Masterton Homes build in Corrimal headed for tribunal over concrete slab problems

Darren and Julie Brown engaged established builder Masterton Homes for their new Whiting Cres home but after a series of problems, largely with the concrete slab, they have halted work to seek a legal remedy.

Masterton stands by its work but says its ability to comment is limited because of the NCAT process.

The Browns say the slab was not laid properly, it did not align with the wall frames (some of which were the wrong size), was uneven and not level, and was beset by "honeycombing" in several places.

They commissioned an independent inspection from a local company and its defect report ran to 89 pages, finding several cases of frames overhanging the slab, plus gaps to the wall frame up to 70mm, and concluding the slab needed to be replaced.

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"I observed the concrete slab set out to be not correct," it stated. "The slab edges are not level and plumb resulting in extensive timber framing bottom plate overhangs to the dwelling.

Mr Brown, himself a builder, said the wrong type of mesh was used in the reinforcement, reinforcement was left exposed then covered up with grout, and the building inspector signed off on the reinforcement before the steel and formwork had been completed.

This was picked up on motion-sensitive CCTV camera he had installed to watch the site. The inspector spent about two minutes on-site, a quarter of which appeared to be spent in the portaloo.

"The certifier ... certified our job in 1.5 minutes and took approximately six photos," Mr Brown said in his evidence to the NCAT. "This certifier did not walk around the job site to inspect the waffle pods/steel/termite barriers."

Mr Brown said he hadn't known the homeowner could appoint their own certifier, and had gone along with one who Masterton had "pre-filled" on the contract paperwork - but who didn't send the owners certification reports.

Before the slab was laid Mr Brown said he had to insist the fill brought in be removed, as it was from a building site he believed to be contaminated with asbestos.

"This build with Masterton Homes has been stressful and financially draining," Mr Brown said in his witness statement to the NCAT.

"I feel very strongly that all certification and poor supervision has got us here today"

Emails seen by the Mercury indicate Masterton CEO Bob Heymel leaned towards a new slab after "being given photos [from] just before the concrete pour, and those photos had made me view the position in a new light".

But after receiving more advice, Masterton decided not to remove it. The Browns have named a figure appropriate to settle the dispute but the matter is headed to the NCAT in the coming months.

In response Masterton CEO Bob Heymel said the company was engaging in the matter through the NCAT and aiming to "finalise the dispute as soon as possible".

"I am unable to readily to discuss the details of the dispute, but can assure you that Masterton stands by its work as it has done for 60 years, during which time it has completed over 60,000 homes.

"Masterton is aware that every build is unique, and can present its own set of variables which are approached collaboratively with our clients and lead by experienced staff who support our strong network of suppliers and dedicated trades.

"The issues raised by Mr and Mrs Brown concerning the structural issues on site, as summarised in your email will all be attended to in a timely and appropriate manner as informed by appropriate engineering and other expert advice."

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