Nelson Bay Residential Development
Case study
The Nelson Bay development demonstrates how integrating StoneShield with Exsulite can deliver NCC compliant, high-performance outcomes without compromising build efficiency.
Case study
The Nelson Bay development demonstrates how integrating StoneShield with Exsulite can deliver NCC compliant, high-performance outcomes without compromising build efficiency.
Project overview
Applicator: Kain Bliss, Green Build Construction
Project: Nelson Bay Residential Development
Location: Nelson Bay, NSW
Works: External cladding system and fire-rated party wall solution for multi-residential construction
Products: Dulux® Acratex® StoneShield™ Cladding System and Exsulite® Cladding system finished with an Acratex coating system
Dulux Acratex Team: Romina Basto, Specification & Compliance Manager
Background
Located in the coastal environment of Nelson Bay, this multi-residential development was designed to deliver modern, high-quality housing with a strong focus on durability, performance and visual appeal.
This project presented a unique opportunity to showcase how integrated cladding systems can deliver both performance and efficiency in multi-residential construction.
By combining Exsulite across the main building envelope with StoneShield for critical wall elements, the project demonstrates how modern systems can work together to meet compliance requirements without compromising design intent.
“The Nelson Bay project was a great opportunity to showcase a successful hybrid cladding approach.”- Romina Basto, Specification & Compliance Manager, Dulux Acratex
The Challenge
Across the entire project, the original design specified Exsulite – a lightweight thermal cladding system comprising Expanded Polystyrene panels and a Dulux Acratex coating system, installed with a cavity system for best practice moisture and condensation management. While suitable for standard external walls, Exsulite could not be used in areas requiring fire-rated construction.
The ‘party wall’ between the dwellings required a compliant Fire Resistance Level (FRL) solution, in line with National Construction Code (NCC) requirements.
“The party wall that separates the two tenancies needed a compliant Fire Resistance Level (FRL) solution, presenting a significant challenge for the builder. Masonry or concrete panels would typically be the only alternative, but the StoneShield cladding system proved to be a far superior option.” - Romina Basto, Specification & Compliance Manager, Dulux Acratex
The solution
The Dulux Acratex StoneShield Cladding System was proposed as a targeted solution for the party walls, providing the required fire performance while integrating seamlessly with the Exsulite system used elsewhere on the building.
StoneShield is a CodeMark-certified system, designed to meet NCC requirements across fire, thermal, acoustic and weatherproofing performance. As a non-combustible system, StoneShield can achieve fire resistance level FRL 90/90/90 for separating walls, ensuring compliance without requiring redesign of the overall façade system.
“StoneShield solves many of the issues contractors face on site - speed, weight, acoustics and thermal. It ticks a lot of boxes - on top of meeting fire compliance across NCC classifications.” - Romina Basto, Specification & Compliance Manager, Dulux Acratex
Another key advantage of the solution was the compatibility between StoneShield and Exsulite systems. Both systems share similar installation methodologies, allowing for a smooth transition between materials on site. This enabled the builder to maintain construction momentum.
System specification
The façade was installed in accordance with the Dulux Acratex StoneShield system specification, ensuring CodeMark compliance and long-term performance.
Lightweight, efficient and builder-friendly
StoneShield delivers significant on-site advantages through its lightweight design and ease of installation. Weighing approximately 12kg/m², StoneShield is significantly lighter than traditional materials such as brick (~80kg/m²).
“It’s very lightweight, cost effective and easy to work with. It’s a straightforward and uncomplicated system. There’s no need for cranes, or even power tools, as the panels can be cut with a blade.” - Romina Basto, Specification & Compliance Manager, Dulux Acratex
Reduced site complexity
StoneShield is designed as a multi-layered system, incorporating wrap, ROCKWOOL FacadeRock DD Dual density stone wool panels, fixings and coatings into a single solution. At the core of the system is a dual density stone wool panel, engineered for both performance and practicality. It has a dense outer layer for strength and coating adhesion and a softer inner layer to accommodate minor framing misalignments. This allows installers to achieve a more consistent finish while reducing the need for rework on site.
This simplifies construction by:
Reducing trade overlap
Eliminating wet trades
Supporting faster progression to lock-up
To support installers, Dulux Acratex also developed clear installation manuals and visual guides, including videos to assist contractors on site.
Thermal and acoustic performance
StoneShield delivers strong thermal efficiency (up to R4.9) and acoustic performance (up to Rw50 ±2), supporting improved occupant comfort.
These benefits are particularly important in multi-residential developments, where noise control and temperature stability are key considerations.
The Result
The Nelson Bay development demonstrates how StoneShield can deliver real-world benefits aligned to modern construction demands.
The project achieved:
Full NCC compliance, including fire-rated party walls
A lightweight system improving site handling and efficiency
Faster installation supporting program timelines
Seamless integration with Exsulite across the building
Enhanced thermal and acoustic performance
A consistent, high-quality architectural finish
The assurance of a Dulux Acratex system warranty
Products specified:
Dulux® Acratex® StoneShield™ Cladding System and Exsulite® Cladding system finished with an Acratex coating system
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