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Surry Hills Village Project
Marshall Roofing was engaged to deliver the façade cladding works to selected areas of the Surry Hills Village development. Their scope included the supply, fabrication coordination, and installation of architectural metal panels to a curved façade, utilising the Expression™ panel system supplied by No.1 Roofing & Building Supplies.
They became involved during the construction phase, working closely with the builder and design consultants to ensure the architectural intent was achieved while maintaining buildability and compliance.
DESIGN BRIEF FROM SJB ARCHITECTS
SJB Architects outlined a design intent focused on achieving a strong architectural statement with a refined, continuous curved façade. Key requirements included high-quality finishes, precise alignment, minimal visible fixings, and consistency of colour and curvature to complement the broader architectural language of the precinct — all of which aligned well with the capabilities of the No.1 Expression™ architectural panel system.
MATERIAL SELECTION RATIONALE
Manor Red COLORBOND® architectural panels were selected to align with the design vision and heritage context of Surry Hills. The colour provided warmth and depth, while the Expression™ panel system, supplied through No.1 Roofing, allowed for precision detailing and adaptability to curved applications.
PERFORMANCE CONSIDERATIONS
Durability and longevity were critical considerations given the urban environment. COLORBOND® steel was chosen for its proven performance, corrosion resistance, low maintenance requirements, and ability to retain colour consistency over time, while also delivering a high-end aesthetic finish. The Expression™ system supported these performance objectives through its engineered panel design.
CURVED FAÇADE CHALLENGES
Installing panels to a curved wall presented technical challenges including maintaining consistent panel alignment, managing tolerances across the radius, and ensuring a smooth visual flow without distortion. Achieving this required careful planning, accurate set-out, and experienced installers familiar with the Expression™ system.
CUSTOM FABRICATION OR METHODS
The project required custom panel shaping and detailed coordination with SCA Engineering Pty. Ltd fabricators to suit the façade curvature. Special attention was given to fixing methods and installation sequencing to ensure panels sat correctly without stressing the material or compromising the finish. No.1 Roofing supported the supply of the Expression™ panels used for these custom requirements.
COORDINATION WITH OTHER TRADES
Marshall Roofing worked closely with the builder, façade engineers, and adjacent trades to coordinate interfaces, access, and sequencing. Regular site meetings and clear communication were essential to avoid clashes and maintain progress within the construction program.
QUALITY CONTROL APPROACH
The team implemented detailed set-out checks, progressive inspections, and continuous verification of curvature and alignment during installation. This ensured a consistent finish and adherence to the architect’s design intent across the entire façade.
TEAM EXPERTISE
Successful delivery of this façade relied heavily on the team’s experience with architectural cladding, curved installations, and complex detailing. Prior experience on Tier 1 commercial projects was instrumental in managing the technical demands of the works, particularly when working with the Expression™ interlocking panel system.
FINAL AESTHETIC OUTCOME
The completed façade presents as a seamless, striking architectural feature that enhances the overall character of the development. The curvature, colour consistency, and crisp detailing are standout elements that reflect a high standard of craftsmanship, supported by the performance and adaptability of the Expression™ panels supplied by No.1 Roofing.
FEEDBACK RECEIVED
Feedback from the builder and SJB Architects was very positive, particularly regarding the quality of workmanship, attention to detail, and the faithful execution of the design intent. The finished result met both aesthetic and performance expectations.
LESSONS LEARNED
Early coordination with designers and fabricators is critical on curved façade projects. Accurate set-out and mock-ups can significantly reduce risks and improve installation efficiency.
ADVICE FOR SIMILAR PROJECTS
Contractors undertaking curved architectural panel installations should invest time in planning, engage experienced installers, and ensure materials and fixing systems are suitable for curved applications. Precision and patience are key — particularly when working with systems such as Expression™.
INDUSTRY TRENDS
We are seeing an increasing demand for complex façades and specialty metalwork, particularly in mixed-use and high-profile urban developments where architectural expression is a priority.
ADDITIONAL HIGHLIGHTS
The Surry Hills Village project stands out as an example of successful collaboration between material supplier, architect, builder, and specialist contractor, resulting in a façade that is both technically sound and architecturally distinctive. The use of Expression™ panels supplied by No.1 Roofing contributed to achieving the desired architectural outcome.
Your Vision, Our Expertise
At No.1 Roofing & Building Supplies, we believe no architectural dream is too ambitious. Whether it’s a custom cladding solution or a unique roofing system, we are here to help you bring your vision to life.
Let us collaborate with you to create spaces that inspire and endure. Reach out to us today, and let’s turn your dream design into reality.
By Marcio Da Silva, GM of Architectural Specifications - No.1 Roofing & Building Supplies
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Expression™ Interlocking Panels
Credits:
Architect: SJB Architects / Installation by: Marshall Roofing
