GELCLAD · Project

Smart Insulation Cladding Panels That Cut Facade Costs and Energy Use by 40%

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Imagine wrapping a building in a single smart panel that keeps heat in during winter and out during summer — like a high-tech jacket for your house. GELCLAD created these panels by sandwiching an aerogel insulation core inside a bio-polymer shell, all squeezed out in one step like toothpaste from a tube. The panels even react to weather conditions on their own, adjusting airflow without any electronics. They were tested on real buildings in Spain and Slovenia, showing they can replace the expensive multi-layer facade systems used today.

By the numbers

40%

Cost reduction over traditional facade systems

40%

Energy savings from GELCLAD refurbishment

20%

Lower embodied energy and carbon than oil-based panels

50+ years

Designed panel life span

Consortium partners across 5 countries

57%

Industry ratio in consortium

The business problem

What needed solving

Buildings account for a huge share of energy waste in Europe, and upgrading old facades is expensive, slow, and requires multiple layers of different materials installed by skilled workers. Current cladding systems use oil-based insulation with high embodied energy, and multi-step installation drives up labour costs and project timelines for renovation contractors and building owners alike.

The solution

What was built

The project built a production line for co-extruded composite insulation panels combining a bio-polymer shell with an aerogel insulation core in a single manufacturing step. They completed small-scale demonstrations and full demo-house installations in Spain and Slovenia, proving the system works on real buildings.

Audience

Who needs this

Facade and cladding installation contractors doing energy retrofitsInsulation panel and WPC profile manufacturers seeking new product linesPublic housing authorities planning large-scale building renovation programmesProperty developers building to near-zero energy standardsConstruction material distributors serving the European renovation market

Business applications

Who can put this to work

Building renovation and retrofit

SME

Target: Facade and cladding contractors specializing in energy retrofits

If you are a facade contractor dealing with complex multi-layer insulation installations that require skilled labour and long timelines — this project developed a single-panel cladding system produced by co-extrusion that replaces multiple material layers. The objective targets 40% cost reduction over traditional facades and a life span over 50 years, cutting both installation time and long-term maintenance.

Construction materials manufacturing

mid-size

Target: Manufacturers of insulation panels, WPC profiles, or facade systems

If you are a building materials manufacturer looking to expand into high-performance insulation products — this project built a production line for co-extruded bio-polymer/aerogel composite panels. The technology uses a single continuous extrusion process, eliminating the need for bonding or lamination steps. The panels achieve 20% lower embodied energy and carbon than traditional oil-based panels.

Social housing and public buildings

enterprise

Target: Housing associations and public property managers planning energy refurbishment

If you manage a portfolio of older public or social housing buildings with poor energy performance — this project demonstrated its cladding system on demo buildings in Spain and Slovenia. The objective projects more than 40% reduction in energy consumption after refurbishment, with easy installation that reduces disruption to residents compared to traditional multi-layer facade upgrades.

Frequently asked

Quick answers

How much does GELCLAD cost compared to traditional cladding?

The project objective targets a 40% cost reduction over traditional facade systems, achieved by replacing multi-material layer installations with a single co-extruded panel. This reduces material costs, skilled labour requirements, and installation time.

Can this be manufactured at industrial scale?

Yes. The project delivered a production line for GELCLAD panels using continuous co-extrusion, a well-established industrial manufacturing method. The consortium includes 8 industry partners, suggesting the technology was designed for scale from the start.

What is the IP and licensing situation?

As a Horizon 2020 Innovation Action with 14 partners across 5 countries, IP ownership likely follows the EU grant agreement framework where each partner owns results they generated. Businesses interested in licensing should contact the coordinator, Instituto Pedro Nunes in Portugal, for specific terms.

How long do the panels last?

The project objective states the GELCLAD system is designed for a life span over 50 years. This was a design target validated through the demo-house installations in Spain and Slovenia, though long-term field data would still be accumulating.

What energy savings can I expect from a retrofit?

The objective targets more than 40% reduction in energy consumption when GELCLAD is used for building refurbishment. The panels also have 20% lower embodied energy and carbon than traditional oil-based panels, improving the overall environmental footprint of the renovation.

How easy is it to integrate with existing buildings?

GELCLAD was specifically designed as an easy-to-install system. The single-panel design eliminates the need for multiple material layers and specialized bonding or lamination on site. Demo installations were completed on existing buildings in Spain and Slovenia.

Is this compliant with EU building energy regulations?

The project was funded under the Energy Efficient Buildings topic (EEB-01-2016), aligning with EU energy performance directives. Based on available project data, specific certifications would need to be confirmed with the consortium, but the demonstrated energy performance targets support compliance with current EU renovation standards.

Consortium

Who built it

The GELCLAD consortium of 14 partners across Germany, Spain, Portugal, Slovenia, and the UK is strongly industry-oriented with 8 industrial partners (57% of the consortium) and 5 SMEs. This composition signals that the technology was developed with commercialization in mind from day one. The coordinator, Instituto Pedro Nunes in Portugal, is a well-known technology transfer institution, which further supports the path from lab to market. The mix of 3 research organizations and 1 university provides the scientific backbone, while the industrial majority ensures manufacturing feasibility and market relevance. The geographic spread across Southern, Central, and Northern Europe covers key construction markets with different climate conditions, strengthening the product's applicability across regions.

INSTITUTO PEDRO NUNES ASSOCIACAO PARA A INOVACAO E DESENVOLVIMENTO EM CIENCIA E TECNOLOGIACoordinator · PT
VANNPLASTIC LTDparticipant · UK
TECNARO GESELLSCHAFT ZUR INDUSTRIELLEN ANWENDUNG NACHWACHSENDER ROHSTOFFE MBHparticipant · DE
LABORATORIO NACIONAL DE ENGENHARIA CIVILparticipant · PT
BUILDING RESEARCH ESTABLISHMENT LTDparticipant · UK
CONSTRUCCIONES GARCIA RAMA SLparticipant · ES
SPECIALIST BUILDING PRODUCTS LIMITEDparticipant · UK
NAVODNIK KEMIJSKI INZENIRING d.o.o.participant · SI
BRUNEL UNIVERSITY LONDONparticipant · UK

How to reach the team

Instituto Pedro Nunes (Portugal) — technology transfer institute, likely has a dedicated industry liaison office

Order a report on this consortium See INSTITUTO PEDRO NUNES ASSOCIACAO PARA A INOVACAO E DESENVOLVIMENTO EM CIENCIA E TECNOLOGIA profile →

Next steps

Talk to the team behind this work.

Want to explore licensing GELCLAD technology or connecting with the consortium? SciTransfer can arrange a direct introduction to the right partner for your needs.

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