Façade | CORE Consulting Engineers

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Commercial Office, Heritage, Façade, Remedial, Structural

124-136 Chalmers St, Surry Hills, NSW

Restoring the Beauty of a Historic Facade

CORE was engaged by Hector Abrahams Architects as the heritage facade remediation engineer for the restoration of the historic Amalgamated Engineering Union building at 124–136 Chalmers Street in Surry Hills.Constructed in 1929, the building’s distinctive terracotta faience facade is listed as a heritage item by the City of Sydney for its architectural quality and technological significance.

Over time, deterioration of the original fixing system and vegetation growth had caused sections of the facade to become unstable, with tiles loosening and posing a potential risk to the public along the busy Chalmers Street frontage. Investigations confirmed that conservation of the fragile terracotta facade would require an extraordinary intervention -the careful dismantling and reconstruction of the facade to address the underlying structural and durability issues.

CORE provided specialist engineering advice to guide the conservation strategy and ensure the heritage fabric could be preserved while addressing safety and structural performance.

The facade was safeguarded through extensive scaffolding works before restoration commenced. Approximately 80% of the terracotta tiles were individually removed, assessed and reinstated -requiring meticulous coordination and careful engineering oversight.

CORE had also previously delivered structural strengthening works to the building, installing carbon fibrere inforcement to the existing floor slabs, enhancing structural capacity while minimising intervention to the heritage structure.

Through close collaboration with key stakeholders, the facade was successfully conserved and reinstated. The project was recognised with a Highly Commended award in the Built Conservation category at the 2024 National Trust Heritage Awards, acknowledging the careful restoration of this significant heritage facade.

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Commercial Office, Residential/Strata, Retail, Façade

5-7 Charles St, Parramatta, Sydney

CORE was engaged to deliver complete facade design and construction-phase support for the 49-storey, mixed-use development at 5-7 Charles Street, Parramatta. From early design through to on-site delivery, our role extended well beyond technical documentation – acting as a trusted advisor to support our client through complex coordination, stakeholder challenges, and real-time construction issues. The result was a high-performance, visually refined facade system that balanced architectural intent, constructability, thermal performance and program certainty.

Design & Technical Scope

Fixed and operable glass window wall system wrapping approximately 80% of the building envelope
Integrated sliding door systems for seamless indoor-outdoor connection
Custom spigot-supported half window wall balustrades
Independent and integrated cladding systems
Detailed THERM thermal modelling and performance analysis
Interface coordination with primary structure and mechanical services

Construction Phase Services

Ongoing QA inspections to maintain design integrity and build quality
Real-time on-site issue resolution and consultant coordination

Delivering Value Beyond Technical Engineering

Our greatest impact came through proactive communication, leadership and ongoing support throughout construction.

Advocacy through clarity: When complex issues emerged on site, CORE carefully reviewed project history, design decisions and technical interfaces to provide clear, factual guidance. This helped our client navigate challenges with confidence, ensuring matters were resolved efficiently and fairly – without unnecessary risk or delay.

Bridging design and delivery: By working closely with builders and consultants, we translated technical requirements into practical, buildable solutions, maintaining architectural intent while keeping the project moving.

Confidence at every stage: Our regular site presence, QA inspections and responsive advice gave the client certainty around performance, quality and outcomes – not just compliance.

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Hospitality, Façade

Club Liverpool, 185 George Street, Liverpool, NSW

CORE was engaged to deliver a facade upgrade for Club Liverpool with the objective of modernising the building’s appearance. The design incorporates new glazing and striking aluminium architectural features, including battens and perforated screens with complex three-dimensional geometry.

Optimised Design for Performance and Cost Efficiency

To achieve the right balance between cost and performance, our facade engineers used Finite Element Modelling (FEM) in Strand7 to optimise the design of the perforated panels. Careful attention was given to panel thickness, as the smallest adjustments could significantly impact the project budget. By optimising the geometry and engineering, we delivered a solution that met the architectural vision while keeping costs under control.

Agile Problem-Solving Through Construction Challenges

As this was an upgrade to an existing building, close coordination with the structural engineer and subcontractors was critical.

Tolerances were tight and as demolition revealed unexpected misalignments across multiple elevations, our team responded quickly by tailoring design solutions for each affected area. This flexible, problem-solving approach ensured construction could progress without compromising on performance or aesthetics.

Through ongoing collaboration with the client and project partners, CORE has helped transform Club Liverpool into a modern, vibrant facility. Our role demonstrates how we combine advanced technical design with a people-first, solutions-driven approach that keeps projects moving forward even when challenges arise mid-construction.

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Aged Care/Health, Façade

Aero Healthcare, 2 Cameron Drive, Armidale, NSW

When Aero Healthcare experienced severe overheating issues in their facility, the client turned to CORE for support.
As a national supplier of first aid and medical products, their building needed to be safe, comfortable and operationally reliable.Instead, newly installed glazing was creating extreme internal temperatures, compromising both comfort and safety.

