“Taking Modular Building to a New Level” with an Agrément-Certified LGS and Precast Concrete Building System
Amid rolling green fields in Garryhill, Co. Carlow, Carlow Build manufactures an innovative building system combining cold‐formed light gauge steel (LGS) framing and pre‐insulated, precast concrete cladding. How does Director Enda Byrne blend experience in building in concrete with a focus on off-site construction?
Materials and building systems falling under the umbrella of Modern Methods of Construction (MMC) are becoming increasingly prominent in Irish developments. From the use of novel materials such as blended concrete for 3D printing to innovative ways of using tried-and-tested materials such as LGS, MMC is changing how we build.
Carlow Build takes this further, combining precast concrete and LGS in a panelised solution. This comprises a galvanised inner LGS leaf, air tightness membrane, insulated core, residual cavity, and an external façade. This system offers many benefits, including insulation u-values of 0.18-0.12, and a factory-fitted membrane and dampcourse to reduce air flow and thermal leaks. The addition of prefabricated floor cassettes and roof modules minimises component assembly onsite, which in turn increases productivity and lowers costs.
How did Carlow Build develop this proprietary MMC system? The company was born from Carlow Concrete, a market leader in water-retaining precast concrete structures in Ireland and the UK. Enda Byrne, Director of Carlow Build, describes how this origin in stormwater attenuation systems led to the evolution of Carlow Build in 2019.
“We had lots of customers and wanted to see what else we could offer them. We already had great precast concrete systems, but we knew that we could maximise their potential more by moving into the residential housing market.”
Director of Carlow Build
Enda expanded, elaborating how Carlow Build developed its innovative product.
“Our research into building materials led us to light gauge steel [LGS] as an option, and we thought we could combine LGS with our pre-existing expertise in precast concrete. We also wanted to develop a product that is hugely design-led and repeatable in terms of design and quality installation. Our clients expect a rapid-build and precision-engineered system. I think we’ve delivered that.”
Director of Carlow Build
Given the innovative nature of the Carlow Build product, the company first sought and soon gained Agrément Certification from the National Standards Authority of Ireland. Carlow Build is also Stage 1 NHBC-Approved in the UK, and boasts a total of 27 business accreditations. A key factor in this recognition of Carlow Build’s success is the decision, led by Enda, to hire a full-time Accreditation Manager. This ensured the business stayed ahead of the curve with regulatory compliance and industry best practice. It also enabled Carlow Build to take up residential projects sooner after launching and start to build a reputation as a high-quality construction partner.
“We are experts in our system – but you're only ever an expert for the day if you’re not learning new things all the time. Through innovation, we want to transform material commodities into high-value building systems for clients.”
Director of Carlow Build
To fuel this culture of continual innovation, Carlow Build has developed a ‘training matrix’ for everyone in the business, from directors to forklift drivers in the warehouse.
“We know the track we want each of our employees to move along to maximise their value to the business. But we also ask that everyone contributes to planning their own progression too, to ensure they have roles that satisfy them. Ultimately, every business should want to invest in their people developing.”
Director of Carlow Build
The training matrix is audited monthly under ISO9001 and EN1090 standards to ensure it is fit for purpose, with individuals also asked to review their individual career pathway to test its suitability.
Philip O’Callaghan, Production Manager at the Carlow Build manufacturing facility, is one individual who has made full use of this matrix to forge his own career path.
“My Father was a builder, and I’ve been around sites since I was 13. I trained as a carpenter, and after time in Australia I worked in Munster Joinery fixing windows and doors. I met Enda years ago, and he wanted to use my years of experience. I started working with Carlow Concrete in the UK, and when I heard they were starting Carlow Build I wanted the chance to get in on the ground with it.”
Production Manager, Carlow Build
Philip’s experience managing construction sites meant he had the aptitude for logistics and coordinating projects that Carlow Build identified as key to efficient manufacturing. This made the move to Production Manager of controlled off-site builds streamlined.
In his role, Philip oversees efficient production and adherence to project deadlines, as well as conducting product quality checks. He also runs regular training with the off-site team, ensuring Assembly Workers and Metal Fabrication Technicians understand the component of the system they are working on and how it fits into the whole.
Outside work, Philip is a keen GAA man. Playing for years with his local football and hurling clubs in Tullow, Philip now trains the youth teams. This is partly facilitated by the controlled nature of the precision engineering done in the production facility.
“Building in the one location is great for the home life. I’m only 30 minutes from the house, and there are no more 12-hour days up and back to Dublin. I can commit to my family time and working with the kids [in the GAA clubs] because I'm not so tired. I’m also more fully into the work and focused when I’m there [at Carlow Build] because I’m not thinking about driving all over the place.”
Production Manager, Carlow Build
The move into modular building has been key to Philip finding a good work-life balance. It also helps that he thinks the Carlow Build system is fantastic for home building.
“I’m all for it [MMC] – I am considering doing my own house in light gauge steel. It’s longer lasting, fire safe, and our system makes the build efficient and easy.”
Production Manager, Carlow Build
To date, Carlow Build has deployed its innovative LGS-precast building system on a number of high-profile developments with one of the largest homebuilders in Ireland. This included running two projects simultaneously, in Donabate and City West, Co. Dublin. The complexity of these dual projects was the difference in deliverable. In Donabate, Carow Build was tasked with manufacturing frames for 54 duplexes, while in City West Carow Build had to complete works on 24 unfinished apartments.
“We were particularly proud of the work on those apartments. We didn’t get onsite until late October, and we were told the timeline we had set of completing by Christmas was too ambitious. We met that deadline. Manufacturing off-site means other work can take place simultaneously and means nothing needs re-designing once onsite because everything was done to the right specifications beforehand. It’s faster and more efficient, and that’s part of the reason we have been able to deliver more than 1,000 residential units since 2020.”
Director of Carlow Build
