategy foresees the following points:
• (in)Direct involvement in initial experiences
• Need for business development/interaction at building design level (engineering/architecture firms)
• Licensing to third parties: façade manufacturers, lightweight façades, curtain wall systems, etc. (e.g. ASTRAWALL, SCHUCO).
The exploitation of KER #4 aims to address several markets and sectors which can be divided as follows:
• HVAC
o Pre-existing buildings with centralised HVAC systems
o HVAC system installed in roof area
• Climate
o South Europe (or buildings with high cooling loads)
o Need for sun exposed south wall
• Building
o Integration with curtain wall sections
o Overcladding/ façade insulation
The KER #5 provides the following innovative aspects:
• New formulations of nanoparticle’s families
• New “industrialized” (on spot) methods to evaluate their:
o Optical properties
o Physical properties
o Special properties
• Development of a pilot plant producing at semi-industrial scale high performance coatings with advanced fully automated “pre – industrial” methods
The new formulations developed have shown improved properties, such as:
1. IR reflectance – IR absorbance
2. Improve substrate’s porosity
3. Water penetration resistance
4. Hydrophobicity or hydrophilicity
5. Low thermal conductivity
6. Algae growth resistance
7. Anti-bacterial behavior
8. Self – cleaning behavior
9. Acoustic insulation
Initial exploitation strategy for such result foresees the following points:
• AMS’s research results have been exploited for other EU financed project (e.g. CommONEnergy) and used as precursors for further research and development of new innovative multifunctional coatings.
• The results have been presented to clients and partners from the construction industry. The incoming experience resulted from the research was especially useful in order to suggest them innovative retrofitting solutions.
• AMS participated at the fair DesignLab, which took place in Athens last May. Main objective of AMS’s participation was focused on “Innovative Materials in the building sector”. During the fair, results of RetroKit project about new innovative materials have been presented: the audience was enthusiastic with the results based on nanotechnology and interested in the benefits from the use of the innovative materials compared with their cost.
• Several scientific presentations took place from AMS’s scientific staff, giving the opportunity for the exchange of views with academic and research partners and collaborators (National Technical University of Athens, National Center for Scientific Research “Demokritos”).
The potential markets and customers addressed by KER #5 are:
• Professionals of the construction industry (wholesale)
o Technical-Construction Companies for energy efficiency of buildings
o Architects & Designers
o Civil Engineers
Free distribution for testing and fairs is envisaged.
• Consumers (retail sale)
o Paint shops
o E-shops
Targeted advertising strategy will be developed above all for the retail sale.
The KER #6 provides the following innovative aspects:
• ICT instrument, and correlated manual (the Tool) that comprises the decision support tool, the methodology and the results of the experience, oriented to ease the best available solutions in response to the actual building refurbishment needs
• To be made available in the form of a web-based ICT tool, to provide data, transparency on payback, guidelines, and design support, according to the experience and the results gathered within the project.
The tool will need 1-2 years after project conclusion to enter the market. DAPP is the responsible partner but the whole RetroKit Consortium is involved.
Different end customers are foreseen in accordance to the finalities and tools quality:
• Building refurbishment companies
• Architects/designers and planners
• Construction Companies
• Building owners willing to get inside to renovation process
The wide span of customers in Europe, associated to the needs felt for retrofitting, make this tool (and the availability online) an interesting asset.
An initial exploitation strategy foreseen the following pathways (in accordance to the customer type) to exploit the tool:
1. Free use of the SW to promote the RetroKit results through an advertising-based model where revenues come from the fees advertisers pay for the access. Money received from advertisers’ fees could help covering costs for hosting and maintaining the website on a commercial server.
2. Freemium proposition for service access to the tool where software is provided free of charge to a large group of users (base version) and revenues come from additional and upgraded features sold to a smaller fraction of the user base (comprehensive version).
3. Pay professional access (annual license fee) through a subscription-based model where users pay a periodic fee (likely annual) for the right to use the software, according to the terms of the agreement signed. Maintenance and support are bundled in the periodic fee and customers get access to the latest versions without having to pay additional upgrade costs.
4. Prefab manufacturers can pay a periodic fee (likely annual) for the right to be listed in the software, according to the terms of the agreement signed.
5. Re-selling of the licenses: the prefab manufacturers pay a big license cost in order to provide customers/partners with the SW free/at lower price.
6. Distribution system: partners can use the normal license to show potential customers how it works and they will receive a fee for every customer acquired.
