Introduction
Aluminium composite panels (ACP) offer excellent durability, design flexibility, and long-term performance when installed correctly. However, poor installation practices can significantly reduce panel life, cause deformation, or even create safety risks. Understanding the most common ACP installation mistakes helps contractors, developers, and façade installers avoid costly problems and deliver high-quality results.
Incorrect Panel Orientation
ACP sheets have a directional grain, especially when coated with PVDF or FEVE. Installing panels without respecting the arrow direction leads to visible shade differences on the façade.
- Always check the protective film arrows before installation.
- Ensure all panels on the same elevation follow the same orientation.
Ignoring Thermal Expansion Requirements
Aluminium expands and contracts with temperature changes. Improper spacing around panel edges causes buckling or distortion.
- Leave proper expansion gaps in accordance with the manufacturer’s guidelines.
- Avoid fixing panels too tightly.
Using the Wrong Sealant or No Sealant at All
A poor choice of sealant can discolor the façade, crack over time, or fail to provide adequate waterproofing.
- Use neutral-cure silicone sealants recommended for ACP systems.
- Avoid acetic-cure silicones or low-quality alternatives.
Improper Joint Widths
Incorrect joint widths cause aesthetic inconsistencies and structural issues.
- Follow recommended joint dimensions for the specific ACP system.
- Maintain consistent joint width throughout the façade.
Incorrect Rivet or Fastener Selection
Using the wrong type of rivet or screw weakens the entire cladding system.
- Use corrosion-resistant fasteners suitable for aluminium.
- Match fasteners with panel colour coatings when appearance matters.
Overtightening the Fasteners
Excessive tightening can deform the aluminium skin and restrict panel movement.
- Tighten fasteners just enough for firm holding without creating pressure marks.
- Allow the panel to float slightly for thermal expansion.
Removing the Protective Film Too Early
Premature removal exposes the panels to scratches and contamination.
- Keep the film on until the façade work is nearly complete.
- Avoid leaving it on for too long under sunlight, which can make removal difficult.
Improper Storage Before Installation
ACP must be stored correctly to avoid warping and surface damage.
- Store panels on a flat surface indoors.
- Avoid leaning panels vertically for long periods.
- Protect edges from moisture and mechanical impact.
Cutting Panels Incorrectly
Using inappropriate cutting tools creates jagged edges and burrs.
- Use circular saws with carbide-tipped blades designed for aluminium.
- Avoid manual cutting methods that compromise edge quality.
Skipping the Substructure Inspection
ACP performance depends heavily on the alignment and stability of the supporting structure.
- Check the substructure for straightness, strength, and corrosion.
- Ensure all brackets and rails are securely fixed.
Incorrect Drainage Provision
Poor drainage leads to water accumulation behind panels, causing long-term damage.
- Ensure proper ventilation and drainage paths in the substructure design.
- Avoid sealing areas that should remain open for airflow.
Conclusion
Avoiding common ACP installation mistakes is essential for achieving a durable, visually consistent, and high-performing façade. Proper orientation, correct joint spacing, appropriate fasteners, and careful handling all play critical roles in the final outcome. When ACP is installed with professional attention to detail, it delivers exceptional weather resistance, long service life, and a premium architectural appearance.
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