What are Nano Aluminum Composite Panels?

Nano aluminum composite panels

Nano aluminum composite panels (ACM panels) are among the newest building materials available in the market, with various advantages. Currently, nanotechnology is creating an industrial revolution noticeable in all aspects of the modern life system. Manufacturers started applying this technology to aluminum composite panels and other construction materials to solve their drawbacks and grow their usage in current architectural projects. The nano-aluminum composite panel features all the previous advantages of the ACM panel, such as anti-scaling, durability, functionality, anti-corrosion, etc.

Nano Aluminum Composite Panels Applications

The traditional aluminum composite panels (ACM panels) are still one of the materials that are commonly used for various structures, products, and building claddings. The construction industry highly welcomes materials such as ACP materials due to their flexibility, versatility, lightweight, and other beneficial characteristics. However, constructions with aluminum composite panel cladding systems face numerous limitations and sensitivities. Cleaning and maintaining the building’s facade is an essential task for both low-rise and high-rise facilities. Thus, the building facade and its clean appearance involve maintenance and the facility’s value as a whole. Moreover, this becomes more crucial for larger and polluted cities.

Nano ACM panels have come to solve the cleaning and maintaining problem. The technology allows cladding systems to clean the aluminum surfaces of the facade on their own without requiring any particular chemical or unique methods.

How Nanotech Works in ACM Cladding Systems

The water droplets on the plant leaves or the ones on a greasy surface are generally spherical, and they are always separated from the surface. This natural event means that the surface is probably dry, and water molecules are attached to form the spheres. This happens due to the physical properties of any substance. Thus, science has divided surfaces into two general classifications, which are hydrophobic and hydrophilic.

The hydrophilicity of a substance’s surface means that the molecules of a particular amount of water tend to depress the area. Thus, water molecules form a narrow-angle or say the droplets’ height is low. In contrast with hydrophilicity, water particles on a hydrophobic surface tend to bond to each other rather than the material. In this case, droplets form a prominent sphere with a broader angle, and the height of the particular amount of water is higher. Additionally, hydrophilic surfaces feature high energy, and in contrast, hydrophobic substances have low energy surfaces. However, with the knowledge of nanotechnology, the physical properties of any surface can be transformed into a selective character. Thus, with the growth of technology, it is possible to create hydrophilic surfaces and change their properties.

Textured surfaces made in another nanoscale feature a greater distance between the air and molecules. This can cause hydrophilicity decrement on the surface, and water droplets will stick to more together than the desired surface. The same can happen with nano aluminum composite panels as water drops do not spread on the surface of the ACM panel and stick to each other. As water drops move on the cladding system, they will absorb the dust or strain and pass through the building facade. Thus, the nano aluminum composite panel’s surface gets cleaned thoroughly without extra cleaning chemicals applied. Additionally, the nano-coating existing on these cladding systems makes it difficult for the dirt and dust to adhere to the ACP surface, resulting in solid stains on the building facade execution.

It is essential to mention that Aluminum composite panels are low maintenance materials naturally, and even with nanotechnology, it is possible to clean them with detergents and cleaning tools. Aluminum sidings and ACM panels cladding systems do not require special equipment for cleaning. The crucial thing about nano cladding materials is that it makes the cleaning process much easier for high-rise buildings.

Advantages of Nano Aluminum Composite Panels

As nano aluminum composite panels have auto cleaning, they bring essential benefits for the building’s owner, which are as followed:

  • Homeowners can save money and energy by using nan ACM panels.
  • The building’s facade will last longer than other cladding materials.
  • The construction and its facade maintain its appearance, resulting in preserving the building’s value, prestige, and overall status.

Like any other composite material, Nano ACM panels consist of various layers, including the core or central layer, the front, rear cladding sections, and finally, the coating surfaces. The modern tech coating is applied to the last layer of the products. The final layer serves the cladding systems as a protector against different elements, including:

  • Urban pollution
  • Oil
  • Wearing over time
  • Sun rays
  • Harsh weather conditions
  • Acid rains
  • Alkaline substances

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.

How do you paint ACM panels?

