Case analysis of Australian prefabricated projects advancing sustainability in the urban built environment

In response to the increasing complexity of urban systems, this research investigates how prefabricated construction (prefab) can offer a viable pathway for sustainable transformation in the Australian context. Through a case analysis of 86 diverse prefab projects across Australian cities, the study applies a thematic analytical framework encompassing material innovation, energy systems, climate adaptation, retrofitting and circular regeneration. The outcomes identify material and technological innovations such as mass timber, composite reinforced concrete, smart and centralised grids and passive thermal systems that enhance both sustainable and operational performance. The research further highlights how prefab systems support urban climate adaptation through rapid deployment, resilient materials, and passive design, while also enabling scalable retrofitting and circular regeneration through minimal-disruption upgrades, material reuse, and design for disassembly. The findings reveal four critical drivers of success: efficiency and quality control, material innovation with early planning, digital tools and stakeholder collaboration. Despite demonstrated benefits in emissions reduction, resilience, and deployment speed, implementation is often constrained by policy, logistics, and site-specific barriers. The study emphasises the integration of prefabrication into urban-level energy and climate strategies, highlighting its alignment with the UN Sustainable Development Goals (SDGs). To support this transition, the study outlines future pathways including bio-based materials, AI-driven urban simulation, and policy reform for scalable prefab urbanism.