Aluminum Plates vs. Aluminum Composite Panel Claddings

aluminum composite panel claddings

Metal buildings and modern facades are becoming more and more common these days. Architects and builders use various metal panels to create beautiful and functional facilities for their clients. Aluminum plates and Aluminum Composite Panel Claddings are two of the best materials to make your home beautiful and energy-efficient.

What Are Aluminum Plates?

Aluminum plates and sheets’ journey begins with mining the mineral used to create this metal. It is called ‘Bauxite,’ and it is the raw material for aluminum and where it comes from.

After mining the material, they need to extract the alumina from the crushed bauxite. The extracting process involves using hot caustic soda and lime mixture. The result of heating and crushing the bauxite and its purifications are crystals and the alumina needed for aluminum metal creation.

The journey continues with the process of aluminum metal creation. Electricity and carbon are used in this process. This process is called electrolysis; it converts the alumina into a liquid state. There are different forms that this liquid aluminum is poured into that produce slabs or sheet ingots, which are then used to create sheets and aluminum plates.

The rolling machine rolls these through after being heated up to 400 ºC, resulting in a thin metal sheet.

The next part of the journey for these aluminum sheets is called “Cold Rolling .”This is where these sheets are flattened into different thicknesses according to the orders that have been made or customer needs.

aluminum plates

Types of Aluminum Plates:

  1. Low-temperature service type
  2. Corrosion-resistant type in various corrosive environments
  3. Atmospheric corrosion resistant type
  4. High tensile strength aluminum plates.
  5. Abrasion-resistant type

Aluminum plates might be manufactured by specialized plants or large metal factories small in size. They are many different types of aluminum products that can be produced, and other types include rolls, sheets, bars, slabs, etc.

Industrial Usages of Aluminum Plates

Aluminum plates are often used for military or Construction and structural applications, offshore and marine equipment, and pressure vessels. The aluminum plate’s grade is also crucial, depending on the application.

How are Aluminum Plates used in Different Industries?

The largest consumer industries include:

  1. Building machines: Aluminum plate systems are used in manufacturing components for agricultural machinery, for example, blades, parts of seeding, harrows, devices, and plows. In manufacturing land and heavy underground machinery, for example, crane jibs, components for mining that are highly stressed, handling machines and roads, housings, casings, etc., to manufacture parts for cargo and passenger transport, aluminum plate products play an essential role.
  2. Construction of other structures and bridges: welded boxes, support profiles that are made by cutting and welding elements from metal plates and section columns, I-beams, aspects of the superstructure of bridges and building floorings, pipes that are medium and large in diameter that can be used both for utility lines (cabling, chimney stacks, pipelines, etc. and as supports for structures and bridges.
  3. Ships and large-diameter pipe manufacturing: LNG cargo ships are mainly used to transport natural gas for long distances. There are fishing boats with a wide variety of aluminum alloys fitting for different waters. They got a thick shell, which provides safety and super high strength.

Aluminum Plates in Buildings:

An aluminum plate is widely used to stabilize structures and different buildings. Aluminum Plate Systems are widely used for projects that require details. This implies that some classes are more suited to various activities than others.

Aluminum plates are one of the best aluminum cladding systems that are used for modern home facades.

Equipment Used for Lifting Aluminum Plates:

For short or long, thin or thick plates, the lifting job has always been tricky for mills or metal structures where containers must be moved and handled daily. Manufacturers have to use reliable lifting magnets for Aluminum plates so they don’t have to worry about dropping a plate during the move and have good efficiency in moving them around as needed.

aluminum composite panel cladding

What are Aluminum Composite Panel Claddings?

An aluminum composite panel is a modern building material made of 2 thin aluminum sheets bonded together with a non-aluminum core. And there is an aluminum outer finished surface, a high-density insulated core, and an aluminum inner surface. If the inner surface is visible from the inside, the finishing of its surface will matter.

Main reasons to consider Aluminum Composite Panel Claddings:

  1. Robust durability and lightweight
  2. High weather resistance
  3. Cost-effectiveness
  4. Easy installation
  5. Low maintenance
  6. Easy to be repaired

Aluminum composite material is made from different types of core substances, which should be assessed for suitability and strictly reviewed.

These include:

  1. Mineral Fibre (usually stone mineral wool)
  2. PUR (Polyurethane) foam
  3. PIR (Polyisocyanurate) foam
  4. Polystyrene and PF (Phenolic foam)
  5. Aluminum Cores (These cores are either made of an aluminum honeycomb structure or solid aluminum.)

The critical point here is to consider their fire-resisting capabilities & the height of the structure for which aluminum composite panel claddings are used.

The covering found in these types of panels varies depending upon the use. For example, in doors and windows, the thermal insulation in the boards is light and with the option of metal or timber reinforcement. Aluminum Composite Panel Claddings are used for:

  1. Building cladding systems, both internally and externally.
  2. Aluminum composite panels are used for windows and doors.
  3. Architectural elements and facade glazing.
  4. Partitions and internal walls.
  5. ACM Panels are used in signs and display boards.

Why using Aluminum Composite Panel Claddings is Recommended:

A wide choice of colors is the first benefit of having aluminum composite panel claddings with special coatings. Aluminum composite material is very resistant to corrosion and can last long, even in the harshest weather conditions.

Aluminum composite panels’ advantages are many, and knowing them will ensure that using ACM panels in your next project will be a good choice.

How to Cut ACM Panels?