Paint ACM Panels

ACM panels are modern and practical cladding materials currently used for various applications, including commercial and industrial building projects. Due to the wide range of ACM panels advantages, from extreme weather durability and minimum requirements for maintenance to aesthetics and modern appearance, architects and builders prefer to use them instead of traditional building cladding materials. However, for many reasons, which we will discuss in the next paragraph, one of the most critical questions for aluminum composite materials is how you should paint ACM panels.

Aluminum composite panels often offer a longtime service which can sometimes exceed 20 years if maintained properly. However, customers may encounter minor damage or peeled paints on the cladding material when buying a home with ACM material for its facade. The good news is that by utilizing proper painting supplies and particular substances, resurrecting these metal claddings will not be challenging, and such issues should no longer be a concern. Thus, it is more cost-effective to paint ACM panels rather than replacing them or reinstalling a new board. The paint finish recovering process is considerably straightforward, and most homeowners can take care of it without any need for professionals.

Equipment and Tools Needed to Paint ACM Panels

Some essential equipment and tools are needed to paint ACM panels with the best quality, resulting in more durable finishes and better aesthetics. These tools and equipment are including:

  • Primer with an Oil Substance: This is used for sealing any porous surfaces, and it will allow the paint for better coverage of ACM panels.
  • Acrylic Paint: For better paint bonding on the cladding material, it is practical to utilize exterior acrylic paint.
  • Brushes with Synthetic Fibers: When working with acrylic brushes, it is essential to use synthetic fiber brushes to paint ACM panels.
  • Lambswool Roller: For having a smoother paint finish and maximizing the surface area coverage, utilizing a lambswool roller can be helpful.
  • Simple Ladder: Use a ladder to reach and access the higher sections of the cladding material.
  • Plastic Bucket: The painter can hang the paint bucket from the ladder during the process, increasing the work speed.
  • Plastic Paint Trays: It is necessary to utilize plastic paint trays for lambswool rollers.
  • Drop Cloths: It is essential to keep the painting area clean with drop cloths during the job to avoid splattering the paint on the floor, which will be difficult to remove.

ACM Panels Painting Steps

There are a few yet essential steps to take when considering painting ACM panels without asking for help from experts. These painting steps are also practical for other cladding materials, including Aluminum sidings. Each phase has its particular role, and to paint ACM panels, the painter should follow them precisely.

Step One: Preparation for Painting ACM panels

Preparing aluminum composite panels for painting starts with scraping off paints that are already damaged or peeled with a scraping tool. Then the painter should remove any mildew with ten-part water to one part bleach combination. If the ACM panel is dingy, it is recommended to rent a power sander and sand down the cladding.

Step Two: Applying the First Coat of Primer to Paint ACM Panels

The second phase to paint ACM panels involves creating a first coat of primer when the weather is mild and dry for preventing different factors such as rain and debris from destroying the paint finish. Using a paint-roller will make the process easier, and it can apply the primer evenly while taking a few seconds per 0.09 meters. Additionally, it is essential to use the first coat in only one direction for maximizing the dry time.

Step Three: Adding a Second Layer of Primer

After applying the first coat of primer, the painter should add the second layer after the first layer is dried thoroughly. Generally, primer takes about four hours to dry. Thus, it is more efficient to start the process accordingly.

Step Four: Start Painting the Cladding Material

The most efficient way to paint ACM panels is to do the process from top to bottom by using long and even brush strokes. For better results, it is recommended to paint the aluminum composite panels in the same direction as installed, whether horizontal or vertical.

Step Five: Applying the Second Coat of Paint

After the fourth step, it is essential to wait about two hours to dry and then apply the second paint layer. This phase will help the painter correct any flaws that occurred during the cladding material painting. Buying an extra gallon of paint is practical for additional touchups.

Step Six: Inspect the ACM panels to Find Issues

Once applying both layers of paint is finished, the paint-finish must be left to dry for at least 3 hours. Then it is crucial to inspect the work for missing spots, drips or bumps. If there is a sign of the old ACM panel finish notable beneath the new finish, the painter should apply one more paint coat.

