Lessons in modular construction with CPAC Modular
⏱️ 3 min read.
Kishoge Community College in Lucan, Co Dublin, is not just teaching students. It is educating the entire construction industry on what is now possible with modular buildings.
While the new twenty-two classroom, two-storey extension may look like a traditional ground-up build, and while it may exceed the highest quality and building standards; it is a modular building made up of 152 units, all manufactured offsite using light gauge steel framing.
The permanent school was built using the ‘CPAC Modular Permanent Building System’ which produces the same look, feel and performance of an architecturally designed, traditionally built structure – but achieves it in 50% less time.
“We’ve created a product that's blown stuff out of the water, as far as what it can do and what it can achieve,” says CPAC Construction Director Mark Whitehead.
Watch a video of the external build of the project below or click here to see the internal view.
From humble cabins to multi-story builds
Since launching as Cabinpac back in 1979, the business has grown from a cabin hire company into Ireland’s leading modular main contractor and has won the Best Modular Company Public Sector award, every year since 2020.
Today CPAC Modular provides a full design, planning, offsite construction, onsite assembly and fit-out service, specialising in multi-storey modular volumetric accommodation.
It also plays a leading role in promoting Modern Methods of Construction within the sector, sponsoring and presenting at numerous industry events, including the Education Buildings Ireland conference and the National Construction Summit.
View a short video about CPAC Modular here.
Investing in People, Process and Technology
In growing the business, CPAC Modular has continually invested in three core areas: People, Process and Technology.
At its large production facility in Dunshaughlin, Co Meath, CPAC Modular employs over 110 specialist workers, including a full design team focused on BIM. With this talent in-house, CPAC is able to work with architects to realise a vision well-beyond “grey boxes”.
Everything is digitalised, allowing teams to collaborate within the CDE (Central Data Environment), using industry-leading software like Autodesk Construction Cloud, Revit, and Tekla. This ensures that the modules produced under production conditions meet strict tolerances and a stringent ISO quality control programme.
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“Our biggest change in the last few years has been our investment in three Howick machines, which has revolutionised the production process for us,” says Mark. Previously, CPAC Modular would buy frames and LGS panels from others which led to delivery delays and quality issues. With three of Howick’s precision roll-forming machines now in operation, production is seamless, and the additional capacity has allowed the business to launch CPAC Framing in 2024. CPAC Framing brings a specialist service that provides cold-formed steel components for frames, walls, floors and trusses back to the sector. |
CPAC Construction Director Mark Whitehead
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The CPAC team running and assembling frames in their factory.
The LEAN road to success
“We feel we are leading the way. Our greatest strength is the way we innovate,” says Mark. “We operate a LEAN production facility and are always looking at ways to eliminate waste and improve our product.”
Mark, who’s inspirational leadership style made the Autodesk’s 40-under-40 list, is also a big believer in the value of a positive “can-do” culture. Coming from a sporting background, where he captained and coached rugby teams in England’s national league, he knows a team’s culture can make or break you.
He sees culture as a huge part of the success of any team, and at CPAC that is no different.
“We have created a culture that rewards, supports and engages everyone with our Movember campaigns, Women in Construction, Safety campaigns and various other campaigns.
“[Projects] are only going to be successful if the people running them are happy and feel respected and needed,” says Mark, speaking recently on leadership insights in a podcast.
The future for CPAC Modular is permanent
Buildings produced using the CPAC Modular Permanent Building System have a lifespan of 60 years, exemplifying the company's dedication to durability and quality. But the company is not resting on its laurels. CPAC Modular is always improving and adapting its products to meet the changing needs of clients.
“Even though we've been around for over four decades, we never stand still,” says Mark.
“Our commitment to innovation drives us to continually seek new ways to improve and enhance our product offerings. We're always pushing boundaries and exploring fresh ideas to meet the evolving needs of our clients. Watch this space—exciting developments are on the horizon!”
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A detailed look inside the student living quarters |
A finished example of CPAC's modular student pod accommodation. |
Visit CPAC Modular to find out more about how they are innovating in modular construction.
October 2024 #Features