The construction industry has seen a steady shift from traditional building materials such as concrete and steel to sustainable alternatives that reduce the depletion of limited natural resources, use less energy to produce, have lower carbon footprints, and generate significantly less waste once they’re repurposed.
Beyond recycled plastics, government initiatives and public awareness have cemented the acceptance and use of low-carbon and self-healing concrete, mass timber, bamboo and engineered wood products, and green alternatives like compressed Earth blocks or Hemp Crete. A newer addition to this list is an aluminium composite panel or ACP.
Breaking Down Aluminium Composite Sheet – Layer by Layer
Low in weight, high in strength, flexible and versatile for various applications, the favourable properties of aluminium composite panels is down to the multi-layered structure and mix of composite materials. At the heart of each panel is the polyethene or mineral core, determining the material’s structural integrity, and resistance to external factors such as heat, impact, wind and rain. The core is covered in thin layers of adhesive film on either side, allowing loads to be transferred between it and aluminium coils.
These are the main structural elements of any aluminium composite sheet, providing strength, flexibility and malleability for a range of applications. Coils are protected from oxidation and rusting by a protective passivation coating along with a PVDR primer paint that shields coils from exposure to sunlight, moisture and heat.
For colour, texture and panels customised to suit construction, signage and other applications, panels also include a polyvinylidene fluoride paint base coat, either in a gloss or matte finish. Lastly, the outermost layer is a protective polyester paint to ward off dust, water and pollutants and maintain the aesthetics and overall structural integrity of the panel.
Long List of Favourable Properties
The composite, layered structure of of aluminium or ACP sheet means a wide range of benefits, across varied uses:
- Durability – the building material is weather, heat and impact resistant. It resists fading after longer exposure to direct sunlight, the protective layers prevent corrosion and discolouring and many panels are fire-rated to meet strict building regulations. Moreover, ACP retains structural integrity and won’t warp or deform in extreme weather conditions.
- Bendable – sheets can bend and conform to both convex and concave surfaces, reducing the need for additional processing or fabrication and allowing them to be used in tight spaces.
- Lightweight and easy to transport – the composite structure is lightweight, more so than a solid aluminium sheet in comparable thickness, making it easy to handle and transport.
- Cost-effective – panels incur low production costs, significantly reducing building costs in larger projects that mostly rely on solid aluminium, wood or concrete.
- Energy efficiency – high thermal performance ensures structures fitted with aluminium composite sheets maintain comfortable indoor temperatures. They reflect heat in summer, and retain more warmth in the colder months, leading to lower energy bills. Moreover, the material is sound-resistant
- Easy installation and low maintenance – hassle-free and fast installation, the ability to be formed in interesting designs impossible with traditional materials, and easy cleaning reduces labour costs, and the need for specialised tools or expensive cleaning and polishing agents.
- Recyclable – all materials in the ACP sheet are recyclable, meaning reduced environmental impact and lower repurposing costs.
Common Uses
Exterior Cladding
Panels are widely used in ventilated facades and exterior cladding systems (canopies, overhangs, soffits), with their ability to withstand harsh conditions while preserving a clean, modern and functional look.
Signage and Advertising
The low weight, durability and high weather resistance make aluminium panels a cost-effective choice for outdoor signage, totem poles, POP displays and more. Panels can be sourced in varied colours and finishes and hold lacquers and printable paints for unique designs.
Interior and Exterior Decoration
ACP sheets are common in interior cladding and decorations, featuring in wall partitions, false ceilings, wall panels, shelving and decorative elements. They’re also used in exterior column cladding.
Furniture and Kitchen Cabinets
Overlooked uses are in cabinets, modular kitchen elements and custom furniture pieces. The ductility and flexibility for varied shapes, textures and colours opens multiple design possibilities.
Industrial Uses
Commercial and industrial settings use aluminium composite panels in containers, machine covers, clean rooms, enclosures and more. They provide high strength, durability and good chemical and impact resistance for a fraction of the price of traditional stainless steel panelling.
Compared to Other Materials
ACP is often compared to solid aluminium sheeting and High-Pressure Laminate (HPL), particularly for cladding purposes. The material is much lighter than solid sheeting due to the composite structure, easier to install and easier to transport. In terms of durability and strength solid sheeting is more durable and more resistant to high impact, though at a cost premium. Newer versions of ACP panels with fire and impact-resistant mineral cores ae good alternatives for decent strength in demanding outdoor uses.
One area where ACP sheets have the upper hand is aesthetics and the variety of customisation options. Textured, coloured and gloss or matte looks can be mixed and matched to better effect than solid aluminium sheets, mimicking natural wood grains, metals or stone finishes. This extends the scope of possible uses. Moreover, composite sheets with mineral cores have replaced more costly solid sheets where fire resistance and sound insulation are necessary. Both materials can be entirely recycled to yield virgin aluminium. However, composite sheets with polyethylene cores incur higher costs due to more complex procedures.
Compared to HPL, a composite material consisting of multiple layers of kraft paper impregnated with phenolic resin, ACP has better weathering and impact resistance, better UV stability, and reduced fading. HPL is more durable against scratches, abrasions and chemicals, but requires specialised tools during installation due to its higher density. HPL sheeting is also more expensive and loses points for not being recyclable. Both materials though can be sourced in a variety of finishes, and are easy to maintain and clean.
Variety of Thicknesses, Colours and Finishes
Brand names like Alupanel and Dibond sell aluminium composite panels and sheeting in thicknesses varying from 2 to 6mm, with 3mm being more common. Thickness is determined by that of the coils and filler materials, leading to different grades. Panels are in standard building sizes (1220mm by 2440mm) and oversized panels (3050mm by 1500mm, and 3000mm by 2000mm). Choose from two dozen colours, brushed, polished or textured outer and in a mirrored, high-gloss or matte look.
