Refurbishing Modular Buildings: A 42% Carbon Saving Solution

At PF Modular, sustainability isn’t just a buzzword—it’s embedded in everything we do. We recently commissioned an independent study by Acreshort Consulting to quantify the carbon savings achieved through refurbishing existing modular buildings compared to manufacturing new ones. The results are remarkable. Read the full report here.

The Carbon Challenge in Construction

The construction industry faces mounting pressure to reduce its environmental impact. While modular construction already offers sustainability advantages over traditional building methods, we wanted to understand how refurbishment could further enhance these benefits.

Key Findings: 47.682 Tonnes of CO₂ Saved

Our independent study examined a typical five-bay marketing suite and calculated the carbon emissions associated with refurbishing pre-used modules versus constructing an entirely new modular building.

The headline figure? Refurbishing existing modules saves 47.682 tonnes of CO₂ per five-bay building—representing an impressive 42% reduction in carbon emissions compared to new construction using 100% virgin materials.

To put this in perspective, a new five-bay modular building typically embodies 113.043 tonnes of CO₂. Through refurbishment, we cut this by nearly half.

How Refurbishment Achieves These Savings

The carbon savings come from three main factors:

1. Reusing the Steel Structure

The primary saving comes from preserving and reusing the main steel frame. Rather than recycling the steel (which itself requires significant energy) or manufacturing new virgin steel, we inspect and retain the existing structure, provided it maintains its structural integrity.

2. Eliminating Virgin Steel Production

Manufacturing new steel is carbon-intensive. By not requiring virgin steel for the main structure, we avoid 36.131 tonnes of CO₂ emissions per building.

3. Responsible Waste Management

During refurbishment, we strip out internal fittings, windows, doors, and wall panels. A typical five-bay building produces 6.96 metric tonnes of waste, with the vast majority being recycled:

• Timber, metal, glass, and plasterboard
• Floor coverings and electrical components
• Up to 40% of floor and roof materials retained where possible
• Even specialist items like lighting tubes disposed of in line with WEEE Directive requirements

While recycling this waste does produce some emissions (4.415 tonnes of CO₂), this is far outweighed by the savings from steel reuse.

The Refurbished Product: No Compromise on Quality

Some might assume refurbished means lower quality. Nothing could be further from the truth. Our refurbished buildings meet modern specifications with:

• High-performance insulation (walls: 0.31 w/m², floors: 0.20 w/m², roofs: 0.24 w/m²)
• Energy-efficient heat pump systems with SCOP 4.1 and SEER 7.0
• LED lighting achieving 94 lumens per circuit watt
• Presence detection controls in frequently unoccupied areas
• Double-glazed aluminum windows and doors
• Brick slip cladding for an attractive external finish

Beyond Carbon: The Circular Economy in Action

This approach embodies circular economy principles. Rather than treating buildings as disposable, we recognise the inherent value in existing structures. The embodied energy in modular buildings is preserved, relocated, and given new life—minimising landfill waste and reducing demand for virgin materials.

As the Arup study referenced in our report noted, modular buildings offer “an alternative and sustainable solution to traditional buildings in that they can be relocated and the embodied energy in them is preserved.”

Looking Forward

With mounting pressure to achieve net-zero targets across all sectors, refurbishment of modular buildings represents a practical, immediate solution for reducing construction’s carbon footprint.

At PF Modular, we’re proud to offer clients a genuinely sustainable option—one that delivers quality, flexibility, and a 42% carbon saving. It’s proof that the most sustainable building isn’t always a new one; sometimes, it’s the one we already have.

About this study: This analysis was conducted by Acreshort Consulting, an accredited low-carbon consultant. The full methodology and calculations are available in our Carbon Savings Report.

Interested in refurbished modular buildings? Contact PF Modular to discuss how we can help you reduce your carbon footprint while meeting your building requirements.