Commercial facade glass jobs are bigger than they look. A two-storey building with thirty panels seems straightforward until you start working through the logistics: access, weather contingencies, tenant impact, structural inspections, certification. The panel itself is the smallest part of the work.
This post breaks down a real facade replacement we completed in St Marys recently, with the project management decisions that mattered.
The short answer
A typical mid-rise commercial facade replacement in St Marys runs 4 to 12 weeks from initial quote to final certification. The actual installation is usually 1 to 3 weeks. The rest is design, ordering, scheduling around tenants, traffic management, and the certification process. Plan around the access constraints, not the install time.
The project: brief overview
The building: a two-storey commercial property in St Marys, originally built in the mid-1980s, with an aluminium-framed facade. The original single-glazed 6mm clear panels were failing (multiple thermal cracks, edge corrosion on the frames, no acoustic performance against the increasingly busy road outside).
The brief from the owner:
- Replace all facade glass on the street-facing elevation.
- Upgrade to thermally and acoustically improved glass.
- Minimise tenant disruption (two retail tenants on the ground floor, one office tenant upstairs).
- Maintain weatherproofing throughout.
- Complete certification ready for a NABERS energy assessment.
The scope: 42 panels across two storeys, sizes ranging from 1.2m x 2.1m to 2.4m x 2.4m, total area approximately 180 square metres.
Phase 1: Survey and design (weeks 1 to 2)
Before any glass was ordered, we ran a full site survey:
- Measured every panel.
- Photographed frame condition.
- Tested the wind load classification.
- Checked the structural support behind the frame.
- Confirmed the floor and ceiling tie-ins.
- Documented current panel marking and supplier where visible.
The design conversation covered:
- Glass spec. We recommended 6.38 acoustic laminated outer / 12mm spacer / 6mm low-E inner. Compromise between performance, weight and frame compatibility.
- Frame approach. Frames were sound enough to retain with new gaskets. Saved time and cost.
- Weatherproofing. A staged install meant each panel had to be weather-tight at end of each work day.
- Certification path. AS/NZS 2208 + AS 1288 + energy compliance documentation pack.
The owner approved the spec and the project moved to ordering.
Phase 2: Ordering and procurement (weeks 3 to 6)
IGUs with custom specifications are not stock items. Our supplier needed 18 working days from order confirmation to delivery, which we built into the program.
In parallel:
- Confirmed council notification requirements.
- Booked the traffic management contractor.
- Arranged the elevated work platform hire.
- Coordinated with tenants on the install dates.
- Prepared the WHS documentation and SWMS.
This phase tends to feel slow from the owner’s side because the glass is being made. We send weekly updates to keep everyone aligned.
Phase 3: Tenant communication (week 5)
Two weeks before install, every tenant received:
- A letter explaining the work and the dates.
- A daily program showing which panels would be replaced each day.
- Contact details for the site supervisor.
- A list of FAQ items (noise, dust, security, access).
- Reassurance that no panel would be open at end of any work day.
Tenants who feel informed do not become tenants who complain to the property manager.
Phase 4: Installation (weeks 7 to 9)
The install program ran for two and a half weeks, four panels per day on average. The order of work was deliberate:
- Started with rear-side panels (less visible, lower tenant impact).
- Moved to upper floor (allowed the lower floor to keep trading).
- Finished with front-facing panels under traffic management.
Daily routine:
- 7am: site setup, EWP positioned, traffic management in place.
- 7:30am: remove first old panel, prepare frame.
- 8:30am: lift new panel into position.
- 9:30am: bed in, seal, check.
- Repeat for panels 2, 3, 4.
- 4pm: pack down, clear site, weather-seal anything not complete.
Weather contingencies were built in. Two days were rained out and we made up the time over the following weekend.
Phase 5: Certification and handover (weeks 10 to 12)
After the install:
- Full inspection of every panel for installation faults.
- Compliance certificates issued for AS/NZS 2208 and AS 1288.
- Manufacturer documentation collated.
- Energy rating documentation prepared for the NABERS process.
- Photos of finished work for the owner’s records.
- Final invoice with full breakdown.
The owner used the documentation to support a NABERS energy assessment that improved the rating by one star.
What went well
A few decisions that paid off:
- Detailed survey upfront. Avoided rework and surprises.
- Retaining the frames. Saved 3 to 4 weeks and significant cost.
- Weekly tenant updates. Zero complaints, two thank-you emails.
- EWP hire instead of scaffold. Faster setup, easier daily pack-down.
- Staged install order. Tenants could trade through.
What could have been better
Honest reflection:
- More weather contingency. Two rained-out days felt manageable. A wet week would have hurt.
- Earlier traffic management approval. Council took longer than expected to approve the front-of-building work. Plan three weeks, expect five.
- Lighting during a winter install. The shorter days reduced our productive hours. Summer installs are easier.
Costs (in the ranges we see)
For comparable jobs in St Marys, Penrith and Western Sydney, typical commercial facade replacements run:
- Small commercial (under 20 panels, ground floor only): $80,000 to $150,000.
- Mid-rise (20 to 50 panels, 2 to 3 storeys): $180,000 to $400,000.
- Larger (50 to 100 panels, 3 to 5 storeys): $400,000 to $900,000.
Pricing depends on glass spec, frame retention vs. replacement, access requirements and traffic management. We quote each job individually.
How to plan if you have a similar job coming up
For property owners and project managers considering a facade replacement:
- Start the conversation 3 to 6 months before you want the work done. Lead times on specialty glass and the supporting trades (EWP, traffic management) need real time.
- Get a proper condition survey. A walk-by quote will not tell you whether the frames can be retained.
- Decide on the glass spec carefully. It is the part you will live with for 30 years.
- Build tenant communication into the program. Trust matters more than perfect schedules.
- Budget for the certification pack. Worth its weight in gold during sale or refinancing.
We work on these jobs across Penrith, St Marys and Western Sydney through our commercial window service.
When to call us
Bring us in if:
- Multiple panels in the facade are showing cracks, corrosion or seal failure.
- The building is being prepared for sale, lease renewal or refinance and needs presentation.
- A NABERS or Green Star upgrade is in the planning stage.
- Tenants are complaining about heat, cold or noise from the facade.
Phone 02 4722 2787 or send the building details and photos through our contact form.
FAQ
Can we do a facade replacement floor by floor over several years? Yes. Staged programs are common for budget reasons. We help plan the sequence to keep the look consistent.
Do we need to relocate tenants during the work? Usually no. With careful sequencing, tenants stay in place. Some businesses choose a brief closure during their busiest area’s work.
Will the new glass look different to the old? The new glass will be visibly cleaner, clearer (or more tinted, depending on spec). If only part of the facade is replaced, expect a visible difference. Plan to replace all visible panels in one elevation at minimum.
How long is the warranty on facade glass? Glass: 10 years against defects. IGU seals: 10 years against failure. Installation: 5 years on workmanship. We provide written warranty documentation.
A facade replacement is a defined project with predictable phases. Plan it right and it lands without drama.
