Project Spotlight: A Newcastle Builder’s Approach to a Unique Mayfield Home
At KPE, every project presents a new challenge and this recent build in Mayfield is a perfect example of how an experienced builder approaches complex structural work while respecting the character of an existing home.
Working alongside Crawcon, the project involved constructing an entirely new second-storey structure above a 100-year-old Henry Albino cottage, while ensuring the original dwelling remained structurally independent.
For any builder, balancing heritage considerations with modern construction techniques requires careful planning, precision and strong collaboration between trades.
Starting the Year with Structural Steel
The first major milestone on site was the installation of the structural steel system.
To support the new build, the team installed multiple steel beams and 14 structural columns, some reaching heights of over 9.5 metres. These steel portals form the backbone of the structure and allow the new floor system to sit independently from the original cottage below.
For a builder, structural steel installation is a critical phase of construction. Once the steel framework is in place, it allows the rest of the build to progress efficiently and safely.
Preserving the Original Cottage
One of the most unique elements of this project is the way the new structure interacts with the original home.
Rather than relying on the existing building for support, the new second-storey system sits on its own structural steel framework throughout the house. This means the original cottage remains structurally independent while the new build is supported entirely by the new portal structure.
Before the steel installation began, the Crawcon team spent weeks preparing the foundations and working underneath the house to ensure everything was ready for the structural work. From a builder’s perspective, this preparation stage is what makes complex projects like this possible.
Moving into the Framing Stage
With the steel structure installed and the new floor system complete, the project quickly progressed into the framing stage.
The team moved efficiently into custom stick framing, a traditional building method that allows a builder to shape and customise the structure directly on site. Stick building provides flexibility and precision, particularly when working with complex designs or heritage properties.
For builders in Newcastle, projects like this highlight the importance of craftsmanship and attention to detail during the framing phase.
A Custom Dutch Gable Roof
As the framing progressed, the roof structure began to take shape.
This home will feature a pitched roof system constructed with LVL beams, spanning approximately 4.5 metres across the house. One of the standout architectural features is the Dutch gable roof, which complements the heritage character of the original cottage while introducing modern architectural elements.
The design also incorporates:
Large raked glazing panels following the roofline
Raked ceilings throughout the home
Structural fascia supporting extended roof sections
A cantilevered roof overlooking a spotted gum deck
For a builder, integrating these architectural features requires careful structural planning and precise installation on site.
Progressing Towards Lock-Up
With the steel installation complete and the custom framing well underway, the project is progressing steadily toward the next major milestone - putting the roof on.
One of the benefits of this design is the open structural layout, which removes the need for many internal load-bearing walls. Instead, structural bracing and engineered framing maintain stability while allowing for expansive interior spaces.
Throughout the process, the builder and site team continually check and verify structural alignment to ensure everything meets the required standards before moving forward.
A Collaborative Build
Complex projects like this highlight the importance of collaboration between builders, engineers and trades.
Working alongside Crawcon has allowed the project to move efficiently through each stage of construction, combining expertise from multiple teams to deliver a carefully engineered outcome.
For any builder, projects like this demonstrate how thoughtful planning and strong teamwork can transform a challenging site into something truly special.
Following the Progress
As the roof installation approaches and the build continues to progress, this Mayfield home is shaping up to be a standout project. At KPE, each project is an opportunity for a builder to apply experience, craftsmanship and attention to detail to create something unique.
We look forward to sharing more updates as this build continues to take shape.
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