Protos Building Consultants Protos Building Consultants

Building consultancy · Defect inspections · Expert evidence · NSW

Building defects, found and explained.

Protos Building Consultants provides defect inspections, condition reports and expert witness reports for homeowners, strata, builders, manufacturers and their lawyers. Residential, strata and commercial buildings across NSW. Engineering-led, standards-literate and independent.

Tape measure showing a gap between the top of a brick pier and the timber bearer above
Photo 1 Gap at top of brick pier, leaving the timber bearer unsupported
Flat roof with cracked and delaminated waterproofing membrane
Photo 2 Failure of the roof membrane and delamination of the topping screed
Digital level resting on steel roof sheeting, with green hills behind
Photo 3 Digital level check on steel roof sheeting

Services

Independent inspection, reporting and advice on residential, strata and commercial buildings.

Defect inspections & condition reports

Inspections of new and existing buildings with a clear photographic record of each defect, its cause, the requirement it breaches and the scope of rectification. Includes defect schedules, incomplete-works records and strata building reports.

NCCHBA 1989NSW Guide

Expert witness reports

Independent expert reports for NCAT and NSW Supreme Court proceedings, including single joint expert engagements, reports in reply, joint conferences and joint reports.

UCPR Sch 7NCAT PN 4HBA 1989

Waterproofing specification

Remedial waterproofing design for balconies, podiums, roofs and wet areas: terminations, falls, drainage and junction details, specified with the membrane manufacturer.

AS 3740AS 4654.1AS 4654.2

Roofing & wall cladding

Steel roofing and cladding assessment: fixings, laps, flashings, penetrations, box gutters, drainage capacity and corrosion in coastal and industrial environments.

AS 1562.1HB39AS 1397AS 4312

Testing & investigation

Flood and water testing, moisture mapping and targeted opening-up to trace a leak to its source before anyone spends money on repairs.

Flood testMoisture

Technical advice to industry

Product and system advice for manufacturers and suppliers: façade compliance, CodeMark, installation guidance, test programs and technical literature.

NCC Vol 1CodeMark

Project files

Selected findings from issued reports. The photographs are from the original photographic records; select one to enlarge it.

Expert reportSupreme Court of NSW · Eastern Suburbs, Sydney

Failed roof membrane under a Building Work Rectification Order

Instructed to give an opinion on whether the work required by a Building Commission NSW rectification order on a residential apartment building resulted from defective work, and what a reasonable builder should have done to avoid it.

Observed
Cracking and failure of the liquid membrane with delamination and rupture of the topping screed; pin holing; patch repairs; ponding water.
Cause
Insufficient membrane thickness, poor substrate preparation and incorrect termination at penetrations.
Standards
NCC F1.4 · AS 4654.2 · HBA 1989 s18B warranties
Failure of the waterproofing membrane and delamination of the topping screed
Delaminated membrane and screed
Insufficient membrane thickness
Defect scheduleNew two-storey dwelling · St George area, Sydney

Upper-floor brick wall rotating off its steel support beam

A defect schedule for a new two-storey home, inspected room by room over three days. Among more than a hundred items, the most serious was structural: the first-floor west wall over the dining room, carried on a steel beam, was out of vertical alignment.

Observed
Brick courses visibly out of alignment along the wall; excess brick overhang over the steel support; corrosion of the steel and a missing drip groove; cracking along the mortar joints.
Advice
Rotation at the steel support beam referred to a structural engineer, together with suspected lintel deflection over large windows and the roof truss fixings.
Rotation of the first-floor wall over the steel support
Excess brick overhang and corrosion to the steel support
Cracking of mortar measured with a crack width gauge
Condition reportRetail building · Regional NSW

Water entering through wall penetrations above a box gutter

Recurring leaks over the trading floor had been blamed on the box gutter, which had already been sealed with bitumen. The inspection traced the water to services penetrating the upper-roof wall cladding directly above it.

Observed
Double Dektites used incorrectly, with gaps filled by tape and excess sealant; a cable bundle through a single penetration letting water run between the cables; gaps around pipe penetrations.
Finding
Water was entering through the poorly sealed wall penetrations. Sealing the box gutter below did not address the source.
Gap in sealant at pipe penetration through wall cladding
Incorrect use of double lapped Dektite, gaps at sealant
Bitumen applied to the box gutter directly below the wall penetrations
Condition reportRetail building · Hunter region, NSW

Roof held together by sealant and paint

A whole-of-roof condition report on an ageing steel roof with internal water ingress. Years of maintenance had relied on sealant and over-painting rather than correct flashing details.

