When we recently caught up with Aaron Hinkley and Bruce Robb on The Good Builder Podcast, the conversation turned to one of the most pressing, yet often misunderstood; challenges facing Australian builders today: thermal performance and condensation management.
It’s a topic that has been circulating heavily among our community of builders, and for good reason. As homes become more airtight and energy standards tighten, the risk of hidden moisture, mould, and long-term structural damage is growing. For homeowners, that risk translates to unhealthy living environments. For builders, it means costly defects, reputational damage, and regulatory headaches.
Hinkley and Robb, now working together at Australian Thermal Industries (ATI), are tackling the issue head-on with innovative thermal break and cavity batten products designed to improve energy efficiency, manage condensation, and ultimately extend the lifespan of homes.
A Career Built on Job Sites and Innovation
For Aaron Hinkley, the path to ATI started in family and on building sites. Growing up with builders all around him – his father, brother, uncle, and cousins – construction was always part of his world. His professional career took him into product development in China, working on factory identification, quality assurance, and supply for Australian companies.
When he returned to Australia just before COVID, Hinckley saw a clear gap: thermal break products that barely scraped into minimum NCC requirements. “Rather than aiming for the minimum, we wanted to maximise performance,” he told us.
That vision led to ATI’s flagship thermal break and cavity batten solutions, which combine high compressive strength, peel-and-stick installation, and industry-first R-value performance.
A Half-Century in Building, Codes, and Advocacy
Sitting alongside Hinkley was Bruce Robb, a true veteran of the industry. Next year marks his 50th year in construction – a career that has spanned architecture, boutique and multinational builders, state government, and industry associations.
Robb is perhaps best known for his time as Executive Director of the HIA, but his CV also includes work with the Master Builders Association and direct involvement in developing legislation and building codes.
When ATI approached him to help launch their product two years ago, Robb immediately saw the potential. “As a builder working with steel frames, thermal breaks were always a problem. When I saw what Aaron had developed, it was just such a brilliant idea I had to get on board.”
Why Thermal Breaks Matter
Thermal breaks have been required for steel frames for almost 20 years, yet the industry still struggles to install and specify them correctly. Too often, builders or trades treat them as an afterthought – a strip on the studs, with plates and noggings left exposed.
The result? Heat transfer continues through the steel frame, undermining energy modelling and star ratings. Worse still, this temperature differential creates condensation inside walls, fuelling mould growth that can go unnoticed for years.
“Thermal efficiency and condensation management go hand-in-hand,” Roller explained. “The NCC’s energy efficiency provisions focus on reducing heating and cooling loads, but unless condensation is addressed, we’re building houses that can’t breathe.”
This is more than a compliance issue – it’s about occupant health. As Hinkley pointed out, “The drier the wall space, the healthier the home is. Especially for kids, mould-free environments are critical.”
Lessons from Overseas and Warnings at Home
Australia is playing catch-up on condensation management. New Zealand endured its infamous leaky building crisis two decades ago. Canada and the US faced similar “attic rain” problems when buildings were wrapped too tightly. Each market learned – painfully – that airtight insulation without vapour management was a recipe for disaster.
Yet here in Australia, the education piece has lagged. “We’re at least 20 years behind,” Robb said. “Condensation management hasn’t been tied in with thermal performance, and we’ve left the industry without the education framework to understand it.”
The consequences are already here. One builder Robb spoke to was forced by the QBCC to demolish a two-year-old home because mould had penetrated every wall. In other cases, clients complain about ghosting on cladding – the studs visibly outlined by mould growth beneath.
Products with Performance – and Simplicity
ATI’s approach is to create products that make best practice achievable. Their peel-and-stick thermal break and CaviVent batten offer:
- High compressive strength – avoiding wavy cladding.
- Superior R-values – boosting wall performance by up to 24%.
- Integrated cavities – delivering both thermal efficiency and ventilation.
- Ease of installation – no more fiddling with strips at awkward angles.
For modular builders, ATI even developed a 10mm thermal break tailored to transport width restrictions. They’ve also introduced a non-combustible product for schools, hospitals, and bushfire-prone areas, plus a joist break that can increase the R-value of elevated modular floors by over 120%.
As Hinkley put it, “We’ve designed these products to be efficient, affordable, and builder-friendly. Our aim is to make compliance easier and homes healthier.”
What Builders Need to Know
The key message from Hinkley and Robb is simple: builders can’t treat thermal breaks as optional extras or tick-box items. Every steel frame member must be covered. Cavities must be ventilated. And condensation risk must be managed at the design stage, not left to site improvisation.
Education is crucial. “Once we explain it to builders, the lightbulb goes off,” Robb said. “It’s not about selling, it’s about helping them deliver better outcomes.”
And the benefits go beyond compliance. Correctly installed thermal breaks and cavity systems mean:
- Reduced heating and cooling costs for clients.
- Longer-lasting structures.
- Healthier homes free from hidden mould.
- Fewer call-backs and disputes.
Looking Ahead
As ATI expands into floors and roofs, their vision is clear: provide a full suite of thermal solutions that improve performance across the whole building envelope. With Robb’s industry gravitas and Hinkley’s product development expertise, the company is positioning itself as a leader in building science innovation.
For builders, the message is timely. With NCC condensation provisions due to roll out in 2026, and insurance pressures mounting, the time to get ahead is now.
As we wrapped the podcast, Hinkley summed it up best: “It’s not just another product. It’s a solution that makes homes better for the people who live in them – and that’s what this industry should be about.”
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