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Enhancing Façade Performance Through Lysaght’s Material Expertise

Lysaght

The NSW Government’s $890 million John Hunter Health and Innovation Precinct is one of the most significant healthcare infrastructure projects ever delivered in regional New South Wales. Designed by BVN and built by Multiplex in partnership with Health Infrastructure and Hunter New England Health District, the landmark 7-storey Acute Services Building is at the heart of the precinct.

Responding to the project’s ambition to create a steel façade that reflected the surrounding landscape while meeting the functional demands of a major healthcare facility, Lysaght provided material selection guidance, colour development support, product supply and logistics coordination throughout the delivery process.“Working closely with architects, specifiers, and designers in order to achieve the best product solution to meet the architectural intent has been the absolute focus,” said Will Pereyra, Business Development Manager for Lysaght’s Design Solutions Group.

The façade features several Lysaght® cladding profiles, most prominently, LYSAGHT HORIZON® a dual-layer system that contrasts a flat steel outer protective skin with a trapezoidal internal backing layer, to deliver a wider, smoother, and overall sturdier panel. The project also featured cladding from the LYSAGHT ZENITH® range, including DOMINION®, SNAPSEAM® and ENSEAM®.

The Lysaght profiles were manufactured from Australian Made COLORBOND® steel, featuring custom organic finishes in Glenwood Green™, Fallen Gumnut™, and Wild Fawn™, chosen to blend seamlessly with the natural environment.

Sustainability considerations were embedded from material selection through to façade performance. ResponsibleSteel™ certified steel manufactured by BlueScope, roll-formed by Lysaght, provides independently verified environmental and social performance data, while the external steel skin contributed to solar control objectives as part of the building envelope strategy, supporting the Hunter New England Local Health District’s target to achieve carbon neutrality by 2030.

Precision logistics were central to the project’s success. The Lysaght cladding was custom-processed and routed through BlueScope’s Tomago Distribution hub to regional fabrication partners, enabling sequential deliveries timed to match the crane and assembly schedule on site. It was this level of coordination, supported by the Lysaght Team, that kept one of the state’s most complex health builds on programme.

The completed façade demonstrates the value of early collaboration, considered material selection and coordinated supply in delivering a complex architectural outcome for a major healthcare facility.

For more information about Lysaght products or to locate your local Lysaght branch, visit lysaght.com



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Co-ordinated Facade Delivery Across a Multi-builind Programme

Seven Facade

Successful façade delivery depends on more than product selection, it requires contractors who can manage complexity, coordinate multiple trades and systems, and maintain quality at scale without compromising programme outcomes.

Established in 2021 by two carpenters with extensive installation experience, Seven Facade delivers integrated roofing and cladding solutions across the ACT region. Based in Queanbeyan, the company specialises in external roofing and cladding, bringing an end-to-end capability that takes a project from subframe setup through to final panel install under one roof.

At MIO in Googong, a high-volume multi-building residential development, Seven Facade applied their delivery model, with the team managing multiple buildings simultaneously while maintaining a consistent, high-quality finish across the entire development.

“The biggest challenge on MIO was the number of buildings being delivered at the same time,” said Director Hayden Birch. “Maintaining consistency across every block while keeping pace with the construction programme comes down to people, systems and communication.”

The product specification played an important role in achieving both the architectural vision and programme efficiency. Lysaght Trimdek steel sheeting provided a clean, durable profile across the larger façade areas. Fairview Genesis pre-finished panels were used to create the concrete-look feature blades that wrap around sections of the complex, forming a picture frame effect that gives the buildings depth, definition, and a striking visual identity.

“The Genesis panels arriving pre-finished as a concrete-look product was a major advantage,” explained Director Rory Stokes. “It eliminated the need for additional finishing trades and helped keep the programme moving.”

The contrast between the two systems was as effective both practically and aesthetically.

Handling the full scope, from wall wraps and waterproofing through to final cladding, gave the project team a single point of accountability and minimised the risk of issues falling through the cracks between trades.

That end-to-end philosophy traces directly back to the company’s origins. Founders Hayden and Rory started the business as working carpenters, and that trade background continues to shape every project they take on.

“Rory and I started out installing cladding themselves, we understand what’s required to deliver a quality façade, not just at the installation stage but from the very beginning,” Hayden said.

