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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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Cladding as Character: Defining Walkerville Recreation Centre

LS Roofing and Cladding delivered precision roofing and cladding, balancing durability, performance, and modern identity.

LS Roofing and Cladding

The redevelopment of the Walkerville Recreation Centre showcases a strong balance of performance, durability, and modern design, with the roofing and cladding package playing a central role in the building’s visual identity and long-term resilience.

LS Roofing and Cladding delivered the full external roofing and wall cladding systems, supplying and installing FIELDERS materials across multiple building zones.

The main roof was completed in 0.48BMT Klip-Lok sheeting in Matt Shale Grey, paired with roof razors and insulation blanket to enhance thermal performance and weather protection.

The gymnasium walls were clad in 0.48BMT Span-Form, continuing the sleek Matt Shale Grey finish, while the lower level features 0.55mm Nailstrip cladding in Metallic Aries, adding contrast and a refined architectural detail.

“The Nailstrip cladding has that nice seamless finish and, when installed correctly, it has little to no oil-canning,” explained founder Leigh Surman.

Precision was critical. “All of the walls were packed out to a 1mm tolerance to provide a level surface,” says Leigh Surman, ensuring the cladding achieved a clean, consistent finish. Flashings in Matt Colourbond and Metallic Aries were detailed to integrate seamlessly with the façade.

Despite tight material lead times, the team maintained progress through careful sequencing of preparation works.

Led by founder Leigh Surman, the business brings strong industry experience to every project. From small re-guttering jobs, LS Roofing and Cladding has grown in three years into a seven-person team delivering medium to large commercial projects across the state.

For more information contact LS Roofing and Cladding, phone 0412 412 514, email leigh@lsroofing.net

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Pioneering Complex Curtainwall and Façade Engineering

Ausrise Façades delivers precision-engineered, curtain walls and architectural façades, combining innovation, and technical excellence.

Ausrise Facades

For over two decades, Ausrise Façades has been at the forefront of façade innovation and precision, specialising in complex curtainwall systems, high- performance glazing, and architectural cladding solutions across Australia.

With 23 years of experience and a skilled team of 50 professionals, the company has become synonymous with quality, craftsmanship,
and collaborative delivery, which were on display in their recent work on the UNSW Health Translation Hub (HTH) project.

Located within the Randwick Health and Innovation Precinct, the HTH project posed a unique opportunity and significant technical challenge: to create a world-class façade system for a facility that brings together education, research, and clinical care under one roof.

“Our scope of work included all external curtain wall façades—glass, GRC (glass reinforced concrete), aluminium feature elements, fixed louvres, and frameless glazing at the podium,” said Kevin Hartin, Director at Ausrise Façades. “Every one of our 50 staff members was involved in this project in some capacity. It was truly an all-hands on effort.”

From the outset, the HTH’s architectural ambition was clear, with striking geometric forms and curved aluminium and GRC features shaping the building’s exterior. Ausrise was brought on for their ability to deliver complex façade systems with high technical accuracy and aesthetic precision.

“What made this project really stand out were the scale and shape of the GRC projections,” Kevin explained. “They involved large- format panels with very tight tolerances and complex curvature that pushed the limits of conventional fabrication and installation.”

Overcoming the engineering challenges of both these curved aluminium and GRC elements required early engagement with structural consultants, iterative 3D modelling, and customised mounting systems.

The Ausrise team worked closely with the builder, architect, and façade engineers to ensure every panel aligned with the architectural vision while maintaining long-term durability and thermal performance.

The podium-level frameless glazing system also presented logistical and sequencing complexities. These were resolved through meticulous staging and real-time coordination with other trades. Despite the scale and technical difficulty, Ausrise delivered their scope on time and to specification.

“The HTH project exemplified what Ausrise does best, bringing engineering, fabrication, and site installation together seamlessly to meet architectural intent,” said Kevin. “We’re proud to have been part of such an important project for UNSW and the broader research community.”

Beyond the HTH, Ausrise continues to push the boundaries of architectural façade delivery. The company is currently working on the Macquarie University Engineering and Astronomy Building, another architecturally ambitious project that showcases their deep capability in technical façade solutions.

With a growing portfolio of major university, commercial, and public infrastructure projects, Ausrise remains committed to its founding values of quality, innovation, and collaboration. Their vertically integrated model (combining in-house design, manufacturing, and installation,) enables them to tackle increasingly complex façades with confidence and precision.

