Ribbed Composite Panel system. EPAL pallets, I-joists, OSB3. Off-grid capable. Demountable. Engineer-certifiable under Eurocode 5.
One RCP module = 1250mm × 2500mm. Build any footprint in 1.25m increments. Recommended maximum span: 6 meters for standard I-joists and timber.
37.5
m²
20
RCP modules
5000
mm
2,500
kg
Select your configuration. All costs are material-only; labour is self-build or community.
Each RCP panel consists of 7 layers. Every component is independently certified. The assembly protocol requires no specialist tools beyond a nail gun and cordless drill.
Type F, fire-rated, 15mm. Zero cuts required — 2500×1200mm sheets align to panel dimensions.
15mm | EN 520 | €6/sheetStructural sheathing, EN300, CE-marked. Installed after erection and electrical routing.
15mm | EN 300 | €7.50/half-sheetFull cavity coverage, no voids. Contractor-applied in one day. U-value: 0.40 W/m²K (single) / 0.22 (double).
Mineral wool | €2,500–3,000/houseCertified softwood, HT-graded, deck board MC below 15%. Three pallets per panel. Ribbed structure provides composite action.
145mm | EN 13698-1 | €0–17/palletFabricated onto pallet core on ground. Sikaflex 512 adhesive + ring shank nails + Spax screws.
15mm | EN 300 | €7.50/half-sheetBreathable weather barrier. Prevents wind-driven rain ingress while allowing vapour escape.
€1.20/m²User choice: timber cladding, render, paint, or marine plywood for wet environments.
Variable| Component | Quantity | Unit | €/Unit | Total € |
|---|---|---|---|---|
| OSB3 15mm 2500×1250 | 52 | sheets | 15 | 780 |
| EPAL pallets (graded) | 78 | units | 17 | 1,326 |
| Sikaflex 512 300ml | 104 | tubes | 10 | 1,040 |
| Ring shank nails | 5 | kg | 16 | 80 |
| Spax screws 4×50mm | 5 | kg | 16 | 80 |
| 2×6 C16 joists | 20 | lengths | 4 | 80 |
| P5 T&G chipboard 22mm | 16 | sheets | 22 | 352 |
| Glass wool 140mm | 3 | rolls | 45 | 135 |
| I-joists STEICO SJ200 | 10 | lengths | 65 | 650 |
| Steel roof + condensation mat | 42 | m² | 12 | 504 |
| Gypsum Type F | 40 | sheets | 6 | 240 |
| Housewrap membrane | 80 | m² | 1.20 | 96 |
| Simpson Strong-Tie connectors | 275 | units | 1.27 | 350 |
| Windows (double glazed) | 4 | units | 150 | 600 |
| Exterior doors | 2 | units | 300 | 600 |
| EMT conduit + fittings | 50 | m | 4 | 200 |
| Total Shell Materials | 7,600 |
| Single pallet wall U-value | 0.39–0.42 W/m²K |
| Double pallet wall U-value | 0.21–0.23 W/m²K |
| Portuguese masonry (reference) | 1.8 W/m²K |
| Passive House target | 0.25 W/m²K |
| Improvement over masonry | 4–5× better |
ISO 6946 calculation verified. Single pallet wall exceeds Portuguese requirements. Double pallet meets Swedish Passive House standard.
| Compression capacity (single wall) | >200× domestic load |
| Wall panel weight | 65–85 kg |
| Two-person carry | Yes |
| Racking resistance | Equivalent to stud wall |
| Bond strength (Sikaflex 512) | >OSB tensile strength |
Eurocode 5 (EN 1995-1-1:2004) load cases calculated. All components independently CE-marked. System overengineered for single-storey domestic by factor of ~200.
| Conventional | RCP | |
| Materials | €90,000 | €13,000 |
| Labour + margin | €150,000 | Self/community |
| Total build | €280,000–€450,000 | €35,000 |
| Time | 12–24 months | 1–2 weeks |
| Cost per m² | €3,000–€4,500 | €437 |
Conventional figures from Turner and Townsend International Construction Market Survey 2025. RCP costs verified from Portuguese supplier pricing 2025–2026.
| Foundation type | Earth screws |
| Foundation removal | Same machine, same day |
| Panel connections | Screws only |
| Roof removal | Unscrew steel from I-joists |
| Complete disassembly | 1–2 days |
| Components reusable | Yes — all intact |
Every connection is a screw. No concrete. No rubble. The structure is assembled, not built. It disassembles in the same time it took to assemble.
8 phases. Each phase has defined inputs, outputs, duration, and tool requirements. No specialist skills required beyond reading instructions and operating basic power tools.
Earth screws installed by compact hydraulic machine. One operator, one day. No excavation, no concrete, no curing. Fully removable.
Build RCP panels on a simple jig on flat ground. Outer OSB + Sikaflex + pallet core + nails + screws. Pre-paint one-time pallets for ceiling.
Two people carry each panel (65–85 kg). Screw to sill beam and adjacent panels. Weathertight structural shell in 1–2 days.
2×6 C16 joists on earth screw brackets. P5 T&G chipboard deck. 30mm marine salt layer in joist bays for biological protection.
I-joists with pre-rigged ridge plate. Lift from floor — no scaffolding. One-time pallets as ceiling. Steel sheet screwed to top flanges.
Blown-in rockwool by contractor. One day. Full cavity coverage, no voids. U-value 0.40 W/m²K (single) or 0.22 (double).
Gypsum Type F (no cuts required). End-grain wood floor. Electrical conduit in EMT. Wet wall assembly with plumber.
Solar PV, battery, solar hot water, composting toilet, smart home hub. Licensed electrician and plumber sign-off.
Shell weathertight by day 5. Interior complete by day 10. Off-grid systems by day 14. No concrete curing. No subcontractor scheduling. No weather delays from formwork.
All specifications, calculations, and protocols are freely available. Download, study, build, improve, share.
Master's thesis with full structural analysis, cost breakdown, and engineering package.
FreeExact dimensions, materials, adhesives, fasteners, and acceptance criteria per panel.
FreeStep-by-step panel construction with photos, tool list, and quality checks.
FreeEurocode 5 load cases, span tables, connection details, and certifiable drawings.
FreeExcel/Sheets with all formulas, supplier links, and regional pricing adjustments.
Free100+ page illustrated guide: day-by-day build sequence, tool list, safety, troubleshooting.
FreeNot ready to self-build? We offer complete design-to-keys service in the Algarve and across Portugal.
Engineer stamp, permit application, municipality liaison. 3–6 month processing time.
We source all materials, cut to length, and deliver to your site. One delivery, one invoice.
Complete build by our team. Earth screws to gypsum. 2–3 weeks on site.
Solar PV, battery, hot water, composting toilet, smart home. Licensed install, full certification.
Starting at €50,000 for 84m² fully equipped
Includes all materials, labour, professional services, and sign-offs. Land and permit fees separate.