This research outlines the processes and methods applied in the ReCreate project for transforming deconstructed precast concrete elements into reusable secondary products. Drawing from real-life pilot projects in four countries, the task was to examine and test procedures for stripping, cleaning, cutting, and retrofitting reclaimed components, such as with new connectors, to meet the requirements of new structural designs.

These processes are implemented and evaluated across the project’s pilot cases in Finland, Sweden, the Netherlands, and Germany, using a variety of wall, slab, beam, and column types that were not designed for deconstruction and reuse. The processing steps include the removal of surface layers such as plaster, paint, wallpaper, adhesives, and wiring, as well as surface cleaning with mechanical and chemical methods. Health, safety, and environmental considerations guide the selection of techniques, including dust control and the responsible handling of solvents and equipment. Refurbishment tasks such as cutting and retrofitting with novel connectors are discussed in terms of digital workflows, leveraging interoperable formats like the IFC, supported by optimization algorithms that solve the optimal cutting problem. The goal is to minimize waste and maximize reuse potential.

Some of the processing tasks were conducted at factory premises or directly on-site, depending on logistical and technical feasibility. Data from pilot projects document the process, from stripping and refurbishment to element handling, protection during transport, and final reuse. The findings demonstrate the viability of converting structural components from existing buildings into re-certified elements for new construction and contribute to scaling reuse within circular construction practices.