“That trade background gives us a practical approach to problem-solving. We understand buildability, sequencing and what builders need from their subcontractors to keep projects moving.”

“A big part of that is preparation,” Rory said. “Wall wraps, waterproofing, thermal bridging, R-values and ensuring the substrate is straight and ready for installation are all critical. We know that getting the basics right is what delivers a quality finished product.”

Seven Facade Directors Rory Stokes (left) and Hayden Birch (right), at MIO in Googong.

As the business has grown, that hands-on mindset has remained constant. Seven Façade has invested heavily in its people, systems, and project management processes. They have strengthened their leadership team and created greater structure around operations, procurement, and site delivery without losing the agility and personal accountability that defined the company from day one.

Rory remains a regular presence on site, working closely with supervisors and the Construction Manager to ensure workmanship, safety, and programme commitments are consistently met.

With the business on track to double in size and revenue this year, and a pipeline that includes Watson Health Hub, Winnunga, Elm Lane, The Heather, and The Googong Hotel, the growth trajectory is significant. Directors Hayden and Rory are clear that scaling will never come at the cost of standards. “Quality remains non-negotiable. Whether it’s MIO or a smaller project, the expectation is exactly the same.”

Seven Facade’s goal is straightforward, to keep working with builders who value quality, collaboration, and long-term partnerships.

For more information contact Seven Facade, phone 02 6297 3552 website 7facade.com.au




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What Goes Behind Crafting Some of the World’s Most Challenging Curved Brickwork

Custom Clad, VIC and QLD–based cladding specialist, supplied and installed the complex curved brick façade at 17 Bennetts Lane.

Custom Clad

Rising 20 storeys above the narrow rhythm of Melbourne’s CBD, 17 Bennetts Lane demonstrates what is possible when technical façade engineering and vision align. At street level, this ambition is expressed through a highly intricate curved brick façade, where horizontal and vertical curves intersect to form a seamless, sculptural surface.

Curving brickwork in a single direction is already complex. At 17 Bennetts Lane, the challenge was amplified by the need to curve across both horizontal and vertical planes simultaneously. Every deviation, no matter how small, had the potential to compound across the façade. This combination of geometry and material behaviour is rarely attempted, not because it cannot be imagined, but because controlling it in practice demands an exceptional level of planning and expertise.

It was within these constraints that Custom Clad’s end-to-end cladding approach became critical. by bringing design, manufacture, supply and installation together as a single, coordinated process.

As part of this integrated scope, Custom Clad supplied a complete lightweight wall cavity system combining steel framing, non-combustible insulation, breathable sarking, and metal battens. The brick slip cladding extended across both the internal and external faces of the front entry, reinforcing the continuity of the curved form. Custom Clad also installed vertical feature cladding made from recycled Oregon timber salvaged from the demolition of the original structure on the site.

“This project began long before fabrication, with a fully modelled 3D steel framework developed by the team at Hacer Group”, said Michael Slowey, Director of Custom Clad. “The 3D model allowed our team to visualise every curve and detail of the building well in advance. Both the primary steel frame and the brick façade sub-frame were fabricated directly from this model, ensuring every line aligned with the intended architectural vision.”

From the 3D model, Custom Clad manufactured precise jigs for accurate setout on site for the specialised curved light gauge steel framing. These jigs ensured consistency across all curved sections, allowing the framing to form perfectly around the intricate window and wall shapes.

Every steel frame was manufactured in Custom Clad’s Hallam facility and delivered to site ready for installation, sorted and labelled for efficient assembly. Managing the logistics of delivery and coordination was crucial given the site tight access in the CBD.

Custom Clad’s ability to manufacture in-house and supply complete system helped reduce downtime on site and maintained consistent quality across every stage of the project. Working closely with Nubrik, Custom Clad ensured that the variations in natural clay pressed materials were managed carefully so that the finished façade achieved both structural and visual harmony.

During installation, multiple cladding installers worked simultaneously to erect the steel framing and lay the brick slips precisely according to detailed shop drawings.

Brickwork was installed progressively before mortar was applied, allowing the curvature to be refined and checked throughout the process. Particular care was taken to ensure brick and mortar colours aligned with adjacent façades and neighbouring buildings, reinforcing visual continuity at street level.

