Walls Construction is delivering the LDA’s and DLR’s Shanganagh Castle Estate in Shankill, one of the largest and the most sustainable social housing project in the state’s history.
As the Design & Build main contractor on Shanganagh Castle Estate for the Land Development Agency (LDA) and Dun Laoghaire Rathdown County Council (DLR), Walls Construction leveraged the benefits of early contractor involvement to streamline the entire project delivery process. By engaging with the client, architects, contractor, and supply chain early in the project, Walls facilitated a collaborative approach that has enabled all parties to work together effectively from the outset. This proactive collaboration has helped ensure the smooth and efficient progression of the project. From the beginning, Walls assumed responsibility for fostering seamless collaboration across the project team and maintaining strong stakeholder engagement. To achieve this, the main contractor developed a comprehensive project plan. A crucial part of this approach includes regular coordination meetings, particularly weekly sessions with the design team, to keep the project on track and address any emerging issues in a timely manner.
In addition to internal coordination, Walls has implemented a structured engagement process with external stakeholders, including LDA, DLR, local community groups, businesses, councillors, and other relevant third parties, such as DLR’s biodiversity officer. This engagement was formalised through a detailed engagement plan that incudes pre-commencement presentations, continuous updates, the appointment of liaison officers, and ongoing meetings with stakeholders. The success of this structured and inclusive approach is reflected in the smooth progression of the project, which has involved complex challenges such as extensive landscaping and the integration of various communal facilities.
Sustainability at Shanganagh
Sustainability is a central focus throughout the project, with Walls Construction incorporating environmentally conscious practices at every stage. One of the standout sustainability features of the project is the innovative approach to stabilising and reusing on-site soil.
By lowering road and parking levels by approximately 900mm, Walls has been able to excavate and store subsoil at a designated soil stabilisation mixing and screening area. Using a screening machine, large stones and unwanted materials are filtered out, and the remaining subsoil is mixed with cement and water at a specific ratio. This mixture is then stored for reuse on site, where it is incrementally compacted to raise roads and parking levels.
The entire process is being monitored through California Bearing Ratio (CBR) tests to ensure the stabilised subsoil meets the necessary strength specifications. To further protect the stabilised subsoil, a 300mm layer of capping stone has been added. Through these measures, approximately 10,000 cubic metres of subsoil has been reused on-site to date, significantly reducing waste and avoiding the need to transport the soil off site. Additionally, the project avoided the delivery of over 1,200 loads of stone, resulting in a substantial reduction in transportation-related carbon emissions.
In parallel, during the demolition of existing dwellings on the Shanganagh site, Walls took a sustainable approach by crushing concrete floor slabs and block walls. This process resulted in the production of over 800 cubic metres of material, which was repurposed for temporary walkways, further reducing waste and the need for new materials.
Biodiversity at Shanganagh
Walls Construction has prioritised biodiversity throughout the project, particularly in relation to the extensive landscaping and public realm works. This included the restoration of an existing pond within the historic grounds, the creation of playground areas, and the construction of new pedestrian and cycle paths connecting to future transportation hubs, such as the proposed Woodbrook Dublin Area Rapid Transit (DART) station.
Working in a live pond area, home to various known amphibian and plant species, presents significant environmental challenges. To address this, Walls is collaborating with ecology professionals and liaising closely with DLRCC to put detailed environmental protection measures in place, ensuring that the local ecosystem is preserved throughout the construction process.
Modern construction methods
Throughout the project also the implementation of modern construction methods are playing a crucial role in driving both efficiency and quality. Walls are employing Lean Construction principles to minimise waste and enhance collaboration among the project team. By reducing inefficiencies and focusing on continuous improvement, Lean Construction has helped keep the project on track while promoting a more productive working environment.
Additionally, Walls has integrated modern methods of construction (MMC) into the project to improve precision and speed up the building process. MMC, particularly the use of offsite precast concrete manufacturing in controlled environments, is significantly contributing to reducing health and safety risks by limiting the number of personnel involved in potentially hazardous on-site operations. This approach has not only improved safety but also allowed for tighter control over quality and reduced the environmental impact of onsite activities.
A key innovation in the project is the use of Takt planning, a production scheduling method designed to align project workflows with customer demand. This approach ensures continuous and efficient progress by improving communication between different project stakeholders. Unlike traditional planning methods, which often rely on specific individuals with detailed knowledge of particular tools, Takt planning facilitates transparency and enables easier adjustments to the project schedule. As a result, the team can effectively plan for materials and manpower, avoid delays and maintain progress within planned timelines.
In conclusion
Walls Construction’s strategic use of early contractor involvement, sustainable practices, biodiversity preservation, and modern construction methods has resulted in a project that is not only meeting but exceeding its objectives. This integrated approach has set a benchmark for future developments, particularly in the areas of sustainability, efficiency, and collaboration.