As Ireland’s Modern Methods of Construction sector continues its rapid expansion, head of MMC certification with the National Standards Authority of Ireland (NSAI), Martin Searson, sits down for an in-depth interview with Irish correspondent Carol Tallon to discuss how his team is working to support industry growth while maintaining rigorous standards
With over 200 offsite construction manufacturers now operating across the island of Ireland and certification applications coming in weekly from companies in Ireland, the UK region and across Europe, the US and Asia, NSAI’s MMC team finds itself at the epicentre of Ireland’s construction transformation.
From innovative folding houses to bio-based materials and mass engineered timber building systems, Searson’s department is processing some of the most cutting-edge building technologies entering the Irish market.
Yet despite the sector’s momentum, certification remains a debatable topic, with many viewing the approval process as a potential bottleneck rather than quality assurance.
Here, Martin Searson outlines what the certification process really involves and how NSAI is working to support the MMC sector.
Q: Martin, your MMC certification team was formally established in June 2023. How has the demand for certification evolved since then?
The growth has been significant. When we started, we had a handful of certified companies under our existing Agrément certification scheme for building systems. Now we have 20 certified companies with another 45 working their way through the process. We’re expecting to publish five to eight new certificates this year alone, with several very close to completion.
What’s particularly encouraging is the diversity we’re seeing – it’s not just Irish companies. About 70% of our applications are from Irish-based organisations, but we have significant interest from the UK, mainland Europe and even companies from the US and China looking to enter the Irish market.
Q: The industry has previously cited certification as a potential barrier to market entry. How do you respond to that criticism?
I understand the perception, but it’s important to remember that Agrément certification has been part of Irish Building Regulations since 1991, as referenced under TGD Part D – Materials & Workmanship. It is not a new barrier; it is an established quality assurance framework that exists because these are novel building systems that do not have existing Irish standards, or do not have CE marking which aligns with current Irish Building Regulations and for the local climate conditions, here in Ireland.
The challenge is that every European country has their own unique building regulations, as market competency rests with each EU member state or EEA country. What works in Germany or The Netherlands might not meet Irish climatic conditions or our specific regulatory requirements, ie with defined Irish Standards such as IS 3217, IS 3218, IS 813, IS 10101, etc.
Our role is to assess these innovative systems against EU Directives, CPR (ie EU/305/2011 and EU/2024/3110), current Irish Building Regulations, Irish Standards and coupled with relevant Codes of Practices to provide a level of quality assurance for end users, warranty providers and regulatory authorities, to reply upon.
Q: You maintain a national database of over 200 offsite manufacturers across the island of Ireland. What does this tell us about the sector’s maturity?
It shows we have a vibrant, diverse ecosystem. These companies range from log cabin manufacturers to technically advanced operations serving multinational pharmaceutical, data centre and other sectors. They are not all doing housing – many have found niche markets in healthcare, education, and commercial sectors.
Under our IS 440 timber frame certification scheme, we currently have 39 certified companies, with other building system companies certified through the NSAI Agremént certification route. The diversity is striking – we are seeing everything from light gauge steel to mass engineered timber, insulated concrete formwork, structural insulated panels and various steel-based systems (welded and non-welded).
Q: What innovations are you seeing come through the certification process?
Some fascinating developments. We have seen a folding house concept from a Chinese manufacturer using hinge systems being proposed, bio-based materials being integrated to replace traditional insulation and wall build ups, and companies exploring disassembly and reassembly capabilities for circular economy principles.
There is significant focus on decarbonisation – companies are exploring the replacement of traditional materials for more sustainable alternatives, which requires retesting and recertification.
We’re also seeing more advanced manufacturing approaches, with lean principles being applied, increased automation and digital integration through mobile tablets, QR coding and barcode systems.
Q: The certification process covers the entire end-to-end system. How important is the on-site element?
This is absolutely critical. We assess MMC building systems from the material inputs right through to final assembly and installation because that is where modules can be compromised despite some very good offsite factory fabrication work. These are highly engineered, expensive building systems that need to be treated with the same care you would give a precision-manufactured component or capital equipment.