Cut ACM Panels

ACM panels (aluminum composite material) are the most modern building cladding materials, beneficial for recent architectural projects. Aluminum cladding manufacturers utilize different fabrication and installation methods to complete a project with the best results. One of the most common ACP fabrication systems is cutting them in any demanding dimensions equivalent to the project and client’s needs. Cutting these building materials is not as straightforward as many people think, and it is often challenging for manufacturers to fabricate them with precision when the exterior renovation is required. This particular process is considered the initial stage of any composite material fabrication process. Building material suppliers and manufacturers utilize various tools and equipment to cut ACM panels. For instance, circular milling cutters and saws are known as hand-held tools for this purpose. Other industrial tools include a CNC router, laser cutting machine, shears, and chisels used for cutting aluminum composite panels. By using these tools, fabricating different aluminum claddings is possible with precision.

Cutting ACM Panels with a Laser Cut

A fiber laser cut system can cut metal materials, including aluminum sidings (another suitable building material for facades) and ACM panels. Modern laser cutting devices can penetrate any metal material without creating tooling wear. When it comes to fabricating ACP materials, a CO2 laser cut machine can do a perfect job. The laser cutting technology is popular due to its unique ability to not leave any shadings on the product’s surface after completing the cutting procedure.

This metal fabricating machine generates a small laser beam, allowing manufacturers to cut ACM panels with higher precision than other router bits and die cutters. Additionally, laser cutting devices can complete complex patterns and provide more freedom than standard cutting tools. By using these particular machines, manufacturers can cut ACM panels with high yield points while delivering high quality and material waste reduction.

Cut ACM Panels with Shearing

One of the oldest metal cutting methods with machines is shearing. Cutting ACM panels with this method is almost similar to using scissors to cut paper. The shearing machine’s blades come together at a minimum offset for fabricating the boards in desired blank sizes, known as blade gap. The wider or thicker the ACM panel, the wider the blade gap between the cutting tools must be. This will decrease the required tonnage amount for fracturing the metal. The components of a shearing device are the mainframe, bed, hold-downs, square arm, gaging, control, and blades. Building material manufacturers utilize two types of sear: swing bear and guillotine, which are available in both mechanical and hydraulic mechanisms.

CNC Routing Machine

Another popular industrial machine that is used to cut ACM panels is the CNC router. This machine is also used to fabricate other metal cladding systems. The CNC cutter operator removes the material precisely to provide a better working flow and reduce the stickiness of the fabricating boards. Using lubricants can also minimize stickiness. Experts utilize a feed rate calculator due to tighter windows of the feed and speed when cutting aluminum composite materials.

Cutting Aluminum Composite Panels With Circular Saw

For creating straight line cuts on ACM panels, the most efficient tool is the circular saw. Cutting aluminum cladding with this method can be done with a DIY process. However, it is essential to follow safety protocols. The operator must evaluate the tool before starting the cutting process. This saw should never be turned on when the cutting blades face the composite panel. Wearing safety goggles is necessary to protect the eyes from dust or flying debris during the metal fabrication process.

Cut ACM Panels with a Jigsaw

Most experts prefer to cut ACM panels with a jigsaw when it comes to lower-budget projects. Jigsaw itself is a versatile industrial tool that can create straight cuts and fabricate sheet metals with any thicknesses. This tool allows experts to create curves and angles. However, it is essential to utilize A 24-toothed blade for a smoother cut for cutting aluminum cladding systems.

Cutting with Cold Chisels

For cutting ACP with cold chisels, the tool must be 2cm wider than the working piece. After choosing a suitable chisel, this tool must be sharpened to a 60 or 70-degree angle with a preferable guide. The alignment of the device is better to be done with screw and hammering. However, the operator should never use a claw hammer.

Aluminum Siding or ACM panels for Building Facade

alumtech bond acm panels or aluminum siding

Construction material suppliers and manufacturers are developing various types of products and materials for the current building industry. The building facade, a cladding system, is the crucial element of any residential or commercial facility that exterior designers and architects focus on for creating attractive and aesthetic designs for their clients. Thus, manufacturers provide various cladding systems with unique characteristics. Due to the importance of energy in the current era, metal wall cladding systems have become the most famous building facade materials in the market. Metal wall claddings come with various materials, including steel, copper, CORTEN, aluminum, etc. However, aluminum metal wall claddings are the dominant products in this industry, including aluminum plate systems, ACM panels or aluminum composite panels, and aluminum siding. However, most people will be confused when choosing Aluminum siding or ACM panels.

Moreover, manufacturers create walling systems with aluminum in two main categories: aluminum siding and aluminum composite panels. It is essential to mention that some other products such as aluminum longboard sidings and aluminum wood sidings are practical and are combined with traditional materials for people who prefer classic looks for their buildings. This article will help you choose between aluminum sidings or ACM panels for your next project.

What is Aluminum Composite Panel (ACP or ACM panel)?

The first Aluminum Composite Panels or ACM panels were produced and invented in the 1960s by various companies. ACM panel cladding systems consist of two exterior layers of aluminum sheets and one core substance. The traditional aluminum composite panels did not have fire-resistant characteristics due to the highly flammable polyethylene core. However, after the growth of technology, ACM panels manufacturers managed to use FR (fire-retardant) core for their new materials, making them fire safety construction materials.

There are generally three types of facilities in the building industry: type A that features more than four floors, type B has three floors, and type C consists of less than two levels. ACM panels are practical for all types, but they are most efficient for classes B and C. Aluminum composite panels (ACM panels) are available in various colors and sizes. The standard dimensions of ACM panels in Canada are 3mm, 4mm, and 6mm.

