How weatherproofing performance solutions help build flood-resilient schools

 

When record-breaking floods swept through Northern New South Wales in 2022, Empire Vale Public School was amongst the casualties. The nearly 150-year-old school, which had served as the heart of its rural community for generations, was left devastated by floodwaters. Across the Northern Rivers, stories were similar: rural schools were forced to close, and communities were left waiting for repairs.

The rebuild of Empire Vale Public School presented unique challenges that demanded innovative solutions. Traditional construction methods would have simply restored the school to its previous vulnerable state, leaving it susceptible to future flooding events. The community was desperate to build back better.

The flood-resilient, modular and weatherproof solution

The design philosophy for the new school is elegantly simple and profoundly effective. Working alongside Modscape, Pedavoli Architects and ADCO Constructions, DDEG’s team ensured the new school is thoroughly protected against everything the weather could throw at it.

“If the river floods again, water can go straight underneath the school and then disappear again, and in theory, the kids go back to school the next day,” explains Paul Mulholland, director at DDEG.

The design has four critical elements:

• Elevation above flood levels: The elevated school infrastructure now sits three metres above the ground on strong metal columns.
• Durable materials at ground level: Anything at risk of flooding is constructed with durable materials that are easy to clean and restore if it becomes inundated with water.
• Fast, modern construction: The prefabricated building modules, complete with floors, walls, and windows, were built off-site, trucked in, and craned into position. This minimised on-site delays and meant better quality control.
• Smart weatherproofing: Expert engineering ensured that when the modules were joined on site, their exteriors formed a seamless barrier against water and wind. Every joint, wrap, and panel had to lock perfectly and function as a single, weatherproof structure

Engineering the weatherproofing solution

The technical challenge was significant: transforming 32 separate factory-built modules into a single, unified building envelope that could withstand the harsh Northern Rivers climate.

DDEG was responsible for the critical tasks of weatherproofing and facade engineering, as well as inspecting and ensuring that every module joined seamlessly.

Unlike a traditional build, DDEG’s involvement started long before construction began on site. The approach included:

• inspecting modules during factory construction to spot and solve problems early
• ensuring weatherproofing layers and tape were applied correctly at every joint
• coordinating closely with contractors to maintain quality from manufacture to assembly.

In the factory

Early guidance was crucial. In the factory, DDEG advised on how to ensure the building wrap was installed correctly and that flashings were left open at the bottom. This small but important detail allows for ventilation and drainage within the facade cavity, preventing moisture buildup.

On site

Once the modules arrive on site, they transitioned from being a ‘product’ to a ‘building’, a distinction that changed the inspection process.

“All the individual boxes were delivered, then assembled to form a school,” Paul describes. “It comes together like a giant Meccano set. It’s quite extraordinary. When you’ve got 32 boxes stuck together, the building wrap has to be taped together properly, and all the joins have to be done correctly. We inspect it independently of the builder.”

This independent oversight proved vital. During an on-site inspection, Paul’s team noticed that formwork for a large concrete balcony had the potential to cover the critical flashing at the base of the lightweight wall. “We were right there to advise the team not to keep pouring to cover the bottom of the flashing,” Paul recalls. “It would have defeated the whole purpose. We wouldn’t have been able to pass it.” This intervention ensured the project complied the first time, avoiding costly rework and delays.

Learning at new heights

The completed Empire Vale Public School stands as a testament to innovative engineering and forward-thinking design. The school reopened in September 2024, featuring three new classrooms, a library, a canteen, collaborative learning spaces, and a multi-purpose area across 1,060 square metres. The historical elements of the original school were preserved, maintaining the connection to the community’s heritage while embracing a resilient future.

The school’s completion also has a profound community impact, with locals reassured that if disaster strikes again, things will be different. Getting schools running is one of the first and most important steps in restoring normality, and in Empire Vale, they’re set up for a fast recovery.

“It will allow the parents in the area to get their kids to school so they can get on with clean up and rebuilding,” Paul observes. “It’s one less thing to worry about when your house has got a foot of mud inside it. It will help the healing process take shape a lot quicker.”

A model for the future

Empire Vale Public School is one of six schools in the region—along with Blakebrook, Broadwater, Condong, Tumbulgum, and Wardell public schools—being rebuilt with flood resilience in mind. It shows what’s possible when innovative construction methods meet specialised engineering expertise.

The success lies in the collaborative approach that brought together modular construction specialists, architects, builders, weatherproofing experts and educational planners to create something truly innovative.

Each contributed unique expertise to create something that none could have achieved alone. For DDEG, this project represents the kind of work that drives us forward, solving real problems for real communities through technical excellence and creative thinking.

As climate change continues to challenge traditional construction approaches, projects like Empire Vale Public School serve as a blueprint for more resilient infrastructure.

The children of Empire Vale are now back in classrooms that can withstand whatever the weather brings. And for the broader construction industry, Empire Vale demonstrates that with the right expertise and innovative thinking, even the most challenging reconstruction projects can become opportunities for genuine advancement.

Looking for innovative solutions for your next project?

We’d love to chat. Whether you’re facing complex weatherproofing challenges, need specialist facade engineering, or require performance-based solutions for flood-resilient infrastructure, DDEG’s expert team is ready to help.