“Over the past 23 years, we’ve built our reputation on consistency and problem- solving,” Kevin noted. “Every project is different, and we pride ourselves on adapting our systems and processes to suit. At the end of the day, it’s about delivering value, performance, and design excellence to our clients.”

For more information contact Ausrise Façades, 6/5 Clerke Place, Kurnell NSW 2231 Kevin Hartin – phone 0422 803 933, email kevin@ausrise.com.au, Paul White – phone 0422 803 932, email paul@ausrise.com.au, website www.ausrise.com.au

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Cladding Engineering: Delivering Thermal Performance & Architectural Precision

CCYE delivered expert internal linings and external cladding for Alba, ensuring precision, performance, and durability.

Cathay Chung Yue Estate (CCYE)

Cathay Chung Yue Estate (CCYE), a renowned façade company, played a key role in the Alba at Square, delivering lightweight internal lining and external cladding solutions as part of Westbourne Constructions’ broader vision for this sophisticated residential development.

With over two decades of industry experience, CCYE brought its extensive knowledge in both internal and external fit-outs to this project, ensuring seamless execution across complex building systems.

“We were engaged to complete the lightweight wall partitions and the full external cladding system,” said Johnny Meng, Project Manager at CCYE. “Our team focused on precision installation to match the architectural detailing and ensure durability across all five towers.”

Located within the transformative Green Square Town Centre— a precinct anticipated to house over 50,000 residents by 2030— the Alba development demanded a meticulous balance of form and function. CCYE’s scope included installing gyprock, Hebel panels, and multiple façade systems that aligned with the project’s high standards in sustainability and aesthetics.

“Our role was critical in helping Westbourne meet the architectural and thermal performance targets,” Johnny explained. “We handled variable designs and evolving site conditions while maintaining quality and timeline expectations.”

Despite a tight construction schedule and intermittent design changes, CCYE mobilised up to 85 personnel at peak to ensure project continuity and consistency. “We faced changes in construction drawings throughout the build, but our team adapted quickly and upheld the high-quality standards required by both Westbourne and the project stakeholders,” added Johnny.

CCYE’s contribution to the Alba showcases the company’s reliability and adaptability in large-scale, high-density developments. With a newly established cladding manufacturing facility and an expanding portfolio that spans residential, education, aged care, and commercial sectors, CCYE continues to position itself as a leader in streamlined, cost-efficient, and high-performance construction solutions.

For more information contact CCYE, Unit 2, 23 Leeds Street, Rhodes NSW 2138, phone 02 9682 6888, email info@ccye.com.au, website www.ccye.com.au

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It’s everyone’s responsibility to think long-term

By Paul Miller, Business Development Manager | BPM Industries Australia

Construction is a multi-billion dollar industry in Australia, and due to the nature of the game some people try to cut corners when it comes to delivering projects on time and on budget. Due to this there is a great deal of responsibility on both the suppliers of building products as well as principle contractors and architects to ensure we’re providing fully compliant high quality products that will provide the greatest long term value for clients by lasting the test of time.

Louvres and architectural façade features are often the final product to be placed on a building. However, the longevity of their aesthetic finish can make all the difference to a façade. At BPM Industries Australia, we place a strong emphasis on ensuring that our products are made to last and only work with accredited applicators to apply finishes to our products so that the quality our clients receive on hand-over is to the highest standard years and decades later.

It’s all too common in the industry where suppliers will provide non-compliant finishes to clients in order to secure the contract and meet the required budget. This is unprofessional behaviour, and leads suppliers giving the industry a bad reputation as well as enforcing the false perception that commercial grade finishes are no different to common house paint and will start to show signs of fading in just a few short years when properly applied commercial finishes can provide film integrity warranties up to and exceeding 25 years.

Everyone in construction including suppliers, fabricators, contractors and architects should renew their focus on understanding the benefits and risks involved with protective commercial architectural finishes. Search out and endeavour to work with contractors who have a good company ethos, invest in the suppliers with a commitment to supplying high quality products compliant with Australian Standards, and reap the rewards of having delivered a project that not only holds its architectural appeal but minimises ongoing rectification and maintenance costs. By being diligent and committed to quality, the product and the construction industry, will be something we can admire for decades.

About the author

Paul Miller is Business Development Manager of BPM Industries Australia, who design, supply, and install architectural louvres and façade features for some of NSW’s biggest projects.

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