Pros of ACM panels

  • The primary material of ACP cladding systems is aluminum, meaning they can be fabricated into any desired shape due to the material’s flexibility.
  • In addition to the flexibility ad lightweight characteristics of ACM panels, they are durable and rigid cladding systems. Thus, they can last for decades without having any damages.
  • Aluminum composite panels feature an easy installation process as they are lightweight and have a defined workflow.
  • Most people choose their construction materials from the prices that are available. Thus, Aluminum composite panels cost can benefit builders.
  • Composite panels are versatile as they feature different colors and finishes.
  • They are UV and chemical-resistant.
  • Modern aluminum composite panels are perfect sound insulation solutions,
  • ACP panels are 85% recyclable, making them environmentally friendly materials.

ACP Cladding Materials Cons

  • In extremely harsh weather conditions, ACP materials are susceptive to dent.
  • While installing ACM panels, the contractor and the builders should seal the cladding boards properly and make them waterproof.

What is Aluminum Siding?

Aluminum siding cladding is a construction material that has been used for cladding systems for decades. These functional materials are the perfect choice for locations that have mid to low temperatures, such as Canada. The primary material in aluminum siding claddings has remained the same from their first day of production. However, construction material suppliers started using various cutting and new fabrication machines for cutting, shaping, bending, and installing. These sheet metals are developed through a process that has less impact on the environment than other traditional cladding systems. Manufacturers roll pure aluminum with special devices and store them or send them to the construction site. To have a vision about how long these materials can last, you can easily find that the existing buildings in Canada have had their siding applied since the 1970s.

Pros of Aluminum Siding Materials

  • Aluminum siding materials are cost-effective materials and are highly affordable.
  • These construction materials are 100% recyclable, and they will not end up in a landfill.
  • Metal wall claddings with aluminum are energy efficient and great insulators during cold and hot seasons.
  • They are considered low maintenance materials, and unlike other materials, they do not require regular cleaning.
  • Aluminum siding panels are durable and can last for a long time.

Aluminum Siding Cons

  • Aluminum contracts and expands due to temperature change which can cause popping noises can be annoying for occupants.
  • As aluminum is a soft metal, sidings made from this substance are susceptible to dents and scratches.
  • These aluminum cladding systems consist of painting coats worn out after years of rainwater and sunlight exposure.
  • Current architects prefer ACM panels to aluminum sidings because traditional sidings are out of style, and creating contemporary designs will be hard.

ACM Panels Installation Guide with Details

Aluminum Cladding Installation Process for Commercial Building

Building a residential facility, an office, or a board for advertisement can sometimes be a challenging and daunting task due to the complexity involved in the installation process. Developing a structure from 0 to 100 requires having a precise plan and schedule, but it also needs to be cost-effective and enjoyable. The essential part for building construction or an advertisement board mostly depends on various elements, including the contractor, project budget, and materials used for the purpose. This is why modern building materials come to the picture, including ACM panels.

Some factors for building a new office or home may not be in the customer’s hands. However, choosing and installing suitable building materials is unquestionably a choice. Choosing and buying construction materials for a custom facility or commercial building has become more manageable after manufacturers started developing aluminum composite material panels (ACM panels). However, before utilizing them in your next project, you will need to know what ACM panels or ACP materials are and how ACM panel installation should be done.

What are Aluminum Composite Materials (ACM)?

ACM panels manufacturers developed these functional materials with beneficial characteristics making the head product in construction and architecture. Compared to other construction materials, Aluminum composite panel (ACP) and supplies reveal their advantages. By looking at some high-quality ACM panels characteristics, including durability, rigidness, flexibility, and lightweight, the difference between other traditional cladding materials is evident. Additionally, it is easy to recycle ACM panels for other projects. Furthermore, the numerous applications of ACM panels make them the perfect choice for architects and builders.

Aluminum composite panels feature two primary layers of aluminum sheets and a core substance placed between other layers. Although ACP materials have not raised severe issues after their development, the core materials have been a leading obstacle. In other words, old composite panels didn’t feature non-combustible core material. However, ACM panels manufacturers managed to find and utilize FR (fire-retardant) substances and solve the issue once and for all. ACM manufacturers changed the polystyrene to a mineral-filled sense, and these materials gained approval from building regulations for safety. Thus, it is essential to check if the core is made from FR materials before ACM panels installation.

ACM Panels Installation Process

Although ACM panels are functional for various applications, including transportation, signage, industry, and more, they are primarily used as exterior building metal cladding systems and interior decoration materials. ACM panels installation involves different steps depending on the client’s demands. Thus, it is better to contact the ACM panel manufacturers and gather the details when buying aluminum composite panels.

