Bretts Frame and Truss, a Queensland fabricator used Pryda Build
software to resolve the comprehensive detailing problems presented by the
complex roof design of a massive $3 million Brisbane mansion project. Many
truss manufacturers in the industry refused to take up the challenging project.
The client’s brief specified a large U-shaped six-bedroom home enclosing
a swimming pool (complete with pool house) and six-car garage underneath. The
roof had a Balinese gable design with sweeping curves from a high centre apex. Once
the architect AAD Design designed the home to the owner’s specifications, the
first challenge was to accurately detail the project.
Queensland Pryda fabricator account manager Ashley Mansfield teamed with
Bretts Frame and Truss to detail the project using the latest version of Pryda
Build software. Using Pryda Build, Ashley Mansfield was able to impose truss
details over the CAD drawings while meeting compliance requirements. Working
over four days, he broke the roof into modules and independently detailed each
one. The roof trusses were more than five metres high at the centre and had to
be manufactured in two sections.
Danny Lake from Bretts Frame and Truss said the roof comprised of 155
trusses measuring more than 45 cubic metres over the three sections in addition
to beams and posts. Each wing had three blocks, which were manufactured one at
a time, with each block taking 10 hours to complete.
The roof curves had to be made perfectly symmetrical for the battens,
which had to be at exactly 170-millimetre centres to accommodate the roof tiles
made from recycled car parts that had been turned into a polycarbonate product.
The roof trusses had to be manufactured precisely to avoid any deflections in
the gutters, fascias and downpipes, which were all made of copper.
Once completed, each block was transported by road to the Chandler
building site where builder Geoff Booth from Tara Homes used the massive
concrete floor slab as a base for erecting the roof trusses before they were
lifted by crane into place onto the timber frame.
The original roof design was first tested on the smaller pool house,
which involved only six standard roof trusses with the remainder made using
saddles and outrigger trimmers. Once the success of the roof design was
confirmed on the pool house, they set to work on the rest of the house
beginning with the master bedroom suite, followed by the raked trusses of the
lounge and dining rooms, then the left wing with bedrooms one to five and the
centre section with its curved tunnel ceiling, and finally the right wing.
The curved ceiling incorporates $7000 of fibre optic lighting to deliver
a ‘starry, starry night’ theme complete with shooting stars and lit planets.
Geoff Booth said he could not have completed the
job, which took three months alone to finish the frame and roof truss erection,
without the active assistance of Bretts Frame and Truss and Pryda experts who
impressed from the first meeting and were in constant communication throughout
the entire project. He was also impressed with the flexibility and capabilities
of the latest Pryda Build software to deal with such a large and complex roof