The ground floor brick facade was constructed in the typical manner of using full bricks with mortar. However, with the aim of improving the overall construction program and delivery timeline, Kane Constructions saw an opportunity to use brick slips for the upper levels of the building. Early-stage collaboration between Kane Constructions, CMG Frames, and Modular Masonry allowed this innovative solution to be realised. CMG Frames were engaged to develop an engineered LGS framing system that would support ‘thin bricks’ and without compromising the architect's design intent for these impressive facades.

Large LGS frames made from TRUECORE® steel were prefabricated to support the entire second storey brick facade which was installed over several weeks, rather than months, as required with traditional brick-laying. An additional benefit of this approach was the mobile lifting equipment used to position the prefabricated panels eliminated the need for scaffolding, ensuring internal trades could work concurrently.

According to Dan Thomson, CMG Frames Business Development Manager.

“The build was a large-scale, complex project which combined multiple curved and straight prefabricated wall panels to deliver a dynamic articulated facade. It required custom-made frames, bespoke fixing brackets, and 3D shop drawings integrated into the project’s overall BIM model. The 3D modelling approach taken reduced the reliance on RFI’s (‘Request for Information’ to clarify documents, drawings, specifications, or other project issues) which expedited the build and maintained the project timeline.”

Takota Williams-Roszczyk, Director of Modular Masonry, added, “In an era where skilled craftsmanship is rare and project demands are ever-increasing, builders and architects need innovative solutions. Our approach combines prefabricated LGS framing with our brick slip facade system, providing a practical and efficient solution to meet these challenges.”

Engineered by LD Consulting Engineers, the curved frames use state-of-the-art laser-cut profiled tracks cut to an exact radius in the steel, ensuring the accuracy of the architectural design. All parties collaborated to create a 3D model of the entire building facade so that individual frame sizes and their connection points could be determined, and the engineering requirements of each frame could be resolved.

CMG Frames used approximately 23 tonnes of light gauge steel framing made from TRUECORE® steel in this project to make the 162 framed panels of an approximate size of 4m by 6m. The frames were all designed, engineered, and fabricated at their manufacturing facility in Sunshine West, Victoria.

From inception through to the delivery of the finished prefabricated panels, a collaborative team of 20 staff worked to deliver the project in three stages aligned with the construction process.