Aluminum Composite Panel Installation Steps:

  • Measurement: The first step of installing any building material is to measure the dimensions and size of the demanding product. It is essential to do the measurements precisely. Even the slightest mistakes can cause money and time loss.
  • Fabricate: After determining the accurate size of the aluminum composite panels, the board provider should fabricate them in the demanding dimensions. ACM panels manufacturers utilize various professional tools for cutting, folding, bending, and drilling their materials. Installing supporters and fasteners can also take place in this step.
  • Waterproofing: Another essential step of ACM panels installation is waterproofing. The weather barrier which should protect the structure needs to be installed before applying the aluminum composite claddings. In this step, a primer should be applied to the framings, and then the barrier is utilized to seal the cladding materials.
  • Applying the Mounting System: Builders use a mounting system to ensure the straight alignment of ACM cladding panels. After applying the mounting system, the cladding boards are installed in a fixed order. The order depends on different factors, such as the priority of shaped areas and corners.
  • Installing ACM Panels: In the final stage, ACM panels should be installed on the mounting. It is better to ensure that the primary profiles (clips) are connected to the aluminum composite panels. Then, the installer must screw the boards to the wall. After ACM panels installation, there will be a gap between the boards. Most ACM manufacturers utilize a strip for matching and hiding these gaps. Other supporters, such as shims and additional clips, are utilized in the final stage for leveling and attaching the cladding materials.

ACM Panels Installation Guide for Outdoor Application and Purpose

ACM panels outdoor applications require different installation methods. All methods require accuracy and precision. Due to the wind loads in the back of the composite panels, it is crucial to install weather resistance barriers. As told earlier, fire retardant core also represents a significant role in ACM panels cladding systems.

  • The primary consideration for aluminum composite cladding panels is preparations. Choosing a fixed direction is essential to paint ACM panels. (Arrow direction on the protective film)
  • For preventing damages and scratches on the boards, it is better to roll, cut or drill the product from the back.
  • Developing a sketch for ACM panels installation is essential since some sections such as windows and doors need to be installed before other portions.
  • Builders should install the first panel in areas such as corners.
  • Permanently remove the protective films as each section’s installation is done.
  • Aluminum composite installation for exterior wall cladding is crucial. The ACM panels should be sealed in the correct order. Otherwise, water leakage will possibly be an issue during rainy weather.

Aluminum Composite Panel (ACP) Compared to other Building Materials

Aluminum Composite Panel (ACP)

Currently, there are a wide array of construction materials available for architects, constructors, and builders. Selecting and buying suitable building material for the demanding project depends on numerous factors, including price, versatility, durability, finishes, and purpose. Thus, clients and architects must choose the most suitable construction materials for their projects and applications. One of these materials widely used in modern and industrial cities such as Toronto is Aluminum Composite Panel (ACP), also known as ACM panels claddings and roofing systems. In the current industry, Aluminum composite panels are utilized not only for construction but for other applications in different industries.

Aluminum Composite Panel (ACP) Structure

ACM panels are also referred to as aluminum composite sheets, sandwich panels, and ACM materials. As told, these modern products are widely used in construction projects and other industries. The thing that made ACM panels unique and different compared to other building materials is their structural properties which provide outstanding quality and functionality among other particles.

The importance of each construction material is summarized in its structure. In other words, if the architect or customer wants to know whether the building material features the suitable quality and characteristics for the demanding project, they will need to learn about its structure and form.

Aluminum Composite Panel (ACP) Core Material

The Aluminum Composite Panel (ACP) features a three-layered structure, including two sheets of aluminum and one fire-retardant core substance. This central core of ACP materials is the essential part of these building materials. However, at first, some issues started when the fire behavior of these construction materials went under question. The early aluminum composite panel featured a PE core substance that is sustainable to fire and spreads quickly. This problem is solved with various solutions. However, some countries abandoned PE cores, and others allow builders to utilize them for low-rise buildings.

Though the former systems seemed to be reliable, modern manufacturers provided better resolutions for aluminum composite panels. They typically utilize fire-retardant (FR) substances to make ACM panels safer than other construction materials. These solutions are perfect for exterior applications, including using ACM panels for cladding systems where safety plays a massive role in the building’s facade. The FR core materials can be varied depending on the local building codes and requirements. However, the common fire-retardant substances are mineral materials and honeycomb, which manufacturers utilize in their aluminum composite panels.

Coating Materials on ACM Panels or ACP Finishes

Although the substance used in the structure’s core is of great importance in an Aluminum Composite Panel (ACP), coating materials on ACM panels are also essential and affect the overall quality. Generally, manufacturers utilize two types of coating for these construction materials. The first one is PE finish, which is the same as for PE core. Thus, this can cause issues similar to the core material. However, it is possible to utilize this coating as the leading material on the surface for interior applications. Some of the internal usages of the PE coating include perforated and decorative panels, wall partitioning, and false ceiling.

On the other hand, experts recommend using coating materials such as PVDF or Nano aluminum composite panels for cladding systems and other external applications. These coating types provide better durability and quality and offer better safety and resistance against fire. Additionally, Nanocomposite panels are anti-dirt and water-retardant. Thus, they will require lower maintenance, and cleaning them is very straightforward.

Best Qualities of ACM Panels

The aluminum composite panel (ACP) has advantageous characteristics, qualities, and features, making it the perfect material for building cladding systems and facades. Due to its structural components and properties, ACP material is one of Canada’s most used building materials. The followings are the primary and beneficial characteristics of aluminum composite panels (ACP).

