Saba Gold Coast Residence
Case study
The SABA Gold Coast Residence utilised the Dulux Acratex StoneShield Cladding System to achieve a striking contemporary façade, delivering lightweight construction, superior thermal performance and full BAL compliance while supporting the project's ambitious architectural vision.
Project overview
Applicator: Mitch Purcell, Director, Next Gen Design & Construct
Project: SABA Gold Coast Residence
Location: Tallebudgera, QLD
Works: External façade cladding system for multi-level residential construction
Products: Dulux® Acratex® StoneShield™ Cladding System and Acratex coating system
Dulux Acratex Team: Dom Wagner (Territory Manager), Adnan Djonlagic (Acratex Cladding Manager)
Background
Set high above Queensland’s Tallebudgera Valley overlooking the coastline, the SABA residence is a standout multi-level home showcasing the best in modern coastal design. Owned and built by Mitch Purcell, Director of Next Gen Design & Construct, the project’s vision was to combine striking architectural form with high-performance materials suited to the local climate.
From the outset, Mitch was open to exploring innovative building systems, creating an opportunity to move beyond traditional approaches and take advantage of emerging advances in construction.
The challenge
Located in a bush setting, the home required compliance across multiple Bushfire Attack Levels, including BAL-12.5 on three elevations and BAL-29 on one side. This immediately ruled out Expanded Polystyrene (EPS)-based systems.
Autoclaved Aerated Concrete (AAC) was initially specified as the cladding solution, however it quickly presented challenges. AAC panels require significant handling effort, particularly on a large-scale residential build. Cutting AAC panels also introduced additional site risks, including dust generation and the need for specialised tools.
“It’s just the sheer weight of AAC, and it’s also really dusty to cut. Silica is a big issue, so we try to minimise any exposure to fine dust.”
Mitch Purcell, Director, Next Gen Design & Construct
“The steep driveway made distribution a particular challenge on this site. I knew the project would benefit greatly from a system like StoneShield, because it can deliver a lighter weight option to AAC while maintaining compliance and performance standards.”
Dom Wagner, Territory Manager, Gold Coast, Dulux Acratex
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.
Early engagement with the Dulux Acratex team ensured the builder had a clear understanding of the system’s performance, compliance (including CodeMark certification), installation and long-term benefits.
“As a future-forward builder, Mitch is always interested in learning about innovative building systems, so he was open to hearing about the possibility of using the new StoneShield walling system on his own home.”
Adnan Djonlagic, Acratex Cladding Manager, Dulux Acratex
Lightweight performance
StoneShield combines non-combustible stone wool insulation with a fully integrated coating system, delivering a lightweight façade that significantly reduces handling requirements.
The hero feature is Rockwool, a 'whipped' blend of basalt and other natural stones which form the innovative 75mm FacadeRock DD panels. Each FacadeRock panel weighs 12kg per sqm, compared to approx. 50kg/sqm for AAC and 80kg/sqm for brick.
StoneShield provided a significantly lighter alternative to AAC, reducing structural load and improving ease of handling on site.
"The FacadeRock panels don't require cranes… it's just easier to move around and install."
Adnan Djonlagic, Acratex Cladding Manager, Dulux Acratex
Faster, simpler construction
The system also delivered clear efficiencies during installation. Panels could be easily cut using simple tools, eliminating the need for specialised equipment.
"It was so easy to cut – the contractors were using a box cutter, hand saw or even a Stanley knife."
Mitch Purcell, Director, Next Gen Design & Construct
"Labour is always one of the biggest expenses on site, so the ability to reduce installation costs was a significant advantage."
Dom Wagner, Territory Manager – Gold Coast, Dulux Acratex
Health, safety and sustainability
StoneShield panels can be cut without generating hazardous mineral silica dust. They are also lightweight, easing manual handling on site. The material is classified as a non-dangerous good, reducing risk during handling and installation. The product is also recyclable.
"Specifiers are always looking to improve the environmental ratings on their projects, and this new system will help with achieving a green star rating."
Adnan Djonlagic, Acratex Cladding Manager, Dulux Acratex
Excellent thermal and acoustic performance
Thermal performance was a key driver for the project, given the Gold Coast's hot climate. Even during construction, the benefits were noticeable.
"Even during construction, the temperature and also the acoustics felt consistent throughout the house."
Mitch Purcell, Director, Next Gen Design & Construct
StoneShield provides continuous insulation, reducing thermal bridging.
A complete Dulux system
A key advantage of the project was the use of a fully integrated Dulux system, covering cladding, render and coatings. This ensured compatibility across all layers and enabled a single-source warranty.
"The builder appreciated the simplicity of specifying Dulux branded products for the whole façade system, ensuring we could provide the highest possible warranty coverage."
Dom Wagner, Territory Manager, Gold Coast, Dulux Acratex
The Results
The SABA Gold Coast residence demonstrates how the StoneShield system can deliver measurable improvements in residential construction.
The project achieved:
Reduced manual handling with lightweight panels
Faster installation than the originally proposed AAC, and improved construction efficiency
Enhanced thermal and acoustic performance
CodeMark certified
Full compliance with BAL requirements
A distinctive architectural finish
Realisation of the home's contemporary design intent, colour vision and rendered aesthetic
Product Specified
Dulux Acratex StoneShield™ Cladding System, RenderWall® AcraPro® P400, Green Render Sealer, Trowel On Tuscany Super Fine, AcraShield® in Dulux Natural White
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