Large-scale façade element renovation project in Düsseldorf

A total of 13 buildings were renovated, with a combined façade element volume of approximately 10,000 m². The total gross floor area of the buildings reached 11,920 m², and the project covered 194 apartments in total. This was a comprehensive neighbourhood-scale renovation programme, in which Matek was responsible for the design, production and installation of the renovation elements.

In close cooperation with the architects and the client, façade element solutions were developed that fit well into the existing urban context while giving the buildings a modern and refreshed appearance. The façades combine standard timber cladding, 3D timber cladding with varying widths and thicknesses, and fibre-cement façade panels, resulting in a visually rich and distinctive architectural expression. Architectural divisions, intermediate floor flashings and façade panel layouts were designed as separate architectural elements, while simultaneously ensuring a high level of factory prefabrication.

The external wall elements were manufactured with a very high degree of factory readiness. In addition to windows, the elements were pre-equipped at the factory with external electric blinds and ventilation units with heat recovery. The elements were designed without a rigid sheathing layer and utilised an intelligent fixing and support system, where the brackets of the lower storeys also carried the vertical loads of the upper floors. This enabled fast, flexible and efficient installation on site.

As a result of the renovation works, the energy performance of the buildings improved significantly, upgrading from energy class H to energy class A. Roof insulation works and heating system renovations were carried out on site by the client, while the façade works were largely factory-prepared. Only around 5–10% of the total work volume remained to be completed on site.

Thanks to the repeated use of standardised detailing, optimised production processes and model-based design, the production and installation of each subsequent building became progressively faster. Depending on the size of the building, the preparation phase (measurements and installation of support brackets) took 7–10 working days, while façade installation progressed at an average rate of 12–15 elements per day. On-site construction lasted on average 21 days for two-storey buildings and 28 days for larger three-storey buildings.

The project is a strong example of how prefabricated timber façade elements, well-considered architectural solutions and optimised construction processes can enable the fast, high-quality and energy-efficient renovation of existing housing stock, while minimising disruption to residents’ everyday lives.