  • Flexibility, Versatility and Durability: One of the unique characteristics of an aluminum composite panel (ACP) is its flexibility, versatility and durability. Most construction materials do not feature three of these properties at once. It is accessible to fabricate and installs ACM panels, and they will last more than 30 years if maintained properly. Due to the versatility of ACP materials, manufacturers can produce various cladding products with different styles and shapes, allowing architects to create limitless designs for their clients.
  • Chemical and Water Resistance: ACM panels are manufactured in a way to withstand harsh weather conditions. These building materials are water and chemical resistant, and they can be utilized in different portions of a facility. This advantage of ACP materials makes them the perfect cladding materials for locations with high humidity and temperature change. However, if these panel systems are not installed properly, they can have leakage. Thus, it is essential to follow a rainscreen installing instructions precisely.
  • Lightweight Material: Most clients should pay considerable money to labor costs when constructing a new building. However, due to the lightweight characteristic of an aluminum composite panel (ACP), it is easy to install these building materials for cladding systems resulting in lower labor costs.
  • Aesthetics: Architects prefer using metal wall cladding systems, including ACM panels, which are the perfect materials for building facades, as they are modern, flat, and sleek. Most manufacturers create ACP materials in different color finishes and textures. Even ACM panels with wood pattern finishes are available for clients who prefer to have a mixture of contemporary and classic designs for their building’s cladding system.

Why ACM panels are more expensive than other Cladding Materials?

ACM panels

Exterior cladding systems for new construction and renovation projects have become a must-have architectural element for commercial or residential facilities. In contrast with traditional methods of simply painting structures, contractors and homeowners prefer to add functionality and support to their building’s facade using various cladding materials, including ACM panels, wood sidings, longboard sidings, etc. For homeowners on their first renovation or new building project, choosing the most efficient cladding system from the array of materials and styles that the market offers can be a daunting statement. If the project requires modernity and flexibility of exterior cladding, it will be challenging to choose between wood, vinyl, ceramics, and aluminum composite panels. The first thing that most people consider when selecting their exterior paneling system is the price. While building materials such as wood and brick tend to come in at about 3$-14$ per square foot, with high-end wood cladding, which is the most expensive system currently, ACM panels often cost anywhere around 15$-35$ per square foot. However, there are several reasons behind the relatively expensive cost of aluminum composite panels.

Advantages of ACM Panels that Make Them More Expensive Than Other Systems

Aluminum composite panels (ACM panels), also known as ACP materials, are created by bonding and securing two aluminum sheets to unique core material. These panels are designed and engineered to provide long-lasting durability for homeowners who want to invest their money in the new construction or renovation of buildings. Using ACM panels offers numerous benefits when used as a facility’s cladding material, making them relatively expensive than other cladding systems. These practical advantages are as followed:

ACM Panels Provide the Best Durability Among Cladding Systems

The production process of ACM panels for providing cladding systems is the key to their popularity. Two sheet metals adhere to a thermally resistant polyethylene core which often features thin characteristics. The resulting aluminum composite panels are lightweight, and molding or fabricating them into different demanding shapes and styles is relatively straightforward. These particular rain-screen systems consist of additional coating that enhances their waterproof property and protects them against dents due to high-impact weather conditions. Metal panel cladding products are all factory-tested for their ability to withstand various damaging external factors. All ACM panels that are adequately produced offer:

  • High wind loads resistance
  • Structural supports during precarious conditions
  • Presumption deflection
  • Air infiltration and leakage protection
  • fireproof characteristics (safety regulations require fire-resistant features for exterior cladding systems)
  • Moisture and humidity resistance (for buildings in locations with high humidity levels)

These characteristics of ACP materials make them unbreakable and impervious to tear or wear from the worst of weather conditions during the year.

The versatility of Aluminum Composite Panels

Other cladding materials such as wood, vinyl, and stone can provide unique visual aesthetics and appeal for architects. However, these cladding systems have a limited range of styles, making them challenging for creating a new and modern appearance for the building. For instance, the stone is often preferred for its rustic, rough appearance and cannot accept other paints or finishes, resulting in the color choice reduction for customers. Moreover, molding and fabricating stone and wood can be challenging due to the current designs featuring curves and modern looks.

In contrast with traditional materials, ACM panels are incredibly flexible and lightweight, making them the perfect materials for fabricating in different designs. Additionally, the light characteristic of ACP materials allows builders to install them more straightforwardly. Manufacturers can shape aluminum composite panels into circles and curves as well as more traditional rectangles or squares. Another essential factor making these cladding systems more versatile than other paneling materials is that choosing any color during the mixing and finishing stage is possible, allowing architects to select from any color under the sun to suit the aesthetic requirements for their customers.

ACM Panels Require Low Maintenance During Their Lifespan

Wood siding cladding systems that are entirely made from natural wood require regular maintenance. While the natural appearance is more appealing to some people, using non-composite cladding materials requires consistent painting, oiling, and finishing. Water infiltration and pests can easily cause several damages to these products, including splitting, erode, and cracks.

On the other hand, ACM panels don’t require regular maintenance, primarily when the building is located in temperate areas. Cleaning aluminum composite panels usually require a simple wash and buff for removing any visible stains. With the highly reflective nature of aluminum surfaces, ACP materials are incredibly resistant to tear and wear from UV rays existing in sunlight, allowing them to maintain their finish and appearance for even decades.

Rainscreen Construction Principle (Part II)

Rainscreen Construction Principle

Rainscreen Construction Principle basic idea is to have an exterior surface or cladding layer that can break the force of sideways, wind load, water movement, resulting in preventing water penetration into the building’s structure. For most of the buildings, from modern to traditional ones, water is the biggest enemy. However, producing a complete watertight cladding system is challenging. Thus, manufacturers started working on the rainscreen construction principle decades ago to provide better protection for the constructions in the city. Rainscreen comes in different styles and types. One of the most popular types is the ACM panels or ACP materials used widely in the modern era. These particular products offer numerous advantages along with their waterproof characteristics.

