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From Concept to Completion: The Value of an Integrated Façade Approach

Chevalier (Aluminium Engineering) Limited

As Australian construction projects grow more architecturally ambitious, the demand for façade contractors who can do more than simply install cladding has never been greater.

Chevalier (Aluminium Engineering) Limited is meeting that demand head-on by bringing together in-house design, engineering, fabrication, and project management capabilities.

“Chevalier has in-house design, engineering, fabrication, and project management teams, making us one of the few façade contractors in Australia that still operates its own manufacturing facility for façade products,” said General Manager Vivian Leung. “With full control over the entire process, we are able to achieve exceptional efficiency, maintain strict quality control, and ensure timely project delivery.”

That integrated model is not simply a point of difference; it is increasingly becoming a prerequisite for the complexity of modern façade work.

That capability was demonstrated on the Harbourside Redevelopment, where the façade design included a series of highly articulated vertical fins intended to replicate the organic texture of weathered sandstone. The original concept called for glass reinforced concrete (GRC). Chevalier’s team, led by Project Managers Max Li and Charles Han, proposed and successfully delivered a precision-engineered aluminium solution, achieving the architect’s intended appearance while reducing weight, improving manufacturing accuracy, and enhancing the façade’s overall sustainability performance.

“Through detailed 3D modelling, extensive prototyping, precision welding, and hand-finishing, we were able to demonstrate that aluminium could faithfully replicate the architect’s vision while delivering real advantages in quality and constructability,” says Max Li. The project also incorporated low-carbon aluminium produced using renewable energy, directly contributing to the development’s sustainability objectives.

On site, the delivery was driven by an experienced installation team including Feng Ji, Frank Qi, Colin Li, and Lucas Gong. “Successful façade installation relies on experienced people, early planning, and genuine collaboration with every trade on site,” explained site team member Feng Ji. “That’s what made Harbourside work.”

The Sydney Biomedical Accelerator (SBA) demonstrated a different dimension of Chevalier’s integrated delivery model. With an architecturally complex façade geometry and demanding structural, weatherproofing, thermal, and acoustic performance requirements, the project relied on close collaboration between design, engineering, fabrication, and project management from the earliest stages.

Project Managers Charles Han and Fred Fan led Chevalier’s response, which centred on extensive early-stage engineering coordination and 3D modelling to identify and resolve interface issues before fabrication commenced, reducing construction risk while creating a smoother pathway for manufacturing and installation.

“The complexity of the SBA demanded that our engineering and design teams were embedded in the project from the very beginning,” explained Charles Han. “By working through the critical details early, we were able to streamline fabrication and installation significantly, and ensure compliance with the project’s strict performance criteria.”

At Iglu Kingsford, multiple materials and systems have been selected to create a single coordinated facade design. Curtain walling, aluminium cladding, terracotta panels, and GRC sunshade elements each bring different structural, manufacturing, and installation requirements.

By bringing design, engineering, fabrication, and project delivery together, Chevalier is able to coordinate those interfaces throughout the project lifecycle rather than resolving them as they arise during construction. Site team members Henry Guo and Charlotte He are central to managing that coordination on the ground.

“The key challenge is ensuring seamless integration between different materials and systems while maintaining the architectural intent and construction programme,” explained Charlotte He. “Having our design, engineering, and fabrication teams all working together makes that coordination significantly more manageable.”

Chevalier’s integrated model has enabled the company to approach façades as complete building systems rather than individual manufactured components. From re-engineering complex architectural features at Harbourside, to resolving performance requirements at the Sydney Biomedical Accelerator, and coordinating multiple façade systems at Iglu Kingsford, the approach provides project teams with greater certainty from design through to installation.

“As buildings become more complex and performance expectations continue to rise, façade contractors need to contribute genuine technical expertise throughout the project lifecycle. Our integrated team allows us to work alongside architects, builders, and developers to deliver solutions that are both ambitious and practical,” explained Vivian Leung.

For more information contact Chevalier (Aluminium Engineering) Limited, Suite 2003, 109 Pitt Street, NSW 2000, phone 02 9232 3189, email cae@chevalier.com, website www.chevalier.com




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Supporting Builders with Fire-Rated Façade Installation

Melbourne Cladding Exteriors

Melbourne Cladding Exteriors has established itself as a specialist contractor in Victoria’s fire-rated façade sector, delivering the supply and installation of autoclaved aerated concrete (AAC) panel systems for premium residential and medium-density construction projects.

Founded by Shanon Farrugia more than a decade ago, the company has developed extensive expertise in CSR Hebel systems.

Working closely with builders, architects and project teams to deliver compliant external wall solutions where fire performance, structural accuracy and finishing quality are critical, Melbourne Cladding Exteriors’ portfolio spans architecturally designed homes, luxury residential developments and selected commercial projects throughout metropolitan Melbourne.

