The challenge

The project had to overcome significant challenges: a constrained rural site with contamination, overhead cables, retained parking requirements, neighbouring properties, narrow access roads of 3.7–4.9m, and community scepticism in a village that had seen no development for decades.

Traditional delivery would have increased programme risk, site disruption and carbon intensity. And because these are social-rent homes for households vulnerable to high running costs, decarbonisation also needed to translate into comfort, affordability and ease of use.

The solution

The strategy was front-loaded and evidence-led, aiming to cut both operational and embodied carbon, lower fuel-poverty risk and reduce emissions at every stage: design, material selection, manufacture, construction and operation. Performance targets were fixed early to avoid specification drift, using whole-life carbon assessment, fabric-first design, BIM coordination and Design for Manufacture and Assembly (DfMA) principles. The approach reflects ZED PODS’ Net Zero 2035 commitment and its fabric-first, fossil-fuel-free delivery model.

The homes combine a fabric-first envelope, non-combustible stone-wool insulation, breathable wall assemblies, alu-clad triple glazing with a 60-year design life, air-source heat pumps, mechanical ventilation with heat recovery (MVHR) and roof-mounted photovoltaics.

How the project works

Crofts House was managed through a single integrated design-and-build model. Client, designers, consultants, factory and site teams worked within an ISO 19650-aligned workflow and Common Data Environment, with Stage 3 coordination completed before manufacture. That early digital freeze reduced rework, optimised materials and protected carbon performance through delivery. Each module also received a QR-coded digital asset record, supporting long-term traceability and a robust Golden Thread.

More than 80% Pre-Manufactured Value was achieved in a BOPAS-, B Corp-, ISO 9001- and ISO 14001-accredited factory, reducing site waste, transport emissions and programme length, with installation taking two days. Embodied carbon was further reduced through BIM-led quantity take-offs, packaging returned to manufacturers, Rockwool offcuts recycled into new batches, and long-life components that lower replacement carbon over the asset’s life.

Residents were given a Home User Guide and low-carbon living training, while IoT-linked environmental sensors continue to monitor humidity and air quality to support healthy operation and asset resilience.

The results

Embodied carbon was confirmed at 425 kgCO2e/m² – 47% below RIBA 2025 targets. Regulated energy demand reached 31 kWh/m²/year, below RIBA 2030 benchmarks, while the photovoltaics generate more than 13,500 kWh annually, avoiding around 11 tonnes of CO2 each year. Water-efficient design saves 160,020 litres annually, and airtightness testing achieved near-Passivhaus levels of 1.50-1.63 m³/h/m² @50Pa.

Resident satisfaction stands at 100%, with residents describing the homes as peaceful, comfortable and life-improving, including feedback that the homes do not overheat.

Beyond energy and carbon, the former hard-surfaced garage court has become a permeable, landscaped micro-habitat with retained trees, planting and biodiversity corridors. The scheme attracted 216 applications for five homes and generated a 5.53:1 Benefit-Cost Ratio, equivalent to £6.8m of net social value. Its success has already informed a pipeline of 143 further homes across 11 rural micro-sites.