Leppington Daycare Centre
Case study
Leppington Daycare Centre utilised the Dulux Acratex StoneShield Cladding System to deliver a striking curved façade that achieved the project's architectural vision while meeting the stringent fire, bushfire and performance requirements of a Class 9 commercial building.
Project overview
Applicator: Circonstruction
Project: Leppington Daycare Centre
Location: Leppington, NSW
Work: External cladding system for a Class 9 commercial building, achieving a curved architectural façade
Products: Dulux® Acratex® StoneShield™ Cladding System, including Acratex RenderWall® Plus AcraPro® P400, Coventry® Medium texture, AcraSkin® and AcraShield® protective membranes
Background
From the outset, the owner of Leppington Daycare Centre in southwest Sydney had a design vision that went beyond the simplicity and practicality of a traditional education facility. The goal was to deliver a new building with a modern, artistic aesthetic and a refined façade finish.
"I didn't want a plain, box-like structure for this new building. I wanted the high-end aesthetic of the curved lines and archways."
Del, Owner, Leppington Daycare Centre
Delivering this vision required a façade solution that could balance design ambition, and performance, while meeting the strict compliance requirements of a Class 9 building.
The challenge
The project presented a combination of architectural complexity and regulatory constraints. The curved design required a system capable of achieving a smooth, monolithic rendered finish, while maintaining consistency across complex geometries.
Lightweight and flexible, Exsulite could easily achieve this desired finish, except this system is not compliant for commercial buildings. As a Class 9 building, Leppington Daycare Centre required a walling system that could meet stringent NCC fire performance requirements, limiting the use of alternative lightweight cladding systems.
"The building's exterior was originally specified as AAC, but the curves were going to be incredibly difficult and expensive to achieve."
Nick Waite, Business Development Manager, Dulux Acratex
The architect originally specified AAC (autoclaved aerated concrete) panels for the building envelope, however this quickly presented challenges. AAC's weight and rigid forms made the creation of curves difficult and labour-intensive, impacting both cost and program.
On-site challenge
At the same time, site conditions added further complexity.
"It was a difficult site with access and logistics, which made coordination between trades quite challenging."
Domenic Zappia, Builder, Circonstruction
In short, the project required a solution that could address:
Complex curved design requirements
Fire compliance (FRL) and bushfire (BAL) performance
Site access and handling constraints
Construction efficiency and program timelines
The solution
The Dulux Acratex StoneShield Cladding System was proposed as a complete walling solution, offering a lightweight, high-performance alternative to traditional masonry systems.
Lightweight performance
StoneShield combines non-combustible stone wool insulation with a fully integrated coating system, delivering a lightweight building envelope. The hero feature is ROCKWOOL, a 'whipped' blend of basalt and other natural stones which form the innovative 75mm FacadeRock DD panels. As an organic product, it is fully recyclable and does not produce toxic dust when cut and handled.
Importantly, the FacadeRock panels weigh 12kg per sqm, compared to approx. 50kg/sqm for AAC and 80kg/sqm for brick. The lightweight system delivered clear advantages on site, particularly in relation to handling and installation. Reduced reliance on heavy equipment and simplified installation contributed to improved construction efficiency and faster progression toward lock-up stage.
"The weight was definitely a big factor, especially when considering the structural design. We were looking for a lightweight wall system, and this one ticked all the boxes. StoneShield made things easier to manage on site, especially with access and logistics."
Domenic Zappia, Builder, Circonstruction
Design flexibility
Unlike rigid systems, StoneShield provides the flexibility required to achieve complex architectural forms, including curves and archways.
"The system is easy to work with and was able to conform to the curves we had designed."
Domenic Zappia, Builder, Circonstruction
This flexibility enabled the project team to realise the original design intent without compromising on finish quality.
Compliance and performance
StoneShield is a CodeMark-certified, multi-layered cladding system, designed to meet NCC requirements across fire, thermal, acoustic and weatherproofing performance.
"It ticks a lot of boxes - speed, lightweight, acoustics and thermal performance."
Romina Basto, Specification & Compliance Manager, Dulux Acratex
Key performance outcomes include:
Fire Resistance Levels (FRL) up to 90/90/90
Suitability for all BAL zones, including BAL-FZ
Thermal efficiency up to R4.9
Acoustic performance up to Rw 50 ±2
NCC-compliant weatherproofing
System specification
The façade was installed in accordance with the Dulux Acratex StoneShield system specification, ensuring CodeMark compliance and long-term performance.
The Result
The Leppington Daycare Centre demonstrates how the innovative StoneShield walling system can successfully balance design ambition, CodeMark compliance and construction efficiency.
The project achieved:
A high-quality architectural finish with curved façade elements
Full compliance with NCC BAL and FRL requirements
Improved construction efficiency and site handling
A durable, long-term walling solution
Products specified:
Acratex RenderWall® Plus, AcraPro® P400, Coventry® Medium texture, AcraSkin® in Dulux Lexicon Quarter, AcraShield® in Dulux Lexicon Quarter
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