In the rainscreen construction principle part 1, we discussed the basics of these practical systems and their structure that engineers designed for better watertight characteristics. This article covers essential information about this principle that anyone in the building industry must know.

Rainscreen Construction Principle Types

The rain screen construction principle is based upon two distinct and separate barriers on the building’s cladding. The outer barrier controls most rainwater while the inner leaf performs multiple functions, including moisture and air barrier, insulation, and the structural wall. The outer section allows the water to penetrate through open joinery, and the volume of the penetration depends on the design principle. This is where two distinct types of products come into the picture: the Drained/Back-ventilated and Pressure-equalized/Compartmented systems.

Both rainscreen systems are available in ACM panels cladding materials and different siding for the facade. They use the principle of controlling water leakage without stopping it from penetrating through the exposed outer surface completely. However, the internal design of both systems functions differently based upon the approach. Moreover, the Rainscreen construction principle has been generalized and consolidated into one unified product in specifications combined with both types’ characteristics. For complicating and confusing matters, the water, and air resistance standards from the traditional building cladding systems are applied to these modern designs and specifications of the exterior material’s exposure. Placing the water and air tightness codes on the outer surface of the barrier contradicts the underlying fundamentals of the Rainscreen Construction Principle. Now let’s get to the fundamental of each system.

Pressure-Equalized/ Compartmented Rainscreen

In this article, we focus on the Pressure-equalized rainscreen principle, which is very design intensive. Please read the third part of this article to learn about Drained/Back-ventilated systems for ACM panels.

Pressure-equalized systems are susceptible to design variations and deviations from their design principle. The openings in this system are created uniquely for both static and dynamic pressure equalization allowance across the rainscreen. The essential factor that separates this system from the D/BV principle is the design and the use of the compartmented method within the cavity. The reason behind the compartment is that the pressure equalization can only happen within limited periods and in the case of controlled volume behind the Rainscreen system. This equalization is essential due to the none-uniformity of wind loads, constantly changing across a single cladding of a building.

The vent numbers and their geometry calculation depend on the cavity volume, allowing sufficient airflow in and out of the internal equalized area quickly enough to respond to the ever-changing wind loads. This promotes the pressure differences between the ACM panels or other types of panels used in the system and the internal compartment pressure resulting in equalizing the air pressure on the external cladding and the inner sides of the building facade. If the conditions exist properly, forces causing water movement will decrease; if not, they will be eliminated.

The effective area of the vent holes in this type of rainscreen construction principle depends on three factors which are:

  • The airtightness of the air barrier on the inner section
  • The stiffness of the cladding material and its inner leaf
  • The volume of the compartments that make up the internal air space

The compartments are the essential elements of a proper pressure-equalized rain screen principle. They come with crucial properties, characteristics, and functionalities. Followings are the reasons why these elements play an indispensable role in the PE systems:

  • They control lateral and vertical airflow.
  • They size the volume of the space that the vent openings must be designed for facilitation.
  • The most crucial role of compartments is limiting water infiltration and controlling the water drainage when air-pressure disequilibrium occurs.

The characteristics above show that rainscreens with non-compartmentalized cavities cannot be pressure equalized. However, many of this system’s construction factors and elements are almost similar to the drained/back-ventilated rain screen construction principle. Still, they have several significant and essential differences, which we have discussed in the third part of this article.

The Best Properties of ACM Panels

The Best Properties of ACM Panels

The Best Properties of ACM panels are what the building industry requires to improve cities and facility’s attractiveness and durability while satisfying construction regulations and standards. Aluminum composite materials or panels are modern construction and decorative products first invented in Germany in the 1960s. These materials take other traditional material’s place, such as cement and wood, in the market.

The best properties of ACM panels made other substances no so significant in the construction industry. Additionally, older and traditional materials are not environmentally friendly products, and they get damaged or even destroyed easily. Thus, architects and builders need new and valuable products to improve facilities with higher quality and resistance. ACM panels are the ideal solution since they provide a wide array of benefits.

What are Aluminum Composite Panels?

Before getting to the best properties of ACM panels, it is essential to know what exactly are aluminum composite panels. Like other composite panel materials, these products are made up of three necessary yet thin layers, including two Aluminum layers and one primary core material. Customers demanding projects can change the core substance since it can vary the product’s fire exposure behavior. For example, the core material may be a solid mineral or honeycomb filling, but the standard ACP products feature polyethylene or considerably combustible polyurethane substances.

The combustibility of the core material made issues for the past few years. Thus, manufacturers decided to change the core material for exterior cladding applications to prevent feature disasters. ACM panels are practical for applications where the project requires a mix of high structural materials. As a result, manufacturers create products with different yet high quality by using the correct core substance. The quality and the best properties of ACM panels have made various companies and manufacturers invest in the production process. The world statistics estimates that more than two hundred companies are active in the aluminum composite panel industry, and the numbers are still growing day by day.

Know the Best Properties of ACM Panels to Understand Their Value

As told, many companies and manufacturers spend their money on developing factories to create ACM panels. However, customers often want to know the reason behind this large-scale investment. ACP materials come with various advantages that made them famous. The best properties of ACM panels include:

Lightweight Characteristic:

ACM panels are one of the most lightweight construction materials in the building industry. This property of ACP materials makes them the ideal choice for cladding applications. Additionally, compared to other traditional materials such as brick, stone, and even other composite materials, ACM panels are considered the lightest.

