MTF Manukau — Structural Fascia Rebuild & Full Exterior Rebrand
One of our largest brand transformation projects to date — complete exterior conversion of MTF Manukau, including a 14m fascia rebuild, ACM reclad over degraded James Hardie sheeting, roadside pylon refurbishment, segmented window banding, and installation of a feature acrylic mark into an architectural pillar.
South Auckland
Manukau
Project Overview
MTF Manukau required a full exterior identity overhaul, replacing legacy branding and addressing deterioration in the original façade. The existing structure was sheathed in ageing James Hardie fibre-cement sheets which showed signs of water fatigue and surface instability — not suitable as-is for long-term ACM.
Rather than remove the original substrate and expose the client to structural remediation scope, we engineered and installed a false fascia system, using a new frame to distribute load and introduce a flat, secure mounting plane. Once reinforced, we fabricated and installed 20.5m of full-print ACM paneling, split into a primary 14m run and a secondary 6.5m extension, both at 1200mm height.
A full roadside pylon conversion, segmented window band install, two additional ACM service boards, and a 1200 × 650mm automotive-grade 10mm acrylic logo set into the blockwork column completed the transformation — turning a dated frontage into a landmark-visible asset.
This job demanded structural thinking, safe access at 9m elevation, cohesive design execution, and controlled staging over multiple crews.
Brief & Challenge
1. Aged Substrate → Stability Risk
James Hardie boards showed fatigue and potential moisture degradation.Rather than risk substrate exposure, we framed over — distributing load and isolating failure points without invasive teardown.
2. Long-Span ACM Alignment
Installing 14m end-to-end fascia panels at 9m height required precise framing tolerance.Panel cuts around the centre blockwork were completed onsite to maintain alignment.
3. Traffic & Access Limitations
Work was staged 7pm–1am to avoid car park traffic, using a large scissor lift with a sliding deck capable of lifting full ACM sheets.
4. Weather Windows
Rain and wind holds extended install staging — this build required flexibility, sequencing, and rapid deployment during clear windows.
What we did
Stage | Team Involved | Duration |
Fascia Design + Fabrication | In-house CNC + print | 4.5 weeks (incl file change delay) |
Structural Framing | 4 techs + licensed builder + engineer | 1 full day |
ACM Install | 3 techs + builder + engineer support | 1 day |
Window & Pillar Graphics | 2 techs — ¾ day | Day install + ladder work |
All print, laminate, finishing & panel application completed in-house on our Roland VG3-640 large-format system.
Structural & Engineering
Assessment of failing exterior fibre-cement cladding
Construction of a timber box frame to carry new ACM load
Frame tied back into building to span potential substrate weakness
False fascia created to overlay original surface without removal
Fascia + ACM Paneling
Full-print ACM panels at 1200mm height
Primary run 14m, secondary 6.5m
MPI1105 + DOL1460 gloss laminate print
End-to-end panel joins, edge-flush with frame
Centre blockwork recess cut onsite for precision fitting
Stainless screws & hardware throughout (no corrosion risk)
Roadside Pylon Rebuild
Original insert slot sign 2250 × 1180mm
Rebuilt with internal timber frame inside existing steel housing
Dual ACM faces installed to cover original structure cleanly
Static — no illumination, high-visibility conversion upgrade
Window Banding
15 segmented sections, each 400 × 1080mm
MPI2015 media, no lamination required
Mullions left exposed black for architectural contrast
Feature Logo Pillar
1200 × 650mm MTF mark in 10mm acrylic
Automotive-grade basecoat + high-solids clear
Wet-sand, cut & polished for gloss depth
Installed flush using construction adhesive + contact cement
Additional Panels
Service board 1600 × 1000mm
Large MTF board 1450 × 2800mm
Both: ACM + MPI1105 + DOL1460, VHB + adhesive fixed
Materials
4mm ACM panels – full print finish (MPI1105 + DOL1460)
Timber box-frame reinforcement substructure
Stainless screws + fasteners for all exterior fixings
VHB + construction adhesive for ACM bonding
Roland VG3-640 in-house printing + lamination
MPI2015 window segmentation film (15 × 400 × 1080mm)
MPI3709 ContraVision perforated window panels
10mm acrylic MTF mark (1200 × 650mm) — basecoat + high-solids clear
Two ACM service boards (1600 × 1000 & 1450 × 2800mm)
Processes
Structural assessment + frame reinforcement over failing exterior
Fabrication + installation of false fascia system (no substrate removal)
Full ACM panel run installed end-to-end (14m + 6.5m)
Roadside pylon internal frame rebuild + dual-face ACM conversion
Window banding installed in segmented sections for clean mullion breaks
3D acrylic logo polished and bonded flush inside blockwork pillar
All prints produced, laminated, and panelled in-house
Night installation via scissor-lift (7pm–1am, traffic-safe staging)
Weather-dependent scheduling + wind-watch lift operation
Outcome
The finished site is now a clean, modern, high-visibility commercial frontage:
Scaled branding that reads at distance
Colour-rich ACM surfaces that transform the architecture
Pylon identity that dominates roadway viewing
Window banding ties both elevations visually
Feature acrylic mark anchors the façade with depth & gloss
From the street, MTF Manukau is now a landmark — immediately recognisable and structurally sound for years of brand presence.
This project demonstrates capability beyond signage.
It shows engineering-level problem solving, large-scale transformation, and the ability to deliver brand architecture — not just apply skins.
✔ Full-site conversion
✔ Structural redesign
✔ Multi-medium integration
✔ After-hours high-access work execution
✔ Long-run ACM fabrication quality
A building, once tired, now signals authority and confidence.
Related Services
Building Signage: https://www.signageworks.co.nz/other-services/building-signage
ACM Panel Signs: https://www.signageworks.co.nz/other-services/acm-panel-signs
Wall Graphics: https://www.signageworks.co.nz/other-services/wall-graphics