Pinpointing the Root Cause of Extreme Heat

Our facade team guided the client through a structured process to uncover the root cause. Testing revealed that, even in winter, the internal surface temperature of the glass could cause third-degree burns within one minute of contact – a clear sign that something in the glass design had gone wrong.

Practical, Cost-Saving Fix with Lasting Confidence

Rather than proposing a costly full replacement, we developed a practical, cost effective solution. By reversing and reinstalling the glazing panels, performance could be restored without major expenditure. A site trial confirmed the
effectiveness of the approach, with retesting showing that surface temperatures returned to safe levels. We also conducted a sun study to ensure the solution would perform year-round across seasonal changes.

The outcome for Aero Healthcare was a safer, high-performing building envelope – achieved with minimal disruption and significant cost savings.

Beyond resolving the technical issue, our people-first approach meant working alongside the client with clear communication, transparency and ongoing support. CORE continues to monitor glazing performance in partnership with the client, ensuring the building remains fit for purpose long into the future.

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Commercial Office, Façade

270 Pitt St – Sydney CBD, NSW

CORE’s facade design team partnered with Built to deliver the facade upgrade at 270 Pitt Street, Sydney – a $170 million transformation into a vibrant A-grade workplace designed to foster connection and growth.

Our role extended from Early Contractor Involvement (ECI) through to completion, ensuring that both the technical outcomes and client experience were of the highest standard.

Adaptive Solutions for Complex Refurbishment Challenges

As this was a refurbishment of an existing building, the project presented challenges that required adaptability and innovation. As demolition progressed, previously concealed conditions were uncovered, requiring us to rapidly resolve
design issues in real time.

Our team worked closely with the builder to refine installation sequences, particularly around complex interfaces with neighbouring buildings such as a church. To support decision-making, we developed 3D models of intricate
junctions, enabling the client to clearly visualise how components would come together and reducing uncertainty during delivery.

Hands-On Partnership That Builds Confidence

Key design contributions included the lobby glazing, stone facade features andtop-floor modifications to incorporate frameless balustrades while ensuring compliance with weatherproofing and performance standards. By developing
practical performance solutions, we were also able to help manage costs without compromising quality.

Beyond the technical delivery, we placed a strong emphasis on being present and hands-on. Our engineers attended site regularly, providing timely input that supported the builder and kept the project moving forward.

This proactive and collaborative approach reflects CORE’s people-first value – we don’t just deliver facade designs, we focus on relationships, communication and problem-solving that give our clients confidence at every stage.

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Faith-Based Buildings, Education, Electrical, Façade, Fire Engineering & Fire Protection, Hydraulic, Mechanical, Remedial, Structural

Sydney Catholic & Anglican Schools

Delivering Integrated, People-First Solutions Across Multiple Educational Campuses

CORE has developed a strong and ongoing partnership with Sydney Catholic & Anglican Schools, delivering end-to-end engineering consultancy services across a number of primary and secondary education projects throughout Greater Sydney and regional New South Wales.

Our multi-disciplinary capabilities have supported the successful planning, design and delivery of projects at:

Holy Spirit Catholic College, Lakemba
St. Patrick’s Catholic Primary School, Mortlake
St Michael’s Catholic Primary School, Meadowbank
Shellharbour Anglican College
St Aloysius College, Cronulla

These projects reflect our ability to respond to the complex and evolving needs of educational environments, delivering tailored solutions that prioritise safety, efficiency, and long-term value for students, educators, and administrators alike.

Our scope of services across these campuses has included electrical, mechanical, hydraulic, fire, civil, structural, and facade engineering. Each site presented unique challenges – from site constraints in dense urban settings to integration with existing infrastructure and staged construction around live school environments.

Through close collaboration with architects, project managers, and Sydney Catholic Schools’ planning teams, CORE ensured that all building services were designed to meet modern educational standards while supporting sustainability objectives, operational efficiency, and ease of long-term maintenance.

Engineering Educational Spaces for Performance and Longevity…

Educational environments require a people-first approach that goes beyond technical delivery. Considerations around student wellbeing, acoustic comfort, natural ventilation, lighting, and safety are central to our design philosophy.

Our ability to deliver coordinated, in-house consultancy services means fewer handovers, faster issue resolution and a more unified outcome that aligns with the school’s vision and values.

Whether designing for new learning spaces, administration buildings, or upgrades to essential infrastructure, CORE consistently provides thoughtful, responsive engineering solutions that support the holistic development of school communities.

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Retail, Façade

Volvo Showroom, 2 Anella Ave, Castle Hill NSW

Our facade design engineering consultants were engaged to transform an existing showroom into a Volvo-branded space that reflected the automaker’s distinctive aesthetic. Tasked with aligning the showroom with Volvo’s brand identity, our team embarked on a comprehensive overhaul of the window systems. This involved careful removal of existing windows and the installation of a new double-height glazed facade, designed to showcase Volvo’s vehicles to their fullest advantage.