High-Quality Surface:

Manufacturers and factories coat and cover ACM panels with two kinds of substances which are fluorocarbon and polyester. These two substances allow developers to create a high-quality product with a perfect surface. Additionally, aluminum composite panels are hard to break and can handle harsh external conditions for decades.

Durability:

One of the best properties of ACM panels is their durability. Every construction material should long last, and ACP manufacturers are aware of that. Thus, with the mix of zinc, magnesium, copper, and aluminum, they create stable products for cladding. This specific advantage of these panels shows up in advertisement projects where durability is in priority.

Fire Resistance:

Modern era construction regulations require so many different properties and factors. One of the common significant factors is the level of fire resistance of the building. Thus, if homeowners use fire-resistance materials, they can benefit from lower taxes. Modern Aluminum composite panels are covered with fire-retardant materials, which make them more fire-resistant products. Therefore, even if the product catches fire, it will not spread to other portions of the facility.

Sound Insulation:

Due to the sound pollution increment in the modern age, buildings require cladding materials to improve sound insulation and provide a more relaxed area for occupants and workers. Aluminum composite panels are the best materials for noise reduction purposes. This property is due to the arc type core in these materials, taking the sound waves and providing acoustic properties.

Thickness:

ACM panels are available in different thicknesses to satisfy any demanding project. Their gauge can be changed equivalent to the customer’s usage. Additionally, the core substance can affect the depth and the width of the panels. The overall thickness of ACP material varies from 3 to 6 millimeters. Generally, for cladding systems, manufacturers produce these materials with a thickness of more than 4 millimeters.

Flexibility:

ACP materials are famous for their flexibility and easy fabrication process. Manufacturers can easily bend, cut, fold and shape them. Thus, designers and architects can create limitless exteriors for buildings depending on the customer’s desires. Even if a piece of ACM is damaged and requires replacement, the homeowner can change only the panel with a problem since it is easy to install.

Among the best properties of ACM panels, other characteristics can be considerably beneficial for the construction industry, including being cost-effective, weather resistance, corrosion resistance, environmentally friendly, flat, and available in various colors and finishes for more satisfying designs.

How to Recycle ACP Materials?

Recycle ACP materials

ACP materials popularity is continuously growing within the construction industry due to its various advantages, including low price, energy efficiency, recyclability, and construction functionality. These materials have a unique design to satisfy renovation and rehabilitation projects in ventilated facades. ACP solutions can adapt to all fields of building and architectural applications. In this article, we will mainly introduce and concentrate on the recycling process of these panels. However, before getting to the process introduction, it is better to know the preliminary information about the characteristics and properties of aluminum composite panels.

Basics of ACP Materials

As it is evident, manufacturers utilize aluminum to produce ACM panels. Aluminum metal is a common element in nature, making it easier to find and extract for further utilizations. This material is located in many silicates, and then manufacturers extract it from the bauxite mineral and apply a complex procedure to obtain pure aluminum. Due to its low density and corrosion-resistant characteristics and being a perfect conductor, it is a suitable element for various industrial processes. Among its typical uses, aluminum materials’ mirror-like appearance helps designers create modern and sleek designs. Thanks to its physical properties, manufacturers can combine aluminum with other materials to produce new products, including ACM panels.

Uses of the ACP Materials

The most common usage of ACP materials is in ventilated facades. These cladding materials feature several layers that stand out for their effectiveness in solving insulation issues and make them a type of coating system for building’s exterior. Due to their physical properties, buildings can achieve efficient thermal behavior. The most notable thing about these ventilated facade systems is that they allow the construction to have a chimney effect between its exterior layers. The chimney effect generates continuous ventilation in the chamber while maintaining a stable temperature, resulting in greater energy efficiency than more conventional cladding systems. Thus, during winter, air circulation slows down and preserves the heat, while in summer, the heat gets evacuated, and the circulating air is renewed.

Recycling Process

The ACP materials are entirely recyclable, and despite their cost, the manufacturers of the world try their best to recycle these materials and not to throw them away directly. The high inherent value of aluminum materials is a significant economic stimulus for its recycling. Aluminum composite panels scarp can repeatedly be recycled without decreasing their value or diminishing their physical properties. Additionally, the energy that manufacturers utilize to complete the recycling process is a mere fraction of primary production requirements. The process involves a few but essential steps and requires machines to meet the recycling procedure. The method of aluminum composite panels recycling working as follows:

Crushing: The first step of recycling is cutting the aluminum composite panel into smaller pieces. This is done to provide easier workflow due to the large size of these panels. Without cutting ACP materials, there is no way to start the recycling procedure.

Grinding: Due to the perfect adhesion between the aluminum and the core material which holds the panels together, it isn’t easy to deal with these pre-cut pieces of ACPs. Thus, it is essential to grind these tiny particles into powder by utilizing special grinding machines to make them easy to separate.

Circulation Water Cooling: It is crucial to note that the grinding process can generate considerable heat which will lead to burning some pieces, resulting in reducing the separation rate. Thus, manufacturers utilize a circulating water-cooling system to reduce the temperature during the grinding stage of the panels.

Sieving Stage: The sieving stage, which features a vibrating screen, involves sending the small pieces without grinding them back to the grinding mill for further grind process. The produced powder will follow its process by continuing to the next stage.

Electrostatic Separation: The last step of recycling the ACM panels is utilizing the electrostatic separation method. According to the different conductivities between the core and aluminum, the electrostatic separator can easily divide the core material from the aluminum composite materials.