Melbourne Cladding Exteriors has built its capability around a highly specialised installation discipline. The company’s experience with fire-rated AAC systems allows it to manage projects from material quantification through to installation, providing builders with a coordinated delivery model that maintains programme certainty and installation consistency.

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“Everything has to be done thoroughly, to 100%,” explained Shanon. “That attention to detail is how I’ve kept my reputation and kept the business running.”

The company’s process is streamlined and client-focused from first contact through to completion. Detailed drawings are reviewed, a thorough estimator-led takeoff process works out quantities, and once a quote is approved, materials are delivered and installed with the same level of care applied at every stage. Managing both supply and installation enables the company to coordinate the façade package through a single contractor.

Having spent ten years focused specifically on fire-rated aerated concrete panel systems, Shanon is now expanding the business into broader cladding categories, including Axon cladding and James Hardie products, bringing the same exacting standards to a wider range of architectural applications. “We’ve built our reputation on doing one thing exceptionally well,” Shanon said. “Now we’re ready to take that same approach into new territory.”

For more information contact Melbourne Cladding Exteriors, phone 0424 114 980, website www.melbournecladding.net



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Revealing New Language for Brick Architecture

Steel Backed Brick

Across Australia brick is re-emerging not as a conventional building material, but as a deliberate architectural language of texture, memory and craft. Sculptural curved façades and adaptive reuse projects are utilising the versaility of brick to ground contemporary developments within the urban landscape.

Steel Backed Brick has over 20 years of onsite experience supporting some of the country’s most technically demanding brick cladding and lightweight brick systems through specialist cutting and façade preparation services.

“We cover the whole industry,” said Operations Manager Irine Klar. “From a backyard feature wall to large-scale restaurants and major commercial projects, and everything in between. We understand the impact of product delays and inaccurate supply on a project, so we make sure that bricklayers are working efficiently and effectively, without setbacks on site.”

That experience is best illustrated through the projects Steel Backed Brick has delivered. At Sydney’s Central Station, the company was contracted to cut 60,000 individual bricks into 10 different angle configurations ranging from just 2mm to 19mm to create an extraordinary animated artwork mural embedded into precast concrete panels. Designed by artist Bronwyn Bancroft, the installation depicts Aboriginal artwork that appears to materialise as trains pass by. The entire brick cutting scope was completed within a three-month turnaround.

At the Parkview Northwest Quarter project, Steel Backed Brick spent 18 months regrooving 180,000 brick faces and 45,000 corners to bring imported bricks into compliance with Australian standards, with zero tolerance for error. While at Seed Heritage in Pitt Street Mall, the team in-stalled a brick cladding facade designed to evoke the heritage aesthetic of a building predating the Westfield development surrounding it.

Steel Backed Brick works closely with recycled brick suppliers across New South Wales and Victoria, and ensures that every by-product of the cutting process, from brick offcuts to water and cutting blades, is recycled or repurposed.

For more information contact Steel Backed Brick, 36 Princes Street, Riverstone NSW 2765, email sales@sbbv.com.au, phone 02 9627 4116, website www.sbbv.com.au



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Façade Design in the Era of Performance-Driven Compliance

RENYI

Australia’s façade sector is undergoing a structural shift driven by increasingly stringent NCC requirements, tightening energy efficiency targets, and the broader push toward net zero building performance.

As compliance thresholds rise, façade design is no longer resolved at the documentation stage, it is being shaped much earlier through thermal modelling, system selection, and performance verification.

This has elevated the importance of certified façade simulation and building physics expertise, particularly in projects where glazing, framing systems, and envelope detailing must be optimised to meet Section J and BASIX requirements without compromising architectural intent or cost feasibility.

Within this evolving context, specialist consultants such as RENYI Pty Ltd are playing an increasingly technical role in bridging design ambition and regulatory compliance through early-stage façade performance analysis and certified simulation methodologies.

Specialist Façade Simulation and Compliance Expertise

Founded by Allan Ang, RENYI operates at the intersection of sustainable building design, thermal performance simulation, façade optimisation, and NCC compliance.

In 2017, Allan became the first recognised NFRC certified simulator operating in Australia after undertaking intensive training in the United States through the National Fenestration Rating Council programme.

RENYI provides certified thermal performance and façade design advice alongside BASIX and NCC Section J compliance assessments across residential and commercial projects. Accredited in both NFRC and AFRC simulation, the consultancy delivers both international and Australian façade performance modelling, enabling a holistic assessment of building envelopes rather than isolated system components. This integrated capability is increasingly critical as façades shift beyond aesthetics and weatherproofing to become key drivers of energy efficiency, occupant comfort, and long-term building performance.

RENYI has built a strong reputation for delivering highly technical outcomes with a collaborative and responsive approach. “We are able to not only undertake window thermal calculations, but we can also set realistic targets for projects as well,” Allan explained. “We can look at the whole building holistically from a sustainability perspective.”