The challenge is that many site operatives simply aren’t familiar with these new and innovative MMC building systems. You cannot just drill into a modular wall like you would a traditional concrete wall – you could compromise the cladding, moisture barrier, fire properties or structural integrity of the building system. This is where coordination between offsite manufacturers and onsite assembly and installation teams becomes essential.
Q: How long does the certification process typically take?
It varies significantly based on complexity and how prepared the applicant company is. For revisions to existing certificates, we can complete the process in four to six months.
For new clients who have been certified in other jurisdictions and have robust documentation certified by other notified bodies, this could take around six to nine months. But for completely new companies or complex systems, it averages 15 to 21 months, at present.
The timeline often depends on factors beyond our control – companies might pause applications due to staff changes, pivoting to different markets or needing to reorganise their operations. We understand that they are trying to manage this certification process alongside running existing production operations or managing potential order books, which is challenging.
Q: Your team has developed a new MMC toolkit to support offsite manufacturers. What does this include?
We recognised that while we are not in a position to consult or advise due to impartiality requirements as set out in the current ISO/IEC 17065 requirements for certification bodies, we can provide significant guidance and support resources, where publicly available.
The new MMC toolkit includes infographics, a two-page Q&A guide, frequently asked questions, and interview focuses from NSAI-certified MMC companies.
Furthermore, there are separate weblinks to the excellent work being done by Construct Innovate and other state and academic initiatives, such as the MMC Accelerate platform, recently launched by CitA Skillnet and Skillnet Ireland, jointly.
The key component is a MMC Self-assessment Readiness scorecard that allows offsite manufacturing companies to assess where they are in the certification process journey before applying.
We are also in the process of developing a Factory Production Control (FPC) guide showing that should typically be in an offsite manufacturing environment. It is about demystifying the process and showing there’s a clear pathway to certification.
Q: What advice would you give to offsite manufacturers considering MMC certification?
Firstly, you know your system better than anyone else so start by “process mapping” everything from the back-office operations and incoming materials receiving to the production floor fabrication, right through to logistics.
Then read our Guide to Agrément Certification for MMC document, with the supporting MMC toolkit documents and do a mapping exercise – identify what you have and what gaps need addressing.
I would strongly recommend benchmarking with other offsite manufacturers, even outside of your sector. A housing manufacturer could learn valuable lessons from a MEP (mechanical, electrical and piping) offsite fabrication company that has been doing modular construction for years.
Take advantage of R&D supports, including grant funding, from Construct Innovate and Enterprise Ireland to offset costs and perhaps employ graduates.
Most importantly, embrace certification as continuous improvement rather than a hurdle. It is recognition of good work and provides input for refining existing operational and fabrication processes. Companies that engage with this mindset typically have smoother experiences.
Q: How do you see the certification landscape evolving as the MMC sector matures?
The ideal scenario is that industry bodies and other stakeholders develop their own MMC standards, like the timber frame sector did in 2009 with the IS 440 standard. When you have consensus-based standards that everyone recognises and follows, it becomes much more straightforward.
We are seeing progress with working groups on mass engineered timber and other building systems. The Department of Housing is funding standardised design work through Construct Innovate for various material types and building systems. As the sector grows and matures, we should see more standardisation, which will benefit everyone, while providing opportunities for further innovation in the MMC industry.
Q: Any final thoughts on NSAI’s role in supporting MMC growth?
We are here to support industry growth while maintaining the standards that protect end users and occupants of these MMC building systems. These buildings need to last 60 years under current Irish requirements, in addition to the Eurocode standards with the National Annexes for Ireland – they are permanent structures for the next generation, not temporary solutions.
Certification is recognition of good work and fabrication methodologies. Therefore, our goal is to make the certification process as efficient as possible while maintaining rigour in the technical assessment and FPC auditing process.
With our new MMC toolkit, clearer guidance and growing experience, we are supporting improved application quality and shorter timelines. The sector is maturing rapidly, and the MMC team within NSAI is committed to evolving services alongside that growth.
For more information about NSAI’s MMC certification services and to access the new toolkit, visit https://www.nsai.ie/certification/agrement-certification/modern-methods-of-construction-certification/
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