Observed
Failed sealant at back-tray joints and flashing laps; flashings over ribs open to water; over-paint failing and trapping moisture against corroding sheets; missing or blocking Dektites.
Finding
Sealant-dependent repairs are likely to keep failing; joints need to be flashed, not sealed.
Failed sealant. Flashing over rib open to water ingress
Failed sealant at back-tray joint
Paint protection has failed
Roof condition reportCommercial building, strata · St George area, Sydney

Box gutter leaks traced to the sump and lapped joints

Commissioned by the strata manager after recurring leaks into a tenancy below the roof. The inspection worked from the damaged ceilings up to the box gutters to identify each source.

Observed
Water ingress from beneath the sump; drop nozzle not extending into the downpipe; zero fall and ponding; excess sealant damming water at the sump; leaking lapped joints; overflow provisions inadequate at every box gutter.
Advice
Box gutter remediation for fall, sump and nozzle, lapped joints, expansion joints and overflows, with a priority scope for the leaking tenancy.
Standards
AS/NZS 3500.3:2021 · HB39
Water ingress from beneath the box gutter sump
Excess sealant damming water at the sump
Water ponding in the box gutter before the sump
Waterproofing specification & inspectionIndustrial site · South-West Sydney

Balcony waterproofing over occupied offices, from failure to flood test

A balcony above offices and a staff lunchroom had been letting water into the rooms below. Protos investigated the failure, wrote the remedial specification with the membrane manufacturer, then inspected the new sheet membrane before tiling.

Found
Membrane failed at the balcony–wall junction with insufficient termination height; water had corroded internal wall studs; inadequate falls to drains.
Specified
Heat-welded sheet membrane with minimum 100 mm vertical terminations, regraded falls, clamped drains and detailed junctions at posts, doors and the walkway.
Inspected
Sample weld joints probed and found acceptable; laps patched at corners; pig-ear folds with no gaps; terminations covered by sarking and cladding. The installer's flood test was observed at commencement, with tiling to follow a successful result.
Standards
AS 4654.2 · MBA Waterproofing Guides · manufacturer system
Before: waterproof membrane failure at the balcony–wall junction
After: new heat-welded sheet membrane across the balcony
Local sample weld joint probed and checked as acceptable
Commencement of flood testing
Waterproofing inspectionResidential strata, 12 units · St George area, Sydney

Balcony remediation with cross-cavity flashings

Inspections for the owners corporation during balcony waterproofing remediation, checking the work against the approved plans and the membrane manufacturer's details while it was being installed.

Checked
Substrate preparation and falls by measure and laser; lap joins sealed; cross-cavity flashings installed at the base of the brick walls with pressure-sealed vertical terminations to the inside skin of the cavity.
Doors
Sliding doors removed and waterstop angles installed, with the membrane terminated at the angle to achieve the required 50 mm vertical termination.
Follow-up
Plinths at downpipes to be sealed over, and additional larger drains in planter boxes.
Cross-cavity flashings in progress along the balcony wall
Cross-cavity flashing at the base of the brick wall, with the wall propped above
Waterstop angle at rear of door with membrane terminated at the angle
Waterproofing inspectionMulti-building residential development · Western Sydney

Hold-point inspections of waterproofing during construction

Field inspections for the project manager across the build, covering façade weatherproofing, balcony hobs and flashings, and the podium membranes before the raised garden beds were filled.

Observed
Sheet membrane welds sound with no gaps and adequate falls to drains; conduit penetrations through walls not sealed; membrane terminations at conduits incomplete; expansion joint covers and overflows still to be provided.
Outcome
Garden beds held from filling until each item was rectified, with a clear list for the builder to close out.
General view of the sheet membrane in a raised garden bed
Conduit penetrations through the wall not adequately sealed
Termination detail at the top of the sheet membrane
Expert report · water testingNCAT · Hills District, Sydney

Water testing to find where the leaks get in

Expert report in a dispute over roof restoration work. Rather than rely on opinion, targeted water testing was used to reproduce each leak and show the path the water takes into the building.

