Background
Rathcoole Educate Together School is a newly developed modular building constructed off-site by Procon Modular Ltd at their Laois manufacturing facility. The school itself consists of 7 primary classrooms, including 2 SEN rooms and 2 SET rooms. In addition to the classrooms, there is a principles office as well as administration offices, changing rooms, toilets and a staffroom.
The school is on Graydon Road in Newcastle Co.Dublin and is due to open in September 2025.
Off-Site Manufacturing
Procon used 3D modular off-site manufactured methodology to construct the individual units using hot rolled steel sections as the primary supports with a timber frame panel infilling between the steels. The external walls build up was the result of collaboration between Saint-Gobain Solutions and Procon Modular using Gyproc and Isover high performance products to ensure the relevant fire testing was successful.
Construction
The hot rolled steel sections are fire protected using 15mm Glasroc F encasement system and the external wall panels themselves utilise Gyproc SoundBloc Plasterboards as the inner face lining with Gyproc Glasroc X as the external sheathing board. The external walls are them externally finished using an alu-clad system.
Using off-site manufacturing ensures speed, efficiency, program and quality and it also greatly helps to reduce waste.
To this end, many of the Gyproc plasterboard products utilised in this instance were manufactured to bespoke lengths which not only helps to reduce waste but also makes for a more efficient installation process.
The units as in this case study are constructed at the same time as the site preparations are being undertaken thus greatly reducing program time for the project.
Gypwall internal partition systems and linings incorporating Gypframe metal components, high performance plasterboards with Isover acoustic insulation were used internally to form the internal walls ensuring optimum levels of acoustic comfort while also offering the robustness that would be required in a typical school environment.
The order for the 1220 sq metre bespoke project was received in January 2025 to commence the design process. Procon designed the building utilising all Gyproc products for structural protection, fire tested and certified external walls and various Gyproc partition wall types to achieve the required fire and acoustic ratings for each area in accordance with TGD B 2024 and the Department of Education SDG's. The site works commenced mid-April with the first modules installed on site at the end of April. The project completion is scheduled for August with the new school to receive its first students in September.
At Saint-Gobain Solutions (Irl), we are always looking to collaborate with the off-site sector and to support new initiatives and solutions.
As founding members of MMC Ireland we understand the importance of off-site manufacturing and other modern methods of construction in terms of contributing to the Irish construction industry and we are always seeking to not only develop our own solutions but also to work with key industry stakeholders in this space.
This project is a perfect example of partnership and collaboration with customers and we were delighted to support Procon Modular with this and other projects.
