An innovative façade system for prefabricated prefinished volumetric construction: Experimental and numerical investigations

Growing demand for rapid housing delivery is driving the adoption of industrialised and automated construction. This shift is particularly evident in volumetric systems, which enable scalable delivery of high-performance buildings. However, research on non-structural elements of these systems, particularly façades, remains limited. This gap has resulted in challenges in waterproofing and installation processes, leading to irreversible damage in some earlier prefabricated prefinished volumetric construction (PPVC) projects. To address these issues, this study proposes a novel façade system based on a customised unitised curtain wall, which has been designed for mid- to high-rise steel modular construction and evaluated under Sydney-specific structural, regulatory, and climatic conditions. The proposed façade system advances construction automation by eliminating the need for scaffolding and minimising on-site alignment adjustments, reducing construction time. It also ensures effective weatherproofing and streamlines the overall assembly process. This system improves efficiency, increases automation, and enhances worker safety. The performance of the system was investigated using advanced numerical models and evaluated against the requirements of relevant Australian Standards. Constructability, proof of concept, fabrication and installation procedures and challenges were examined through the assembly of a half-scale mock-up, demonstrating the system’s practical feasibility. The waterproofing performance was further tested in accordance with AAMA 501.2 to assess resistance to water penetration. The results indicate that the proposed system supports reliable and efficient automated assembly of prefinished modules. It eliminates the need for scaffolding and reduces manual on-site adjustments. • Proposes a façade system for Prefabricated Prefinished Volumetric Construction. • Eliminates the need for scaffolding or mast climbers during façade installation. • Demonstrates constructability via half-scale façade mock-up testing. • Validates watertightness with on-site AAMA 501.2 field spray testing. • Indicates potential reductions in construction time, cost, and façade-related CO 2 e. • Future research directions for modular façade technology