Early-Stage Façade Optimisation and Specification

Renyi provided technical advice for the facade design of the Macquarie luxury residential development in Sydney CBD, and this occurred before a façade subcontractor had even been engaged. “Façades come with a high level of risk. Consulting with us early in the process allows us to identify potential issues, which can otherwise become very expensive design changes later.” Allan said.

At Harbourside Darling Harbour, RENYI worked closely with the façade subcontractor during the early design phase to optimise window profiles and glazing selections against Section J energy efficiency targets.

“We undertook NFRC thermal calculations and worked out if the proposed system and glass selection would meet the target,” Allan said. “For the windows that didn’t meet the target, we provided improvements to how the window frames should be designed, without blowing the budget.”
That process took approximately three months and involved highly detailed analysis of frame design, glazing systems, thermal breaks, and façade composition. Using years of technical knowledge and simulation experience, Allan is often able to make subtle adjustments that produce significant energy efficiency improvements without forcing major redesigns.

RENYI’s expertise spans major healthcare and residential developments, including the Women’s Hospital in Perth, John Hunter Hospital, 699 Park Street for Mirvac, and current projects across Melrose Park and Rhodes.

As Australia’s construction industry continues pushing toward higher-performing and more sustainable buildings, RENYI is helping project teams bridge the gap between design ambition, compliance, cost, and buildability; ensuring façade systems perform not only for today’s standards, but for the future of the built environment.

For more information contact RENYI, Level 23, 520 Oxford Street, Bondi Junction NSW 2022, phone 02 9316 8882, email info@renyi.com.au, website www.renyi.com.au




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Co-ordinated Facade Delivery Across a Multi-builind Programme

Seven Facade

Successful façade delivery depends on more than product selection, it requires contractors who can manage complexity, coordinate multiple trades and systems, and maintain quality at scale without compromising programme outcomes.

Established in 2021 by two carpenters with extensive installation experience, Seven Facade delivers integrated roofing and cladding solutions across the ACT region. Based in Queanbeyan, the company specialises in external roofing and cladding, bringing an end-to-end capability that takes a project from subframe setup through to final panel install under one roof.

At MIO in Googong, a high-volume multi-building residential development, Seven Facade applied their delivery model, with the team managing multiple buildings simultaneously while maintaining a consistent, high-quality finish across the entire development.

“The biggest challenge on MIO was the number of buildings being delivered at the same time,” said Director Hayden Birch. “Maintaining consistency across every block while keeping pace with the construction programme comes down to people, systems and communication.”

The product specification played an important role in achieving both the architectural vision and programme efficiency. Lysaght Trimdek steel sheeting provided a clean, durable profile across the larger façade areas. Fairview Genesis pre-finished panels were used to create the concrete-look feature blades that wrap around sections of the complex, forming a picture frame effect that gives the buildings depth, definition, and a striking visual identity.

“The Genesis panels arriving pre-finished as a concrete-look product was a major advantage,” explained Director Rory Stokes. “It eliminated the need for additional finishing trades and helped keep the programme moving.”

The contrast between the two systems was as effective both practically and aesthetically.

Handling the full scope, from wall wraps and waterproofing through to final cladding, gave the project team a single point of accountability and minimised the risk of issues falling through the cracks between trades.

That end-to-end philosophy traces directly back to the company’s origins. Founders Hayden and Rory started the business as working carpenters, and that trade background continues to shape every project they take on.

“Rory and I started out installing cladding themselves, we understand what’s required to deliver a quality façade, not just at the installation stage but from the very beginning,” Hayden said.

“That trade background gives us a practical approach to problem-solving. We understand buildability, sequencing and what builders need from their subcontractors to keep projects moving.”

“A big part of that is preparation,” Rory said. “Wall wraps, waterproofing, thermal bridging, R-values and ensuring the substrate is straight and ready for installation are all critical. We know that getting the basics right is what delivers a quality finished product.”

Seven Facade Directors Rory Stokes (left) and Hayden Birch (right), at MIO in Googong.

As the business has grown, that hands-on mindset has remained constant. Seven Façade has invested heavily in its people, systems, and project management processes. They have strengthened their leadership team and created greater structure around operations, procurement, and site delivery without losing the agility and personal accountability that defined the company from day one.

Rory remains a regular presence on site, working closely with supervisors and the Construction Manager to ensure workmanship, safety, and programme commitments are consistently met.

With the business on track to double in size and revenue this year, and a pipeline that includes Watson Health Hub, Winnunga, Elm Lane, The Heather, and The Googong Hotel, the growth trajectory is significant. Directors Hayden and Rory are clear that scaling will never come at the cost of standards. “Quality remains non-negotiable. Whether it’s MIO or a smaller project, the expectation is exactly the same.”

Seven Facade’s goal is straightforward, to keep working with builders who value quality, collaboration, and long-term partnerships.

For more information contact Seven Facade, phone 02 6297 3552 website 7facade.com.au




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