Working with Aptella, Superior Group deployed the Mechasys XR Projector to transform interior layout across a 38 level premium residential tower in Surfers Paradise. A traditional two person set out crew would have needed around 2,130 hours to complete the full scope. A single operator completed it in around 870 hours using the XR Projector, cutting total layout time by approximately 60% and reducing labour costs by more than $193,000.
Project | Coast Tower, Surfers Paradise, Gold Coast QLD |
Type | Multi-Residential Wall Track Layout and Interior Partitioning |
Scope | 38 levels, 54 premium units, 575 m² per floor |
Contractor | Superior Group (Wall and Ceiling Professionals) |
Tech Distributor | Aptella |
Spanning 38 floors with four premium units on each level, the Coast Tower project demanded millimetric accuracy at scale. Traditional set out relies on a two person crew working floor by floor, an approach that created a persistent bottleneck and put pressure on programme, cost and quality the longer the project ran.
Superior Group needed a smarter approach that could:
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Redirect skilled labour away from repetitive marking tasks and onto higher value work
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Accelerate floor completions when programme required it, without adding crew
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Identify structural discrepancies earlier in the process, before any marks were placed on the slab
With variances of up to 40mm found across the structure, early detection was not optional. It was essential.
Superior Group integrated the Mechasys XR Projector through Aptella, fitting it into what the team calls their New DNA philosophy: a commitment to pairing people with better processes and giving them tools that actually change how work gets done.
The XR Projector projects CAD files at a 1:1 scale directly onto the floor surface. A single lead carpenter could manage the full layout workflow independently, moving freely between preparation and marking while the instrument held position.
Clash detection improved significantly. Structural discrepancies showed up before any marks were made, giving the team time to adjust architectural plans on the spot rather than discovering problems partway through a floor.
Every project has different demands, and the right tool depends on scope, budget and programme. For contractors currently running traditional set out, the figures below show the gains achieved by switching to the XR Projector on a project of this scale. Total Station is also included and continues to deliver strong results for many projects and remains a valued part of Aptella’s technology range..
| Traditional | Total Station | Mechasys XR Projector | |
| Avg Hours per Level | 56 hrs (2-person crew) | 36.9 hrs (1 operator) | 22.9 hrs (1 operator) |
| Cost per Level (labour) | $6,999 | $2,718 | $1,912 |
| Crew Required | 2 crew | 1 operator | 1 operator |
| Clash Detection | Manual measurement only | On site, limited | Before any marks are made |
| Workflow Flexibility | Low | Moderate | High |
| Time Reduction vs Traditional | — | 34% | 59% |
Figures based on verified project data across the 38-level Coast Tower programme, Gold Coast QLD.
For contractors currently running traditional set out, the shift to the XR Projector delivers clear gains: faster floor turnaround, lower crew costs, and earlier clash detection. For projects where the XR Projector isn’t the right fit, whether that’s budget, scale or portfolio mix, Aptella’s Total Station remains a dependable choice, still cutting layout time by 35% against traditional methods.
With the XR Projector in the workflow, Superior Group consistently completed one full level in under three days, with full confidence in as-built accuracy. The productivity gains held across all 38 floors.
Layout speed increased 2.4x compared to traditional set out. There was no downtime between floors.
Structural discrepancies of up to 40mm were identified before any marks were placed. Plan adjustments could be made immediately, removing the risk of costly rework later in the programme.
Total layout hours fell from ~2,130 to ~870 across the project, saving around 1,250 hours. At an approximate 60% reduction in layout time, the team had capacity to take on additional work without adding resources.
Return on investment (ROI) is a figure Superior Group come back to often when discussing the value of the XR Projector. As a business, they cite an ROI of approximately 16 months on the instrument, a figure that reflects the confidence they place in it as a long term addition to how they deliver projects.
A single lead carpenter replaced what traditional set-out would require of a two-person crew, reducing per-level cost from ~$7,000 to ~$1,900. Across all 38 floors, total layout cost fell from ~$266,000 to ~$73,000, a saving of ~$193,000.