Timeline

Design – 6 months

Construction – 6 months

Project Details

Value management played a crucial role throughout the project, as our engineers endeavoured to preserve the integrity of the original facade while adhering to Volvo’s exacting brand standards. To optimise costs without compromising quality, we strategically implemented an overclad of select areas of the facade. This approach not only achieved budgetary objectives but also maintained the cohesive Volvo brand aesthetic throughout the showroom.

Collaboration was key to the success of the project. We worked closely with the contractor to navigate logistical challenges and integrate design specifications seamlessly into the construction process. Our team meticulously documented every aspect of the design, ensuring that all requirements were met while accommodating supply chain, fabrication, and installation considerations.

Coordination with the client, architect, structural engineer, ESD and mechanical services ensured that the new facade not only met aesthetic and functional criteria but also aligned with broader project goals.

This holistic approach enabled us to deliver a showroom that not only met Volvo’s exacting standards but also enhanced the overall customer experience, reinforcing Volvo’s brand presence in a compelling and visually striking manner.

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Residential/Strata, Façade

Opera Residences, 79 Macquarie St, Sydney NSW

Our facade design engineering consultants played a pivotal role in the development of the Opera Residences, a hallmark of luxury residing at Sydney Harbour. Over a meticulous two-year period, our team was entrusted with delivering comprehensive design and construction services for the architectural stonework both externally and within the lobby spaces of this prestigious development.

Timeline

Design – 9 months

Construction – 12 months

Project Details

The project encompassed the crafting and installation of intricate elements using San Francisco granite, carefully selected to harmonise with the iconic stone prevalent at Bennelong Point. Our scope included the fabrication of large-format double-curved column panels, facade cladding panels, overhead stone soffits, and the interior detailing of the double-height lobby and fireplace stone walls. Each piece required bespoke support systems and steelwork framing to accommodate the unique shapes and weights, demanding exacting structural coordination.

Upholding Safety and Design Integrity

Navigating the challenges inherent in integrating eccentric stone designs into a modern architectural framework was a focal point of our work. We meticulously identified and addressed gaps in structural support, innovating solutions that ensured both safety and design integrity were upheld throughout the project. Our commitment to safety in design was paramount, as we safeguarded against compromises in the aesthetic or structural robustness of the final installation.

Today, the Opera Residences grace Sydney’s skyline and stand proudly among the city’s most revered landmarks. Our team takes immense pride in our contribution to this development, knowing that our dedication to precision and innovation has left a lasting impression on Sydney’s architectural landscape.

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Residential/Strata, Façade

Emporium Apartments, 305 Anketell St, Greenway ACT

Our team was engaged to provide weatherproofing FP1.4 (F3P1 2022) reporting and facade consultant certification for the ‘Emporium Apartments’ development in Greenway, Canberra, following issues with the initial engineering consultant’s delivery.

Project Details

Upon receiving the project, our team reviewed the architectural drawings, conducted thorough design load assessments, and performed prescriptive engineering reviews of the facade elements. We reviewed sub-drawings and diligently prepared comprehensive weatherproofing FP1.4 reporting.

During on-site weatherproofing testing (Site Water Hose Test to AAMA 501.2), we identified critical defects in the window and door systems, which were swiftly rectified to ensure compliance with regulatory standards.

Throughout the process, we maintained direct communication with both the client and the architect, facilitating detailed briefings on scope and delivery requirements. Our team’s extensive knowledge of FP1.4 requirements and our experience in delivering precise performance solution reporting enabled us to provide thorough and reliable facade consultant certification.

We take pride in our ability to present complex technical information in a clear, accessible format that meets professional standards and ensures complete understanding by all stakeholders involved.

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Education, Façade

Macquarie College, 182 – 222 Lake Rd, Wallsend NSW

Our facade design engineering team was thrilled to be engaged in the design of Macquarie College’s new educational building. We were tasked with a comprehensive scope including the design of:

External wall systems
Facade window glazing
Bespoke oculus skylights
Decorative perforated screens supported by prefabricated steel frames

Timeline

Design – 3 months
Construction – 6 months

Project Details

Collaborating closely with structural engineers and other stakeholders, our team navigated the intricate process of integrating these elements seamlessly into the architectural vision. One of the critical challenges we addressed was the design of prefabricated steel frames, carefully considering building movement and installation sequences to align with the architect’s geometric aspirations. The corrugated perforated screens, crafted into striking triangular shapes, required detailed planning to ensure structural integrity while upholding the aesthetic intent of the project.

Moreover, we focused on optimisingthe project’s cost-effectiveness, particularly in the value engineering of the perforated screens through careful selection of aluminium grades and thicknesses. Our team also played a pivotal role in coordinating with framing suppliers to deliver facade window glazing solutions that met rigorous thermal and wind pressure requirements.

Working on such a significant educational facility resonates deeply with our team, as we understand the profound impact of this college on future generations. We take pride in contributing our expertise to projects that support learning environments, ensuring they not only meet functional demands but also inspire and enrich the educational experience.