There is one thing we can all agree on within the construction industry, and it is that the popularity of aluminum composite panel has not stopped growing over the past few years. Its use has been expanding under the cover of energy efficiency, low price and construction possibilities.
This type of material is specially designed for the construction of ventilated facades, their renovation or rehabilitation. It provides solutions that can be adapted to all fields of architecture.
In this post you will know everything you need to know about the composite panel, how it is produced, its main characteristics, finishes, transformations and its most popular uses.
Aluminum is the third most common element found in the earth’s crust. In its natural state it is found in many silicates, and is extracted from the mineral known as bauxite, a sedentary rock with a high aluminium content.
As a metal, its low density and resistance to corrosion, in addition to being a good conductor, make it an extremely useful element for many industrial processes.
Currently, with China leading the way as a producer, it is estimated that around 60,000 metric tons are produced annually, 20% of which are recycled
Among its usual uses, and it could looks incredible, is the manufacture of mirrors (thanks to its optical properties), containers and cans or, of course, as aluminum foil for domestic use. It has multiple standards of alloys that fit to sectors as diverse as the automotive industry, telephony or construction.
Aluminium can be easily combined with other materials to produce new materials such as those used in briks or in the composite panel.
STACBOND composite panel is composed of two aluminium sheets and an inner thermoplastic base core that can hold mineral charge.It is specially designed for new construction ventilated facades as well as for renovation or rehabilitation. Its manufacturing standard is composed of an outer sheet of 5005 aluminium alloy and an inner sheet of 3105.
It is divided into two groups depending on the mineral load of its core and can be incombustible or fireproof and (according to UNE 13501-1:2007) classified as A2-s1, d0 and B-s1, d0.
The composite panel is produced by a continuous lamination process, in which a sheet of the material that will make up the core is extruded and compacted between two aluminium sheets that are unwound at the same time. Finally, the flatness of the material is compacted and perfected and a protective film is applied.
As I told you before, its most common use is in ventilated facades, a type of coating system in several layers that stands out for its effectiveness in solving the buildings insulation, thanks to the thermal behavior that the facade achieves.
The most curious thing about the ventilated facade is that it allows the creation of a chimney effect between its layers. This chimmey generates a continuous ventilation in the chamber, maintaining a stable temperature that results in greater energy efficiency compared to more conventional systems. Thus, during the summer, the heat is evacuated and the circulating air is renewed. In winter, air circulation is slowed down, preserving the heat.
Since the aluminium composite panel began its journey in the construction sector, its characteristics have been improving until it has become a highly modifiable product, which admits different forms of assembly, colours, transformations and uses.
As an example of its great versatility, we can find it in both minor works and interiors, combined with other materials to cover certain areas of a facade or as the main element in complicated transformations.
Among its properties we find:
As a material, the composite panel does not present deformations in its dimensioning, whic means that the material remains stable whatever its size without losing its properties
The wide range of finishes that the composite panel allows gives it a great aesthetic versatility. From solid to textured, mirror or wood type finishes, the composite panel can be adapted to almost any type of project
Recent studies confirm the durability of aluminium in building facades due to its long life and resistance to wear and corrosion
The core material and cover sheets of aluminum composite panel can be recycled and reused. Due to its characteristics, aluminium can be recycled indefinitely
The hanging systems for the assembly of aluminium composite panels are designed to facilitate their assembly on facades in a quick and easy way. In the same way, in case that a cassette is damaged, it is easily replaceable
The low density of aluminium makes it the ideal material for substructure systems on ventilated facades
Depending on the finish that is sought, the panel can receive multiple types of treatments and coats. Among the most common finishing paints there are:
It is the most popular finish for architectural applications. In a 70/30 proportion of resin it has a higher folding capacity, as well as a better resistance to ageing and protection against UV rays.
FEVE is a type of coating with a very similar structure to PVDF, but with greater hardness and less flexibility. It allows to achieving a greater gloss range.
HDPE paint, on the other hand, allows a high range of gloss and some special finishes such as textured surfaces.
The aluminium composite panel allows a large number of different finishes. In addition, it can be adapted to any colour from the RAL colour chart. Over time, special finishes have been added with texture effects, imitating wood or concrete, or iridescent with special lighting effects.
The solid finishes are homogeneous and hardly suffer the variation of their tonality with the incidence of light. They provide a sensation of solidity to the facade and are easily combined with other finishes.
Metallic colours, very similar to those used in the automotive sector, vary their shade with respect to the incidence of sunlight and are very popular for large facades and outstanding projects.
Textured effects, matte or high-gloss surfaces, iridescent and wood finishes are some of the special finishes. To them we are constantly adding the new technology advances.
Currently, aluminum composite panel can be transformed in many ways. Among them are punching, which allows the creation of pointy-type shapes on the surface of the panel, creating drawings or forms; roller bending, to achieve curved shapes; CNC stamping and engraving to create reliefs; 3D shaping to project volumes on a flat surface, etc.
