PROJECTS

Framework

The construction sector is currently facing structural challenges that require innovative and sustainable solutions. The shortage of skilled labour, increasingly tight project timelines, and the need to reduce environmental impact make the industrialisation and digitalisation of the construction process imperative. The demand for modular and prefabricated solutions emerges as a response to these requirements, enabling increased productivity, ensured quality, and reduced waste. At the same time, the transition towards more sustainable construction necessitates the development of energy-efficient, durable, and economically viable systems, aligned with the principles of the circular economy. In this context, the I-LSFastPanel project proposes the development of an innovative modular construction system in cold-formed light steel, addressing the current challenges of the sector and promoting a new generation of industrialised and sustainable solutions for the construction industry.

Objectives

The main objective of the I-LSFastPanel project is the development of an innovative and sustainable modular construction system, based on double-wall multilayer panels in cold-formed light steel. The project aims to design an innovative metal profile and an optimized assembly process, integrating connection elements that facilitate installation, disassembly, and potential reuse of components on-site. High-performance double-wall solutions will be developed to provide superior thermal, acoustic, and structural performance, contributing to faster, more efficient, and environmentally lower-impact construction. The project also includes the creation of a matrix of flexible electronics-based sensors, fully integrated within the panels, to monitor parameters such as temperature, humidity, gases, and deformation. These developments aim to promote the digitalisation and industrialisation of the construction sector, enhancing its long-term competitiveness and sustainability.

Activities and Expected Results

A1 - Requirements and Specifications Survey and Analysis

This activity corresponds to the initial phase of industrial research and aims to identify and analyse the requirements and specifications necessary for the development of the new modular construction solution. Applicable legal and regulatory requirements will be defined, site constraints characterised, and the singularities of the various construction elements analysed, such as openings, corners, and connections between panels and LSF and concrete elements. Simultaneously, continuous technological monitoring will be ensured to update functional requirements and incorporate innovative solutions. Based on this information, the functional specifications of the system will be defined, covering mechanical, thermal, acoustic, fire, and environmental performance. Finally, the preliminary design of the double-wall LSF panels and their connection elements will be developed, including numerical analyses and small-scale tests for initial optimisation of overall performance.

A2 - Development of the Innovative LSF Profile

The objective of this activity is the development of a Light Steel Framing (LSF) profile with an innovative geometry, allowing the assembly of multilayer panels with air gaps between layers and rapid connection between profiles. The dimensional and functional parameters of the new sections will be defined, considering mechanical, structural, and thermal, acoustic, and fire performance requirements, exceeding regulatory standards. Simultaneously, parametric numerical simulations will be carried out to optimise the profile geometry and maximise the functional and structural performance of the system. The activity also includes the preparation of detailed technical drawings of the profiles and the final system, produced in a BIM environment, which will serve as the basis for manufacturing and subsequent integration into the construction system. Finally, the developed profiles will undergo intermediate and final laboratory tests to evaluate mechanical strength and thermal performance, ensuring compliance with regulatory requirements and suitability for on-site use.

A3 - Development of the Assembly System

This activity aims to design and develop an innovative assembly system that simplifies and standardises the connections between structural steel profiles used for fixing prefabricated multilayer panels. The materials, dimensional and functional parameters of the assembly element will be defined, selecting polymers and reinforcing fibres suitable for the previously identified mechanical and structural requirements. The activity includes the development of technical drawings in a computational and BIM environment, modelling of the mechanism, and optimisation of the production process, ensuring efficiency, waste reduction, and cost control. Prototypes will be manufactured using appropriate technologies such as moulding, additive manufacturing, or infusion, and subjected to intermediate tests for mechanical, thermal, and morphological characterisation. These tests will validate the component’s performance, ensuring compatibility with the overall construction system and compliance with regulatory requirements.

A4 - Development and Characterisation of the Construction System Incorporating the Modules (Profiles, Materials, Components)

This activity aims to develop and integrate the components of the modular construction system, including profiles, multilayer panels, and assembly elements, ensuring high mechanical, thermal, acoustic, and fire performance. Prototypes (specimens) will be produced for laboratory testing and experimental characterisation, assessing airtightness, insulation, and structural resistance. In parallel, flexible sensors will be integrated for monitoring environmental and structural parameters, with data acquisition and control implemented through hardware, firmware, and a Web application. The activity also includes life cycle and economic viability analyses, ensuring the solution’s sustainability and competitiveness. Finally, the system will be digitalised in a BIM environment, enabling parametric compatibility, efficient production planning, and integration into construction projects.

A5 - Real-World Application

This activity focuses on the production, assembly, and evaluation of I-LSFastPanel prototypes in a real-world environment. Manufacturing, transport, and assembly specifications will be defined to ensure compatibility between profiles and composite materials. The prototype will be monitored in situ, recording temperature, humidity, and structural performance, and subjected to tests such as thermography and Blower Door to validate airtightness and insulation. The developed sensors will be tested for robustness, reliability, and system modularity over a 3–6 month period. Finally, an application guide will be prepared, including detailed technical drawings, assembly instructions, and identification of system-specific singularities.

A6 - Promotion, Dissemination and Communication of Results

This activity focuses on the transversal dissemination of the project results, enhancing their visibility within the scientific and industrial community. Internal resources from the company and co-promoters will be used to develop informative content such as newsletters, videos, reports, and website updates. Participation in international conferences, fairs, and high-profile congresses is planned, along with the organization of workshops, Open Days, and demonstration events for potential clients. The objective is to share project progress, showcase the innovation of the I-LSFastPanel system, and create opportunities for its commercial exploitation and implementation.

 

A7 - Project Technical Management

The objective of this activity is to plan, coordinate, and monitor all project tasks, ensuring compliance with deadlines, responsibilities, and deliverables through the definition of management methodologies, periodic progress updates, and preparation of internal and external reports.