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 Strong Is Aluminum Composite Panel?

aluminum composite panel

The aluminum composite panel is an industrial building product that is practical for cladding and facade applications. The building facade is the first element people notice when they see a construction, including home and commercial facilities. Every building design should have a unique soul, and it must represent the owner and a specific brand. Most of the facilities in the modern era have a perfect plan and soul, and due to the availability of different materials, architects can expand and improve their designs equivalent to the needs of the current time. However, products made from materials such as wood and steel are not very easy to work with for better creativity. Additionally, these materials have drawbacks such as fading of paint and heavyweight, making them challenging to install and maintain long-term usage.

Due to the growth of architecture ad modern materials, it is easier to have creativity when designing a facility. One of the practical substances which relieve the overall process of creating claddings is aluminum. Utilizing aluminum composite panels is an efficient way to add a modern touch and elegance to a building by producing shapes and patterns that were not easy to create decades ago. They are elegant, stylish, and easy to work with, but they have a wide array of benefits and advantages for which landlords and building owners must consider using them. The following are the primary characteristics that make ACP materials strong and efficient for any construction project.

ACM Panel is a Perfect Material with High Durability for Creative Solutions

Manufacturers can create shapes and designs with aluminum composite panels that are harder to produce with other facade materials. These panels will help architects and builders to create a look that is aesthetically pleasing and highly functional. Every construction material has to have high durability, and by combining it with zinc, copper, and magnesium, aluminum can become very durable and robust. Aluminum panels can be cut, drilled, bent, perforated, folded, and fabricated without losing their fundamental integrity. Due to the flexibility and durability of these materials, they have become ideal choices for all types of projects which require almost thirty years of life span.

Aluminum Composite Panel is a Strong and Lightweight Product Comparing to Other Composite Materials

Aluminum Composite panels are among the classification of the lightweight material while being extremely strong, making them perfect for cladding systems. Compared to steel claddings, aluminum is 66% lighter, a perfect and suitable alternative for architects who used to utilize steel for their projects. Most manufacturers compete to create more robust and lighter ACM panels to provide for contractors or building companies.

Low Cost of Maintenance

The cost and effort of maintaining ACP cladding systems are almost nonexistent compared to wood, steel or solid walls. If the construction project is located in a rural area, aluminum composite panels can receive a cleaning process twice a year; they should be cleaned once a year for urban areas. In low rainfall and coastal zones, once a year is appropriate. However, if the material exists in heavily industrialized areas, twice a year will do the job. Additionally, the cleaning process for aluminum composite cladding is relatively easy. For removing the soil, cleaning experts must use water rinse with moderate pressure, and in the worst case, other chemical solutions can clean the material thoroughly. It is essential to contract and consult with a distributor or contractor before considering hiring a cleaning expert for the cladding.

Cost-Effective Solution While Being an Efficient Material

Due to the very light characteristic of aluminum composite panel, there is no need for many fixing points, which lowers the labor and material cost and makes them a cost-effective solution for a building facade. Additionally, the installation and fabrication methods are easy for these panels resulting in lower maintenance and labor cost.

High Functionality of Aluminum Composite Panel

Manufacturers create a large variety of aluminum composite materials for cladding systems and panels while providing efficient functionality and suitable characteristics for building standards such as thermal, sound, and wind insulation, earthquake safety etc. Some of these functional properties lower the energy cost for the building owner. Other characteristics are anti-graffiti and easy cleaning, corrosion-resistant and recyclability.

Corrosion-Resistant Characteristic

ACP materials receive a pre-treating process for having a protective film to keep allowing them to have corrosion-resistant characteristics. However, aluminum panels themselves creates a thin layer of oxide when exposed to air, making the facade resistant to rusting and damaging. If the building is located in some extreme humid location, a special coating and maintenance are required to protect the product from further damages.

Non-Combustible Aluminum Composite Panels for Construction

Some of the aluminum composite panels are classified as non-combustible materials for construction while respecting fire-resistant standards and regulations. When exposed to a temperature as high as 600 degrees Celsius, aluminum melts, but the essential thing is that they are inflammable. As a result, these materials are environmentally friendly construction products that do not generate toxic gas even when a fire occurs.

How to Make Aluminum Composite Panel?