“It has been incredibly fulfilling to push the limits of cladding innovation again with Hacer Group, setting a new standard for what can be achieved with modern construction tools, exact setout and a collaborative approach”, said Slowey.
The finished result appears calm and effortless, a seamless curved brick façade that conceals months of planning, coordination and technical discipline.

At 17 Bennetts Lane, complexity has not been eliminated, but resolved, demonstrating how careful modelling, material understanding and craftsmanship can bring ambitious architectural forms to life with precision and elegance.

Custom Clad logo

For more information contact Custom Clad, phone 03 9791 2904, email info@customclad.com.au, website www.customclad.com.au

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Delivering External Cladding Under Restricted Access

Delko coordinated external cladding delivery at 88 Leveson, managing access, weather, and sequencing during a high-risk construction phase.

Delko

As urban residential projects continue to tighten access and sequencing windows, external cladding scopes are increasingly required to absorb risk rather than pass it on.

With a combined 50 years of industry experience, Delko, a partnership between Adrian De Amicis and Lee Delcus, formed a model with a multitude of services to ensure the right level of quality and production in a demanding environment

At 88 Leveson, Delko’s approach demonstrates how disciplined co-ordination and site-level decision-making can stabilise delivery during one of the most exposed phases of construction.

Delko’s works included the installation of polystyrene panels, Hebel cladding, full rendering, external membrane paint systems and detailed caulking, a package that formed a critical part of the building’s visual and weatherproof performance.

Restricted site access defined the early challenges of the project. “Without lifts or Alimaks, all materials had to be handled manually. That naturally slowed efficiency, but our appointed trades navigated through it with professionalism and a strong commitment to meeting the builder’s timeframes,” General Manager Adrian De Amicis said. At peak delivery, Delko co-ordinated up to 20 active contractors onsite.

Weather, access equipment hire costs and sequencing pressures further complicated delivery. To maintain programme momentum, Delko implemented overtime and weekend work as needed. “While weather did affect us at times, we found ways to navigate through it,” Adrian said. “Access equipment on hire meant we had to install, render, paint and caulk without hesitation.”

“With constant communication and on-site coordination, we completed our scope without creating delays for following trades. I’m proud of the efforts of every contractor who contributed to delivering a product we all stand behind,” Adrian says. “At Delko, we aim to execute with trust and provide a hassle-free service.”

“Developing sound relationships with both Daniel Perna and David Grady gave us clear visibility of timelines and allowed us to plan each stage with confidence,” Adrian said. “A massive thank you to David Grady for maintaining a steady and safe working environment throughout.”

For more information contact Delko Pty Ltd, phone 0401 330 642, email adrian@delko.net.au

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Bringing Architectural Vision to Life at the New Gosford Library

J.R Prime Group delivered precise interior and exterior linings for Gosford Library, enhancing its distinctive architectural identity.

J.R. Prime

J.R Prime Group has played a vital role in shaping the architectural identity of the new Gosford Regional Library, proudly delivering the majority of the interior and exterior linings for the landmark civic project.

“Our scope included partition walls, feature walls and ceilings, and external fibre cement panels,” said Anthony Sun, Project Manager at J.R Prime. “Most of the linings, both inside and out, were completed by our team.”

The striking library design presented its fair share of construction challenges, including a distinctive zigzag façade on the building’s northern side.

“Setting the zigzags was the biggest issue at the start,” Anthony explained. “It took us a couple of weeks to get it right and aligned precisely with the architectural drawings. We worked closely with the architect and suppliers on shop drawings and procurement to meet the short programme.”

“Every two weeks we had a meeting with North to confirm tasks and timelines. We also met weekly with the project manager and site manager to ensure we had enough manpower,” said Anthony. “We even worked with the builder and client to secure early payments to suppliers to keep things moving.”

On the sustainability and accessibility front, J.R Prime delivered all work to meet the architect’s specifications. “We’re confident the finishes meet the highest standards,” Anthony explained.

As a local business and the largest contractor on the project, J.R Prime sees the Gosford Library as a defining moment. “It means a lot to us. We’ve demonstrated our full capability, in both management and quality. After this, we can confidently say we’re ready for any library project,” said Anthony. “It’s also a step forward in our commitment to contributing to our community.”

For more information contact J.R Prime Pty Ltd, Unit 7, 24 John Hooker St Islington, NSW 2296, phone 0420 419 788, email Anthony@jrprimegroup.com, website www.jrprimegroup.com

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