100 Factories
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Key findings and potential impacts
Findings from systems’ codesign with industrial partners
The development of digital systems comprised 2 co-design cycles with 8 industry partners including manufacturing organisations, a design company, and community trust involved in the delivery of affordable housing. Data included audio and video recordings, 3D scans of building blocks, images, and notes. This was analysed using a thematic coding, identifying emerging themes, conflicts and patterns in the data. Our results indicate a range of views in areas such as labelling, database design, privacy and security, or the need for user support. An interim report of analysis findings can be found here, and a further breakdown of detailed findings will be published shortly.
The analysis
We worked with SCS Partnership on an embodied carbon analysis that compares the Dell cabin with a traditional "brick and block" construction. The analysis also included a "circular economy" scenario, assuming that some Wikihouse blocks can be reused in the future. Please see the report PDF with details of assumptions, material data, and contingency factors utilised in the study.
How was it conducted?
The study was made using the life-cycle carbon analysis framework by the Royal Institute of Chartered Surveyors. This includes modules of assessment in areas such as product transport and manufacturing, construction, in-use carbon emissions, or end-of-life.
How much carbon is in the Dell cabin?
The total carbon emissions associated with the construction works of the Dell cabin is 29.2 Tonnes Co2e. The highest impact comes from materials (foundations and timber blocks).
We demonstrated that the Dell cabin is a more environment-friendly alternative
A "brick and block" structure would result in a 142% increase in upfront carbon emissions (this includes pre-construction, product, and construction stages) compared to the Dell Cabin. When considering the complete life of the building, the "brick and block" structure would result in a 12% increase in embodied carbon emissions.
Carbon savings for future buildings. All the blocks used in the Dell cabin have their own Material Passport so they can be reused in the future. When the Dell cabin reaches the end of its life, reusing blocks will generate a further 3% reduction in total emissions. This also creates a carbon "savings account" for future buildings, with the Dell cabin resulting in a 36% increase in theoretical carbon that re-enters a product lifecycle.
Areas of convergence and agreed priorities across participants include:
The importance and usefulness of traceability
From production through on-site installation and eventual reuse and recycling, including a record of the carbon embodied within those processes.
The need for robust data integrity and accessibility Considering the potential large amounts of data associated with each building element to be made accessible to the relevant users.
Educational support
Was consistently highlighted, especially by end-users and community housing representatives. Participants agreed that for the MP system to be effective, particularly for non-professional users, it must be accompanied by clear guides and instructions on how to use the data within the system.
Areas of convergence that require further work include:
When is a passport “born”? While some participants suggested creating the MP early in the design phase, manufacturers preferred generating it during the manufacturing process, which they felt would more accurately capture real-time data and minimize potential errors.
Who has the time? Manufacturers expressed concerns about the feasibility of including detailed data for each block uniquely, particularly in high-volume production scenarios where time efficiency is critical.
Construction data is complex System developers advocated for integrating detailed control mechanisms and certification processes to maintain data integrity and regulatory compliance. However, manufacturers worried that these additional steps would slow down production and add complexity to their workflow.
Findings from the demonstrator building
A main takeaway from the demonstrator project is that our proposed digital systems work to scale. The Dell Cabin is built using the Wikihouse system and locally sourced timber for battens and cladding elements.
The bill of materials included:
237 OSB3 sheets utilised to create 85 blocks.
154 m2 of sheep wool insulation.
Repurposed timber frames for windows and doors.
6.5 m3 of locally sourced larch for cladding and window reveals.
Other commercially available materials such as foundation jackpads, rainscreen cladding, and roofing material.
Materials were transported from Leicester, Plymouth, and sourced locally from the Staverton woods. Others were sourced commercially. The full report from SCS includes details on energy use, waste generation during manufacturing, and waste generation in the building site. From an LCA analysis, we can report that:
Given this is a timber based system there is a finite lifespan to reusability of the WikiHouse blocks, which if maintained in accordance with production and assembly controls, is likely to be around 5 cycles. At this stage, end-of-life disposal guidance for each block element will be embedded in the MP, recommending timber recycling options. In the Life-Cycle Analysis of the Dell demonstrator, it was interesting to note that the ‘notional’ brick & block equivalent building sees 20% lower CO₂e when looking at B1-5 ‘in use’ emissions – this comes from lower emissions associated to B4 material replacement as the brick & block materials that have longer ‘service lives’. This evidence shows how critical it is that there is a clear pathway for recycling and disposal of timber components that have surpassed their initial service life.
Meet the Team
