Project Case Study: McNab Place Podium Façade, Footscray, Melbourne, Victoria, Australia
Background
CMG Frames is an Australian light gauge steel framing (LGSF) specialist with deep roots in façade and cladding delivery. The business evolved from a cladding company that operated for more than a decade, where the team gained extensive hands-on experience delivering prefabricated façade solutions for complex commercial and infrastructure projects.
Established in 2018, CMG Frames was formed to bring façade design, framing and buildability together under one roof. Today, the company works across residential, commercial, and large-scale infrastructure projects, with a particular niche in complex façades involving curves, corbelling (a construction method where each layer projects slightly beyond the one below, creating a stepped overhang to support or span a space), and non-standard geometry.
What sets CMG Frames apart is not just its use of advanced software and manufacturing technology, but its practical construction knowledge, helping clients turn ambitious architectural concepts into buildable, cost-effective outcomes using light gauge steel (LGS), prefabricated façade systems, and modular façade construction.
“We’re not just designing what’s been drawn and handing it over,” says Luke Cockerell, Managing Director of CMG Frames. “Clients come to us with an idea and ask, ‘How do we actually build this?’” and that’s where our experience really adds value.”
Project Overview: McNab Place
McNab Place is a podium façade project in Footscray, Melbourne, delivered for builder Roberts Co. The architectural vision called for a highly articulated brick façade featuring deep corbelled arches and stepped brickwork wrapping the building in an aesthetic more commonly associated with historic masonry buildings than contemporary construction.
The challenge was clear - how to achieve the architectural intent without resorting to slow, expensive and impractical traditional brick construction methods.
CMG Frames was engaged early in the process to answer a critical question:
“When the builder first came to us, the question was simple,” says Cockerell. “Is this even possible to build?”
The solution was a prefabricated, modular façade system built from lightweight steel framing, allowing the project team to retain the design intent while gaining certainty around cost, timeline and installation.
The Challenge
The podium design presented several significant challenges:
- Large-format arched façade modules, up to approximately 12 meters long
- Extensive corbelling and stepped geometry
- A requirement for a true brick finish using real brick (not imitation tiles)
- A constrained site and timeline where traditional bricklaying and full-height scaffolding would be slow and costly
A conventional full-brick solution would likely require extensive structural backup, complex lintels, heavy scaffolding and long construction durations, pushing the project beyond practical and economic limits.
 |
 |
CMG Frames’ Solution: Prefabricated & Modular
CMG Frames designed and manufactured a prefabricated façade system using lightweight, LGS framing, allowing the façade to be delivered as large, pre-clad modular sections.
These modules were craned into position and fixed to purpose-designed brackets attached to the building structure. The building was waterproofed first, after which the architectural façade was installed as a separate outer layer. This approach transformed a complex, site-intensive façade into a controlled, off-site-manufactured solution.
Collaborative Delivery
To ensure seamless execution, CMG Frames coordinated an end-to-end delivery team, including:
- A specialist bricking contractor
- Modular Masonry, supplying real cut-brick cladding
- Casello, responsible for installation, lifting, cranage and onsite coordination
This integrated workflow from design through manufacture to installation minimized handover gaps and reduced risk for the builder.
Design & Engineering Approach
CMG Frames led the full engineering and execution detailing for the façade system.
Key elements of the design process included:
- Site-first surveying: Physical slab surveys were undertaken to capture real-world tolerances rather than relying solely on Revit models.
- Bracket set-out and module coordination: All brackets, module interfaces and tolerances were resolved digitally before arriving on site.
- Single-platform modelling: The entire system of LGS framing, modules and brackets was modelled in FRAMECAD software, providing a direct pathway from design to manufacture and site set-out.
Manufacturing & Materials
Manufacturing system
- FRAMECAD 325iT-L roll-forming system
- Steel framing produced primarily from 89mm profile members
Material specification
-
External framing manufactured from Z450-coated steel, as required by the project specification
Build logic
The framing system was designed to support the façade’s stepped brick geometry through:
- Layered framing depths to align with corbelled brick returns
- Pre-defined bolt holes and fixing points
- Repeatable internal spacing to reduce onsite interpretation and speed assembly
.jpg?width=481&height=640&name=Mcnab3%20(1).jpg)
Installation Method
Once the building envelope and waterproofing were complete, installation followed a clear sequence:
- Brackets installed to the structure using CMG set-out drawings
- Large, prefabricated modules delivered to site
- Modules craned into position and bolted off
- Final finishing completed to achieve a continuous brick appearance
The lightweight nature of LGS framing was critical, keeping modules liftable and eliminating the need for heavy temporary works.
 |
 |
Why LGS Framing Was Essential
LGS framing enabled the project to succeed in ways traditional construction could not:
Lightweight, liftable modules
Large façade sections could be craned safely and efficiently.
Geometric flexibility
Cold-formed steel allowed complex corbelling and stepped forms without excessive weight.
Speed and repeatability
Despite every module being slightly different, CAD-driven manufacturing ensured speed, accuracy and consistency.
Timeline
- Design phase: ~6 months
- Manufacture (framing): ~3 months
- Production and installation: ~6 months total
Outcome
Architectural outcome
The completed podium façade reads as authentic, solid brickwork, complete with mortar joints and natural brick imperfections, despite being delivered through modular façade construction.
Construction outcome
The project delivered:
- A buildable solution where no clear traditional method existed
- Full preservation of architectural intent
- Timeline, certainty, cost and installation
- A modern construction approach that still achieves heritage character
“When you look at the finished building, you would never know it was delivered in modules,” says Cockerell. “You cannot tell it was modular, it looks and feels like it was built in full brick.”
The Future
Looking ahead, projects like McNab Place reflect a growing shift toward modular and prefabricated façade solutions using light gauge steel (LGS), as the industry looks for more efficient and predictable ways to deliver complex architectural design.
Please contact our team for more information about LGS here.
