MTF Manukau · South Auckland
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
The project
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.
The brief
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
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 buil
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