Reusable Brick Walls Enable Circular Construction With Up To 60% Lower CO₂ Emissions

Researchers at Graz University of Technology (TU Graz), together with Austrian brick manufacturer wienerberger, have developed a reusable brick wall system that can be dismantled and rebuilt without damaging the masonry elements. The innovation supports circular construction by extending the lifespan of building materials beyond that of the buildings themselves.

The construction sector remains one of the largest consumers of raw materials and a major source of greenhouse gas emissions. Demolition waste continues to be a significant challenge, especially for buildings with relatively short service lives such as supermarkets and retail facilities. The new system addresses this issue by allowing brick components to be reused several times instead of being discarded after demolition.

Reversible Connections Replace Traditional Mortar

The Re-Use Ziegelwand project centres on prefabricated brick wall elements that use reversible connections rather than conventional mortar joints. As a result, builders can dismantle the walls without destroying the bricks and reconstruct them at another location.

According to project leader Hans Hafellner from TU Graz’s Institute of Building Physics, Services and Construction, brick is a durable and high-quality material, but its production requires considerable resources. Reusing the material therefore offers substantial environmental benefits. The research team estimates that the system can reduce CO₂ emissions by around 60% across three building lifecycles when compared with conventional masonry construction.

Combining Circularity With Building Performance

The researchers faced a major challenge: creating a wall system that could be dismantled while still meeting strict performance requirements. The walls needed to provide structural stability, airtightness, thermal insulation and long-term durability.

To achieve this, the team developed 44 cm-thick wall elements made from bricks filled with insulating wool. The manufacturer also applies plaster finishes in the factory, reducing labour and installation time on site.

The system offers two options for structural stability. A sufficiently heavy roof structure can stabilise the building. Alternatively, vertically threaded and pre-stressed rods can provide the necessary support.

Full-Scale Demonstrator Confirms Feasibility

The researchers tested the concept by constructing a full-scale demonstrator building. They later dismantled the structure and rebuilt it at a different location. The wall elements maintained their performance throughout the process and met all technical requirements after reassembly.

The team also investigated methods to assess the condition of reused walls over time. They use modal analysis, a technique that measures changes in natural vibration frequencies. This approach allows engineers to evaluate load-bearing capacity without damaging the building components.

The successful demonstration shows that reusable masonry systems can perform under real-world conditions. In addition to reducing embodied carbon and material consumption, the system could increase the residual value of buildings. Instead of becoming waste at the end of a building’s life, the masonry elements remain valuable resources for future projects.

The project brought together TU Graz’s Institute of Building Physics, Services and Construction, the Institute of Structural Design, the Laboratory for Structural Engineering and wienerberger. The Austrian Research Promotion Agency (FFG) funded the research.

Source: TU Graz