From Brownfields to Low-Carbon Cities: A Methodological Framework for the Sustainable Renovation of Industrial Buildings and Their Envelopes

The sustainable renovation of ageing industrial buildings presents both a challenge and an opportunity to enhance energy efficiency while preserving architectural and structural integrity. This study develops an integrated methodological framework for assessing and optimising multilayer wall systems in such conversions, combining thermal, environmental, and durability analyses. Six composite wall configurations were designed and numerically evaluated using steady-state 2D heat conduction and vapour-diffusion models. The results reveal substantial thermal improvement compared to the reference uninsulated brick wall (U = 1.41 W/m2·K). The proposed systems achieved U-values between 0.351 and 0.172 W/m2·K, meeting or surpassing European energy standards. The BP–EPS wall exhibited the lowest U-value (0.172 W/m2·K), while the FC–EPSR configuration achieved superior corner performance with a 2D surface temperature (Tsi) of 17.99 °C and the highest surface temperature factor (fRsi = 0.943), along with a reduced condensation risk, indicating more balanced overall performance. Weight and thickness reductions of up to 80.5% and 52%, respectively, were observed, enhancing retrofit feasibility and space efficiency. Life Cycle Assessment results indicated that optimised wall configurations reduced embodied carbon (A1–A3) by up to 78% and total life cycle emissions (A1–A3 + B6) by over 86% relative to the reference case. Vapour-diffusion analysis confirmed the FC–EPSR wall’s lowest condensation fraction, indicating excellent hygrothermal durability. Multi-criteria evaluation using the simple additive weighting method and Monte Carlo robustness analysis verified FC–EPSR as the most balanced and reliable system. Overall, the findings present a validated and replicable pathway for the sustainable renovation of industrial buildings, supporting the goals of European carbon neutrality and the circular economy.