This transformation capacity of the aluminium composite panel gives it a plus of versatility in order to being used for constructing risky and creative designs.
It also makes it an ideal material to combine and make the areas of the facade which would be impossible with other kind of materials.
Beyond the usual picture of a ventilated flat facade, we see how the panel can be used for other more striking projects and risky designs that contribute to give a special character to the buildings.
Let’s see it in a little more detail:
The composite panel can be punched and die-cut with CNC. The result ranges from the creation of pointillist or artistic style patterns to complicated and detailed drawings on the facade
There are three types of edging:
The panel can be easily bent following the minimum necessary bending radii. To do it, it is best to use bending machines with 3/4 rolls.
By bending the product, columns can be covered, concealing the corners with a rounded appearance, etc.
With more limitations than the previous transformations, we find that in the panel, through modifications in its depth, it is possible to make engravings creating forms without having to get to cut-die the panel
The 3D forming process, besides of being used to manufacturing aluminium composite panel for hanging systems, can also be used to create projected three-dimensional surfaces
The milling of the panel gives results that differ from other types of processing such as punching and, of course, from the usual conception of the composite panel as a cassette-type tray. It can be made with CNC, with a wall saw or a portable one. The partial milling of the panel allows the subsequent folding of the pieces to give them creative shapes
Depending on the composition of the interior mineral core of the composite panel, it will have some proper characteristics. For example, it will have a greater resistance in case of fire or a special malleability, a very useful aspect when making creative transformations of the facade.
As has happened with the types of finish, as technology is moving forward, the composite panel has also developed new mineral cores that give it special resistance and make it more adaptable to what conditions.
The FR (Fire Retardant) type panel, on the other hand, contains an interior fire retardant core made of thermoplastic resins with mineral charge.
Its reaction to fire classification B-s1, d0 (according to UNE EN 13501-1:2007), makes it a coating material that fulfils most of the architectural applications
In the case of the A2 panel, this is a non-combustible panel composed of a mineral core developed to meet the highest regulatory requirements of fire classification
Its reaction to fire classification A2-s1, d0 (according to UNE EN 13501-1:2007), makes it the ideal cladding solution for high-rise buildings and high occupancy.
Aluminium is widely used in architecture for its innate qualities and its malleability which, combined with different treatments – such as continuous anodising -, makes this metal ideal for various applications. Lightweight, resistant, elegant and eco-friendly, anodised aluminium for architecture and construction is supplied in sheets and coils, which can take an infinite number of shapes. Find out how to choose the most suitable materials for your projects, depending on the functions they have to perform.
Aluminium panels and aluminum sheets can be easily customised to fit a project. The material is easy to work with, so it can be bent, curved, moulded and roll-shaped, to name a few.
Even if we only think about products strictly related to architecture and construction, we can easily see that aluminium is used in various applications in these industries such as:
For their many uses in architecture and construction, aluminium sheets can also be coupled with other materials to create different types of panels. Aluminium panels can feature various backings, such as continuously produced aluminium composite panels (ACP).
This type of panel consists of two thin aluminium sheets bonded to a non-aluminium core. The core material can be made of polyethylene (PE), polyurethane (PU), or fire-resistant (FR) mineral core, for example. This unique sandwich structure gives aluminium panels exceptional strength and durability while maintaining a lightweight profile. Composite panels made by anodised aluminium allow for increased rigidness and mechanical strength of the panels and can be integrated with many building systems. The anodised layer also protects the material from corrosion and ensures long-lasting durability.
When thinking about aluminium sheet designs there are several factors to consider, but also numerous opportunities in terms of choice.
There are, in fact, different types of aluminium (or aluminium alloys).
Alloys are created by blending two or more metals to enhance desirable characteristics such as increased strength or higher melting points. Different aluminium alloys and different treatments allow to create optimised surfaces for the needs of a specific application in terms of resistance, corrosion, combustibility, reflection, but also colour.
For example, the alloys of the 1000 series – which have an aluminum content of 99% or higher – are particularly suitable for creating specular panels which can be used in interior applications for their pleasant and elegant visual impact, or as a substitute for glass surfaces as a less fragile alternative.
The 5000 series alloys, on the other hand, are widely known for their exceptional resistance to corrosion, remarkable versatility, moderate strength, and weldability, and are used for both indoor and outdoor applications.
The treatment to which these aluminium alloys are subjected plays a key role in the development of the panels, as it allows various characteristics of the metal to be enhanced, as well as conferring additional properties necessary for the application or, for example, to comply with regulatory requirements.
Aluminium anodising is a process used to enhance the surface properties of aluminium by creating a protective oxide layer that protects the material both from external agents and scratches or abrasions. The thickness of the layer may vary depending on the application for which the material is intended to be used.
One of the additional benefits provided by the oxide is the possibility to colour the surface, thus adding aesthetic value, and giving it optical properties, that raw aluminium does not have or that need to be optimised, such as heat exchange properties in ceilings for air conditioning.