Aluminum Composite Panel

Aluminum Composite Panels, which are also called ACP materials, are popular construction products that are widely used in modern building architecture. These panels are not just a reverberation for interior or exterior designers and architects but also are beneficial for the environment. They are considered new sustainable materials known as sandwich sheets and brought new fields to the architecture. This means the composite panels do not just increase the durability of modern buildings but also contribute making the whole world sustainable and cleaner. Thus, using them has been expanded in the last few years to cover up energy efficiency and low price possibilities. Additionally, they are specially created for the ventilated facades rehabilitation and renovation.

Obtaining Aluminum from Nature

Aluminum is one of the most common elements found in the mother earth’s crust. However, the pure material that is used for developing different industrial products such as ACP does not occur naturally. Thus, there is a standard process defined for obtaining the usable material. This process is broken down into three main stages, which are extracting bauxite, turning them into alumina, and then producing pure material using electrolytic reduction. Bauxite, which is found naturally on the surface of the ground, contain aluminum in their structure and is made up of aluminum oxide mixed with other elements and minerals. Experts extract this material by using open-pit mines. For turning the material into alumina, a common process, which is called Bayer, is utilized. The produced alumina has an unlimited shelf life.

However, it should be stored under precise conditions due to its property of absorbing moisture. After this process, for creating the pure material, another component is required for creating the best environment for electrolysis, which is called Cryolite. In modern manufacturing systems, it is made by mixing up aluminum hydroxide, soda, and hydrofluoric acid. The last stage of producing pure aluminum is the electrolytic reduction, which requires an area for smelting the material. This area consists of many large rectangular constructions, which have a length that exceeds one kilometer. Inside these buildings, there are hundreds of pots or cells arranged in rows, which are connected to power sources through massive cables. In each of these cells, pure aluminum is being developed from alumina. The material is extracted from the cell by using a special vacuuming bucket for two to four times per day. A hole needs to be created in the cryolite and then the liquid aluminum is sucked into the bucket through a pipe connection.

Production of Aluminum Composite Panels

Aluminum composite panels can be produced in different methods and ways. The production procedure can be divided into two methods of cold composite and thermal composite. These two can additionally be classified with continuous and intermittent methods. ACM is generally manufactured by joining thin aluminum skins to both sides of a lightweight core, which is typically thermoplastic.

The production process of aluminum composite panels starts with cleaning the coil material. This material, during its creation, due to the needs of the process, is coated with anti-oxides and lubricants, thus a speck of considerable dirt and dust will be attached to the material during transportation. This can affect its adhesion thus precise cleaning is required. After coil cleaning and chemical treatments, a dense protective film starts to form on the surface of the material. This coat can improve the oxidation resistance of the panels and will increase the lifetime of the paint finish.

The produced panels of exterior composite sheets are coated with two layers of primer and paint. The top layer of the cladding materials is an extreme weather-resistant fluorocarbon, which has, resin substance and called polyvinylidene fluoride. This coat keeps the surface of the product protected due to its ideal UV resistance and environmental pollution characteristics. In addition, the surface can have beautiful marble color and pattern, which makes it perfect for creating modern architectural designs. The fluorocarbon substances are usually applied to the coils by roll process and then baked at lofty temperatures for drying. The last layer of coating is a varnish surface and this creates a total thickness of 30 micrometers. Each of these layers must be baked and dried at 200 degrees of Celsius for almost 60 seconds. After the drying process, the heating oven must be cooled by an air cooler. The interior wall paint is generally made of polyester, epoxy resin, or acrylic. It is important to have precision during installation and transportation for preventing any further damages on the product such as surface scratches.

The protective film, which is a self-adhesive material, needs to be removed after the installation procedure. Then, the aluminum coil, which is coated with fluorocarbon resin, can be compounded with the core material. This material is also a three-layered substance that contains adhesive on both sides and PE plastic in the middle section. In the case of Alpolic materials, the core portion can be either a proprietary mineral-filled, fire-resistant, or polyethylene material. In both cases, the standard layers will be produced in 0.5mm thickness. Some Heavy-duty skins that have 0.8 thicknesses are also available on the market. The completed ACP material is available in 3mm, 4mm, and 6mm thickness that the last one is the most used thickness for the building industry. However, there are some custom sizes available for special demands.