A complete family home built from EPAL Euro pallets, CE-marked I-joists, and standard OSB sheathing. Permanent, insulated, certifiable — assembled in 1–2 weeks by non-specialists.
The RCP (Ribbed Composite Panel) system is a two-component structural system for single-storey residential construction:
The complete structural shell — earth screws, wall panels, roof, insulation, windows and doors — costs approximately €15,000–€18,000 in materials. Less than the VAT alone on a conventional build.
The RCP is a site-fabricated structural insulated panel using EPAL Euro pallets as the internal ribbed core. Two layers of 12mm OSB form the structural faces. The pallet structure provides:
The RCP panel operating at single-storey height carries well under 10% of its theoretical compression capacity. The system is structurally overengineered by a factor of approximately 200× for single-storey domestic construction.
| Property | Single RCP | Double RCP |
|---|---|---|
| Thickness | 145mm | 290mm |
| U-Value | 0.39–0.42 W/m²K | 0.21–0.23 W/m²K |
| Compression capacity | >200× design load | >400× design load |
| Weight | ~22 kg | ~44 kg |
The default foundation uses helical earth screws — steel piles screwed into the ground using a handheld machine. No excavation. No concrete. No curing time. Removable and reusable.
Every decision is a spectrum. The system accommodates:
The roof uses CE-marked engineered I-joists spanning wall-to-wall. STEICO or equivalent I-joists at 600mm centres support:
Span tables: 400mm depth I-joists span 7.5m at 600mm centres with L/480 deflection limit — well within serviceability requirements.
The default build includes complete off-grid infrastructure:
Total off-grid package cost: approximately €8,000–€12,000 depending on specifications.
| Component | Cost (€) |
|---|---|
| Earth screws + timber floor joists | 1,200 |
| Wall RCP panels (78 panels) | 2,600 |
| Roof I-joists + OSB deck | 2,800 |
| Insulation (rockwool, blown) | 1,800 |
| Windows + doors | 3,500 |
| Exterior finish (pine tar, cladding) | 1,200 |
| Interior finish (OSB + paint) | 800 |
| Off-grid package | 8,000 |
| Fixings, adhesives, tools | 1,500 |
| Contingency (10%) | 2,300 |
| TOTAL | €25,700 |
| Component | Cost (€) |
|---|---|
| Complete structural shell | 18,000 |
| Off-grid package (upgraded) | 12,000 |
| Interior finishes (higher spec) | 4,000 |
| Fixings, adhesives, tools | 2,500 |
| Contingency (10%) | 3,650 |
| TOTAL | €40,150 |
The RCP system uses a four-layer fire strategy:
The principal fire risk in single-storey timber housing is not structural collapse — it is ignition of contents. The RCP system addresses this through compartmentation and rapid egress, not through exotic fireproofing.
Assembly follows a three-team parallel workflow:
With 8–12 people organised into three teams, the complete weathertight shell is achieved in 5–7 days. Interior finishing and services take a further 3–7 days.
All material arrives on a standard rental flatbed trailer (€80/day, standard driving licence). A family of four unloads everything in one hour. Assembly begins immediately. No crane. No scaffolding beyond simple trestles. No specialist equipment beyond a nail gun, circular saw, drill, and level.