Tested
Hose testing at the base of the external garage wall, and along the extended flashing installed under a rainwater spreader on the garage roof.
Found
Water entered the garage at the base of the wall straight after testing. On the roof, water tracked between the extended flashing and the roof/wall flashing into the garage ceiling cavity.
Standards
AS/NZS 3500.3:2021 · HBA 1989 statutory warranties
Water testing at the base of the external wall junction
Internal water ingress at the base of the garage wall immediately after testing
Water entering between the extended flashing and the roof/wall junction flashing
Investigation · water testingResidential strata · Eastern Suburbs, Sydney

Water testing traces leaks down a cavity wall to the unit below

Commissioned for the owners corporation after long-running water damage to a unit below a terrace. Targeted hose testing on the terrace and windows above showed where the water enters the brick cavity and how it reaches the rooms below.

Tested
Missing mortar joints beside the terrace door, the gap under an upper window sill, the door jambs and the terrace floor, with moisture readings before and after.
Found
Water entering under the upper window sill ran down the cavity and appeared at the terrace door head. Water at the missing mortar joints reached the unit below. There were no cross-cavity flashings or weepholes, and the sill and head flashings stopped short of the openings.
Advice
Remediation of the terrace membrane with cross-cavity flashings and weepholes, prepared as regulated design work.
Water testing at a missing brick mortar joint on the terrace
Water applied into the cavity through the gap under the upper window sill
Water ingress at the terrace door head following testing
Water ingress at the top of the door opening in the unit below
Testing & investigationResidential bathroom · Inner West Sydney

Flood test shows water leaving the shower within minutes

Inspection and flood testing of a bathroom with suspected leaks. Water appeared outside the shower soon after testing began, well away from the shower itself.

Observed
Water egress at the base of the side wall opposite the vanity and at the wall beside the door within about five minutes; elevated moisture in the hallway wall; water reaching a timber floor joist below.
Cause
Failed waterproofing at wall–floor junctions, missing grout, and zero fall across several zones of the floor.
Standards
AS 3740:2021
Water egress from base of side wall opposite the vanity
Water egress at wall adjacent to door, opposite shower

Project locations are given by area only. Client and property details are withheld to protect confidentiality.

How an expert matter runs

For solicitors and parties to residential and commercial building disputes. Each engagement follows the same disciplined sequence.

Letter of instruction

We confirm scope, the questions to be answered, the documents provided and any conflicts before accepting.

Inspection

Site inspection and testing, with every observation photographed, located and recorded.

Expert report

Each defect is described, tied to the contract, NCC or Australian Standard it breaches, and given a rectification scope.

Joint conference

We confer with the other party's expert and prepare a joint report setting out agreement and disagreement.

Evidence

Concurrent evidence or cross-examination at hearing, if the matter proceeds.

Our duty is to the Tribunal or Court, not to the party paying the fee. Reports are prepared in accordance with the Expert Witness Code of Conduct, and that is what makes them useful to you.

About

George Nikolas

Director · B.E. (Civil)

George is a civil engineer with more than twenty-five years in the building products industry and building consultancy. He began on site as a project engineer with John Holland, then spent sixteen years in technical services leadership at CSR Building Products and Stramit, including design engineering for CSR Hebel.

At CSR he led façade system design, testing and NCC compliance work, including CodeMark certification of façade systems used in Class 2 and 9c buildings. Before founding Protos he was a senior building consultant with The Construction Adviser.

That background means he reads a defect from both sides: how the system was designed and tested to perform, and how it was actually installed.

Engineering
Bachelor of Engineering (Civil), UTS · Member, Engineers Australia
Trade
MBA Certificate III in Construction Waterproofing
Building
TAFE Certificate IV in Building Studies
Licensing
NSW contractor licence holder
Panels
ASBC strata inspector panel
Courts
Expert evidence in NCAT and NSW Supreme Court proceedings

Standards & industry

We help write the guidance we assess work against.

Australian Institute of Waterproofing

NSW Chapter Lead and committee member

Supporting training, technical guidance and better practice across the waterproofing industry.

ASI Industry Reference Standard

Key contributor, metal roofing and wall cladding

Contributing to the industry reference standard for steel roofing and wall cladding installation.

Sydney & regional NSW

Discuss a matter

Send a short outline of the property, the issue and any hearing dates. We will confirm availability and any conflict before you send documents.

Suite 4, 193–195 Rocky Point Road, Ramsgate NSW 2217

Helpful to include

  • Property address and building class
  • Who you act for, and the other parties
  • Tribunal or court, file number and timetable
  • Contract, plans and any existing reports
  • The questions you need answered