Façade systems for industrialised prefabricated prefinished modular construction

Industrialised construction, through the offsite manufacturing of standardised components, is emerging as a response to the growing demand for the mass production of high-performance buildings. A review of existing research and projects reveals a significant gap in the development of façade systems compatible with Prefabricated Prefinished Volumetric Construction (PPVC)—the most advanced form of offsite building manufacturing. This gap has contributed to inefficiencies in construction and, in some cases, irreversible damage. This paper critically reviews current façade systems used in PPVC, analysing opportunities to develop more compatible systems across three key areas: weatherproofing, connections, and installation processes. It also examines challenges such as labour-intensive scaffolding, misalignment and collisions during assembly, and limited flexibility for automated solutions. The waterproofing of horizontal and vertical joints is identified as a critical issue, necessitating innovative approaches. The findings offer insights for industry professionals and policymakers to support the development of efficient modular façade systems. • Critical review of façade systems for prefabricated prefinished modular construction. • Automation potential to eliminate scaffolding in PPVC façade construction. • Key challenges in weatherproofing, connections, and façade installation processes. • Identifies research gaps in façade transport, lifting, and automated construction. • Investigates misalignment and collision issues in PPVC offsite assembly.