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0 months Total time on site
0 Than traditional build


Kilkenny, Ireland




72-bed modular extension
5 storeys
30-day install
Internal courtyard feature
Staff accomodation & facilities
Roof level plant room
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ESS Modular was appointed as the main contractor responsible for the design, construction and delivery of a 72-bed modular ward extension, over 5 floors at St. Lukes General Hospital, Carlow-Kilkenny. The new facility replaced some of the pre-existing multi occupancy 'nightingale' wards which were built in the early 1940s and significantly increases the overall bed capacity of the hospital.

The building consists of 4 floors and a plant room at roof level with tie in’s back to the existing hospital at each floor level. The ground floor accommodation includes offices, lockers rooms, overnight room, staff rest, kitchen/pantry, stores, lift lobby, toilets and plant room area. The first, second and third floor accommodation consists of 24 bedrooms, 24 ensuites, offices, dirty utility, stores, toilets, discharge lounge, staff base, drug prep, clean utility and linen room. The roof level plant room includes a vacuum plant room, comms room, AHU room and lift overrun.

ESS worked closely with the appointed team and led in the coordination of all of the disciplines to ensure a seemless project delivery for the client. Collaboration and early-engagement with supply chain partners enabled us to provide more certainty to the programme, establish risk reduction workshops, develop our risk register and quantify overall risk exposure. This was particularly important for this project as it commenced in the height of the Covid-19 pandemic.

The position of the new build on site was very prominent within the hospital campus and involved careful consideration and sequencing. The new building was positioned directly in front of the current main entrance to the hospital building and also overlaid the bus and set down areas. ESS Modular has extensive experience of completing projects in a live hospital environment and so we worked with the client team to develop a site procedures and phasing plan to ensure the operation of the hospital would not be impacted by the works.

This was a continual process and included:

  • Site enabling works for aspergillosis monitoring and sealing
  • Re-routing of ambulance roads, bus set down, patient drop-off, fire escapes, etc.
  • Stair extensions to existing stairwells
  • Tie into existing hospital streets
  • Tie in of services to the existing hospital infrastructure.

A live Construction Phase H&S Plan and Traffic Management plan ensured works were carried out safely and securely. Site signage was installed to direct pedestrian and vehicle traffic into, around and out of the site. Module installation was coordinated and planned from leaving the factory with numbered load schedules, holding points off site for vehicles and a call-in system to avoid congestion in the surrounding area.

All works were controlled by approved method statements and risk assessments. ESS ensured a dedicated full time Health & Safety presence was on site during all high-risk activity and ample time was provided to ensure full stakeholder engagement and review of RAMS was done prior to undertaking any tasks.

By delivering this project using MMC, we were able to run a comprehensive programme involving two distinct elements concurrently. The site establishment and enabling works and foundations were managed on site, while the procurement and manufacture of the building took place in a controlled factory environment. The project was handed over in April 2022.



We believe that modular construction is the future and we are looking for energetic people who share our ambition to join us on our journey.