Finally, the strategy agreed among the partners is drafted in accordance to the following:
• DAPP is the SW owner and is in charge to complete, maintain and upgrade the SW (proprietary code) from the programming and hosting sides
• Project partners (PP) are in charge to update the solutions database and to test the tool
• DAPP and PP can use the SW for free for internal projects
• PP will pay a fee to DAPP when using the SW for commercial purposes under a contract (e.g. customer support)
• Customers that want/need an account will pay the license costs to DAPP
• PP will receive a fee if they provide customer willing to pay license
Three levels of access are planned:
• DAPP: administrator
• PP: power user
• Customer: user
Money coming from the fees will be used to maintain and keep active the SW. About this, partners agreed on the fact that the system is based on trust, hence if nobody pays the fee, the system cannot be maintained.
The RetroKit Methodology (KER #7) will be exploited as a commercial product addressing companies involved in retrofitting apartment buildings.
At project completion such result will reach TRL 9.
In particular, two companies are already interested in exploiting the RetroKit Methodology and they are:
• DWEcoCo: a sustainable design company with architects
• Dragados: a large construction company
DWEcoCo has identified the following market opportunities in Ireland:
• 140,000 apartments in Ireland, about 10% of total dwellings
• Assuming 1% retrofitting rate then 1,400 apts retrofitted pa
• Assume €10,000 deep retrofit cost per apt = €14 M pa
• Consultancy service @ 2% = €280,000 pa income
Dragados found market opportunities in Spain as follows:
• 17 M apartment in Spain
• Assuming 1% retrofitting rate then 170,000 apts retrofitted pa
• Assume €10,000 deep retrofit cost per apt = €1.7 B pa
• 5% of market share for Dragados = € 85 M
DRAGADOS is the exploitable responsible partner for such result, while SP and BLATRADEN are the main contributors. Anyhow, the whole consortium is involved.
Concerning KER#8, partners SEGEL and D'APPOLONIA have both contributed in the work with business modelling as part of the RetroKit project. Both companies may freely exploit the results in any country. The Business Models will be built according to specifics of customers and sectors targeted.
Potential Impact:
RetroKit provides an holistic and systemic approach for the retrofitting of residential multi-storey buildings allowing them to achieve the energy efficiency levels of new buildings.
Holistic because it addresses the whole value chains and components, from decision making to construction processes, from windows to integration of renewable energy systems, from assessment metrics to business models.
Systemic because the approach aligns the stakeholders through the retrofit phases of building assessment, solution design, industrial scale up of developed technologies (manufacturing), and on-site construction processes.
RetroKit aim to meet the call targets of 50 kWh/m²/year, the reduction of peak loads, and a reduction of 30% energy consumption with respect to new building standards by developing new retrofitting systems based on prefabricated elements has been almost achieved. Last post project refinements consist in an industrialization of some of the technologies developed and the mass production will reduce the current prototype production costs.
A payback close to 7 years was made possible through the project approach to develop prefabricated multifunctional retrofitting solutions. Business models accounts for benefits not only directly related to energy saving but also on the avoided impact of the traditional retrofitting systems and tool, not used in RetroKit due to the technologies prefabrication.
Benefits can be seen at different levels:
- at macro-level, by inducing important savings in terms of energy consumption and emissions and by increasing turnover for the benefit of the almost 3 million construction SMEs operating in building renovation with a consequent impact on job creation;
- as buying drivers for the apartment/building owners, as they can have clear economic savings in the energy bills and more attractive higher value properties, while at the same time avoiding the discomforts and burden often associated to retrofitting intervention;
- for the actors involved in the retrofitting supply chain, as new skills and profiles will be required, and new business opportunities can be generated.
RetroKit target is the 10 million multi-family residential buildings built from 1945 to 1980, which are supposed to require a general maintenance and refurbishment and where energy-efficiency measures could provide added value at a reasonable extra cost.
Starting from the difference in thermal transmittance before and after retrofitting intervention and the heating degrees hours for the building location, assumed in central Europe, the total energy saving that can be obtained with intervention on the envelope only is about 4,2 billions kWh per year if the new retrofitting solution is applied in 5% of the target buildings, leading to almost 1 Mton of CO2 saved.
Considering an average energy cost of 0,12 €/kWh27 between 2010 and 2030, this energy savings corresponds to an overall saving of about 500 M€, considering the expected market penetration of 5%.
RetroKit followed approach will result also in an increase of turnover for the whole European construction sector, through new investments which couple structural retrofitting to energy efficient solutions. Assuming that a standard intervention with the RetroKit approach over the whole building combines the solution for the outer envelope, the total investment costs (including installation) can be estimated as 120 €/m2 in total. With these numbers and assuming again a penetration rate of 5% within 5 years after the end of the project, this will result in an increase of turnover and additional investments for the construction sector of almost 4 billion €.
This market share will have a positive impact also on job creation as it includes effects on the volume of construction works, effects on the volume of jobs related to the components manufacturing and to the façade assessment and many others. The additional investments can be compared to the turnover and employment of the construction industry, where 14,9 million operatives generate a total turnover of 1173 billion €28, corresponding to a turnover of 78 k€/y per employee. It can be assumed that the share of material costs for the proposed retrofitting process is a factor of 2 higher than conventional construction activities.