Depending on the properties that the surface must have, the colour of the panel is also a factor to consider. The treatment must therefore be adequate not only in terms of the thickness of the oxide layer, but also in terms of the colour pigments that will be deposited during treatment. For example, brighter colours (blue, red, green) are suitable for interior applications, while gold, bronze and black tones can also withstand outdoor environments.
Architectural aluminum panels offer numerous benefits. They are widely used in the construction industry due to their remarkable properties, making them a popular choice for architects, contractors, and builders alike.
One of the key advantages of using architectural aluminum panels is the fact that aluminum is a lightweight material, which makes handling and installation much easier and more cost-effective. This characteristic is particularly beneficial when constructing large buildings or structures where weight considerations are crucial. The reduced weight also allows for faster installation, saving time and labour costs.
Versatility is another key advantage of architectural aluminum panels. These panels come in a variety of finishes, colours, and designs, allowing architects and designers to create visually appealing and customised structures. Whether they are seeking a sleek and modern look or a more traditional and textured appearance, aluminum panels offer a wide range of options to suit any architectural style or preference.
In addition, aluminium cladding sheets and panels offer a valid solution in those applications where fire resistance is required. Aluminium, in fact, is a non-combustible material, meaning it does not catch fire or contribute to the spread of flames. This makes it an excellent choice in fire-resistant applications, as it helps to limit the potential for fire to spread.
It must be remembered, however, that even in this case, the treatment process leading to the final panel is crucial for achieving the desired characteristics. Composite panels, in fact, often integrate other materials, such as wood, with the aluminium. Therefore, even if aluminium is not combustible, it does not mean that the panel itself is not: it is the choice of the materials that will constitute the panel that makes the difference.
Furthermore, aluminum panels are highly sustainable. Aluminum is a recyclable material, and using recycled aluminum in the manufacturing process reduces energy consumption and greenhouse gas emissions. This makes aluminum panels an environmentally friendly choice, contributing to sustainable construction practices.
Durability is another significant benefit of an aluminum panel system. These panels are highly resistant to corrosion, making them ideal for both interior and exterior applications.
They can withstand harsh weather conditions, including rain, snow, and UV radiation, without deteriorating or losing their structural integrity. This durability ensures the longevity of architectural aluminium panels, reducing the need for frequent replacements or repairs.
However, as we have previously mentioned, not all panels can be used both indoors and outdoors. For example, materials for interior use do not need an excessively thick oxide layer because they are not exposed to environmental elements, while exterior panels must have the appropriate thickness of oxide to protect the material so that to guarantee the aesthetic appearance over time.
In addition to durability, another characteristic of aluminum panels is the fact that they require minimal maintenance. Unlike other materials, such as wood or steel, aluminum panels do not rust or rot. They can be easily cleaned with water and mild detergent, making them a low-maintenance option for building exteriors. This saves both time and resources in the long run.
Now that we have talked about aluminium types, alloys, properties, and factors that should be considered when choosing to use aluminium, let’s look more closely at a few common applications and advantages of using architectural aluminum panels and systems.
Among the different uses, aluminium panels are widely adopted for false ceilings. The material is especially suitable for ceilings, both for its lightweight, much lower than steel or copper, and its qualities which make it ideal for virtually infinite designs and, even more, make it perfect for air-conditioned spaces.
The air-conditioned ceilings are based on the radiation effect principle: cooling/heating coils are hidden behind the climate control panel that performs as a heat exchanger. This way, these particular panels end up looking like any other suspended ceiling panel.
Among the other features that make aluminium panels suitable for false ceilings, one of the most important is, of course, aesthetics. The different heights can be hidden with the aluminium panels, and the building infrastructures, such as piping, wiring and ducts, lighting systems and sprinklers, can be integrated, thus hiding them from view. Acoustical properties make perforated aluminium panels suitable for spaces where noise control is essential, with or without a rear absorbent core. The aluminium surface finishing reflects light, both natural and artificial, and can be used to improve lighting efficiency, thereby increasing the comfort of interior spaces.
Many furniture items are made of aluminium panels that, due to their qualities, are suitable to be coupled with different materials, such as MDF, HPL, or feature honeycomb backing, in order to get high-efficiency performance. The aluminium composite panels thus obtained can be used for vertical elements, such as doors or sides. Composite anodised aluminium is also perfect for the side panels of drawers, that house the sliding guides. The many finishes and colours available for anodised aluminium allow designers to project in a creative way many different interior design styles.
Anodised aluminium, besides being a material with unique aesthetic requirements, features excellent fire resistance. The anodised layer makes it resistant to corrosion, rubbing, and extends its life. Easy to maintain, it is non-toxic and contains neither volatile organic compounds (VOCs), nor formaldehyde, paint, or lacquer. Moreover, it is virtually infinitely recyclable without loss of quality.