Machines Used for Recycling ACP Materials

Waste aluminum composite material is the most valuable raw material to recycle for complete PVC and high productivity characteristics. One of the machines used for the purpose is the recycling machine named YX-800, a device with a high handling property. This machine is mainly used to process and recycle scrapped ACM panels that often come from old outside walls of buildings, decorative panels for interior walls, notice boards, billboards, renovation, and portable house projects.

Things to Know about Aluminum Composite Panels Installation

Aluminum Composite Panels Installing Methods

Aluminum Composite Panels are popular external cladding products that are widely used in modern architecture and buildings. They are also used as the internal surface designing and coating material. To ensure that these products fit correctly into the design of the construction, they need to be fabricated precisely and then installed in various methods. Almost all of the methods utilized in the industry for this purpose are approvable. Before installing ACM panels, some prior action needs to be taken, considering thermal contraction and extraction, removing the protective film, and defining the process direction.

Thermal Contraction and Expansion

Change of temperature can lead the ACP fasteners into intolerable overstressing and bowing. Thus, to avoid this type of damage, heating the construction work and ambient air process must be considered. It is essential to know that aluminum composite panel has a coating system, damaged if the temperature exceeds 100-centigrade degrees. This means that the thermal resistance of the material must be modified before installation.

Removing Protective Film

Generally, aluminum composite panels’ manufacturing company leaves a non-transparent protective film for covering the material before leaving the product line. Humid ad hot weather conditions can make the film’s residual glue stick onto the lacquered surface of the ACP. Thus, removing the protective film as soon as the material reaches the construction site is necessary. After the removal, it is essential not to use a marker pen or tape on the coated surface. Particles such as acrylic, rubber, and epoxy can be very harmful to coating integrity.

Aluminum Composite Panels Process Direction

It is crucial to install the ACP materials in the predefined direction, whether horizontal or vertical. Manufacturers apply the paint finish in one consistent order. Thus, for maintaining the finish and the color across the panels, each ACM panel must course in the correct direction. Identifying the path is not so hard. The protective films are being developed, having an arrow on them, which defines the proper installing order and the applied finish. Builders need to install all the panels in the same direction throughout a construction project.

Aluminum Composite Panels Installation Methods

After the preliminary preparation steps, it is time for the installation process, which can be done utilizing many methods. Here are some of the most common ACP installation methods in the industry.

Hanging Method for ACP

One of the most common ACP installation methods is the hanging method. This installing system can simplify the procedure, and as a result, it shortens the construction period. In this system, panels are not fastened tightly to the mainframe and are suspended. Thus it is easy to loosen the movement of thermal expansion and contraction. The hanging installation system must follow the steps below.

  • The design of the facing is defined relative to the axis of the construction. The ACM panel skeleton consists of vertical and horizontal pieces. The vertical rod should be fixed, followed by the anchor point determination of the vertical frame.
  • Then installing the fixed connection part of the basis of the pay-off line is required, followed by an electric welding fixture. Thus, the connection partition is welded to the embedded domain.
  • The welding frame is utilized to take the main skeleton on it. This step of installation includes checking the elevation and center lining the position. Additionally, the cross-section weld should be treated as anti-rust paint. Then the quantity, height, and depth of the insertion will be set.
  • The last step is to install the Aluminum panel on the inner frame of the profile using the screw holes and fixing them to the steel frame block with particular supplies such as rivets. The boards need to have 10-15 mm of a gap and be injected with silicone-based material for sealing purposes.

Wet Sealant Joint

Another renovation and modern method for aluminum composite panels is using wet sealant joints. This method includes applying appropriate sealing material to the joints to ensure water-tightness and prevent water infiltration into the building structure. Followings are the six steps that need to be followed in a wet sealant joint installing system.

  • Choosing an hourglass-shaped sealant is essential, and the width should be twice the depth of the gap.
  • The backer rod diameter is generally 25% larger than the central joint, which needs to be filled.
  • Joint sizes are typically designed to be four times greater than the expected movement.  
  • The sealant is not made of caulk, and it should never be tooled with a finger. Choosing the right tool is always a priority.
  • Then, preparation for sublayers is necessary.
  • Applying wet sealants under average temperature is recommended. This is due to the expanding and contracting characteristic of the joints.

Dry Gasket Joint used in Aluminum Composite Panels

There is another installing method for ACP materials instead of wet sealant joints, including dry gasket joints. This method is durable and can reduce the amount of strain and dirt on the panel’s surface. The process will be completed by doing the following 11 steps.

  • Inspecting the gasket to ensure the absence of defects and checking if it has clean cuts with no rips or tears is essential.
  • The gasket should be placed between the panels with precision.
  • Avoiding applying to release joint compounds on the surface of the gasket is needed.
  • It is familiar to insert 2-3 bolts through connecting panels to reduce the damages and pinches.
  • Load bearings need to be coated with lubricants considering many factors such as particle types, sizes, and temperature.
  • Consulting with the gasket manufacturers is vital in defining the torque values that need to be applied to the nuts.
  • The most efficient way to tighten nuts is by utilizing a cross-bolt pattern and multiple tightening rounds during the ACP installation procedure.
  • The nuts need to be tightened by hand but generally with 20 percent lower torque than the recommended amount.
  • Each nut will be torqued 30 percent of the predefined torque amount.
  • The last step needs to be repeated by applying 40% torque until 100% of the maximum torque is approached.
  • Finally, involving at least one final maximum torque to all nuts is needed to place all nuts in a uniform torque.