Thus, an additional 150 k€/y invested into energy-savings packages would generate one new position. Therefore additional investments of 4 Billion € would roughly correspond to 27000 additional new jobs in the construction and installation industries across Europe.
To get continuous feed-back from the market and other stakeholders, it is of great importance to disseminate public results from the project. The project partners in RetroKit have disseminated actively on a national, as well as international, level.
A number of 101 separate dissemination activities have been carried out within the project since the project started in September 2012.
The RetroKit partners has mostly made oral presentations of the project at both scientific events as well as to wider publics. The project has also mainly been included in newsletters and at the project partner’s websites. In addtion to that RetroKit Newsletters has been issued and sent to almost 1000 contacts and afterward published on the project website.
The RetroKit project partners have arranged and participated at seminars on national as well as international level.
Among many others, the partners have disseminated RetroKit at:
• BAU 2013 and 2015 in Munich, Germany;
• The 35th AIVC Conference in Poznań, Poland;
• Clima 2013 in Prague, Czech Republic;
• The project has also been presented in a PhD Course at Luleå University of Technology in Sweden;
• ABGNova has a permanent exhibition about RetroKit at Sophienhof, in Frankfurt.
At a national level the project partners have arranged and participated at 8 seminars with national stakeholders.
Finally a design contest for architect students was set up. The main objective was to involve and engage young architects in the innovative and energy efficient RetroKit concept, hence a design contest for architect students was run autumn semester 2015 and spring semester 2016. The contest was developed by DWEcoCo and EMVS, with support from SP.
The competition was made as a student task in a course at the universities in Alcalà de Henares and Dublin, and was in that way not an open competition.
All students’ projects can be viewed in a book at the website: http://www.retrokitproject.eu/wp-content/uploads/2016/06/RetroKit-Design-Project__Compressed.pdf
DWEcoCo introduced the design project to the students in the Masters in Sustainable Design programme with the RetroKit project as a source of information. Through a combination of seminars on retrofitting and the sustainable design of buildings and design workshops focused on design concepts and solutions for a selected apartment building in Dublin.
The building in Dublin; Glovers Court, is of a similar type to the focus of the RetroKit project. Plans of the building were made available to the students in a CAD format so that they could focus their efforts on the design of suitable retrofit solutions using the RetroKit Toolbox.
Ten students completed the project with various innovative ideas for the building in Dublin, with focus on energy efficiency and attractive design for the residents.
EMVS introduced the RetroKit project as a source of information, to university students at the 4th Year course on Innovation & Sustainability, at the School of Architecture at Alcala de Henares University. The students developed their projects while going through a combination of seminars on retrofitting and the sustainable design of buildings and design workshops focused on sustainable and bioclimatic design concepts and solutions.
18 students from different countries, grouped in eight different teams completed the project with various innovative ideas for the buildings in Spain & Greece, with focus on energy efficiency and sustainability.
In a first phase, each group chose an existing building, analyzed climate and performance and proposed a retrofitting solution, based on RetroKit developments. The second part consisted of designing a new build small industrialized extension with RetroKit products as well.
The definitive updated list of Key Exploitable Results (KERs) and their characterization were agreed among partners during the exploitation strategy seminars and following updates occurring along the course of the entire project.
Eight Key Exploitable Results has been identified, 6 related to products, 2 related to services:
1 Multifunctional framing elements (BGTEC);
2 Integrated façade elements (FHG) – This KER is split in three sub-KER;
3 Envelope integrated solar thermal and PV (STO);
4 Renewable prefabricated cooling systems (TECNALIA);
5 Novel high reflectance and/or insulating coatings (AMS);
6 Decision Support System (DAPP);
7 RetroKit retrofitting methodology (DRA);
8 RetroKit business model (SEGEL).
For each of the KERs the following analyses have been performed. First of all a characterization of the result is provided with all the necessary information to describe and contextualize the KER, then a PESTLE Assessment has been performed which collect the impact on and influences of the external factors. Then a simple Business Model has been drafted to evaluate the impact of the internal factors influencing the exploitation strategy and the potential commercial path.
An Evaluation of the possible risks is performed as well, together with an analysis of the patents and publications landscape, in order to allow partners to understand the potential room for patenting and to identify the competitors and similar solutions.
Finally an Exploitation route is provided, encompassing the role of the partners into the exploitation of the result, their exploitation claims and future activities to be done to completely achieve the necessary conditions to enter the market.
List of Websites:
www.retrokitproject.eu
Andrea Ferrari (coordinator)
andrea.ferrari@dappolonia.it
D'Appolonia S.p.a.
Via San Nazaro 19
16145 Genoa
Italy
Phone: +39 010 3628148
