Architects, designers, builders, and developers can use Aluminum Composite Material (ACM) panels and Aluminum Composite Panels (ACP) for interior and exterior building and signage applications.
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ACM panel systems provide high strength, low weight, good dimensional stability, and a sleek, modern appearance. ACM panels are an aesthetically versatile and easy-to-install alternative to aluminum or wood sheets.
Read on to explore how ACM panels systems' many features, benefits, and applications can help you achieve the structural and aesthetic needs of your next building or signage project.
ACM panels provide building owners and developers with a stylish and practical product that can be utilized for renovation and new construction projects.
Composition and Structure of ACM Panels
Aluminum composite material panels include two thin, pre-painted flat aluminum composite panels bound to a non-aluminum core center. Manufacturers combine natural fibers extracted from plants and animals with aluminum foil to produce an aluminum composite, which creates a more effective, robust, flexible, and aluminum composite than those made with synthetic fibers. Manufacturing the composite panel system involves a continuous lamination process of compacting the core between two aluminum sheets, then flattening the product and applying a protective coating.
Different Types of Core Materials Used in ACM Panels
Manufacturers offer two material choices for the core: Polyethylene (PE) and fire retardant cores.
PE cores offer a less expensive, lightweight option for buildings up to two stories tall.
While more costly, fire-retardant core ACM panels help meet the fire-retardant requirements for multi-story construction.
ACM panels come in limitless color combinations, surface finishes, and thicknesses and allow routing, cutting, and roll-forming, which gives architects and designers endless aesthetic freedom.
Several features of ACM panels make them long-lasting:
The fluorocarbon coatings of ACM panels make them resistant to extremely high temperatures, wear and tear, harsh weather, and pollution.
ACM panels' flexible plastic core prevents warping and distortion, which provides long-term durability, rigidity, and stiffness in any climate.
The non-corrosive nature of aluminum makes ACM panels ideal for external facades and signage.
High wind-resistant ACM panels with lighter weight make them suitable for signage and high-rise cladding.
Its resistance to humidity prevents water-related damage.
Advantages of ACP Wall Systems
The many benefits of ACP wall systems explains their growing popularity among designers, builders, and others in the construction industry.
Lightweight Nature and Ease of Installation
An aluminum composite panel with a small-density core material only weighs about 2.5 lbs ft2 (0.11 kg m2) after installation, which makes them significantly lighter than other sheet metal panels, to provide several benefits:
Easy to transport and install
Lessens the wall framing and foundation load, which contributes to the structure's durability and longevity
Building components use less material for construction cost savings
The outer aluminum sheets of the ACM panels provide strength within the panel's core, to give it rigidity and achieve a high strength-to-weight ratio. In addition, the panel's dimensional stability maintains its shape and flatness against exposure to extreme temperature changes.
ACM panels' design versatility and aesthetic appeal make them ideal for exterior claddings, interior walls, signage, and more:
Architects and designers can choose from nearly 40 colors or create a custom color to fit any project application.
Aluminum's plasticity and malleability give designers the flexibility in curving, finishing, and laser cutting to repeat decorative metal panels around an entire façade or wall system, cost-effectively.
Photocopying technology can replicate granite, wood grain, aluminum, copper, zinc, and stainless steel patterns, for a distinctive texture and high-quality pattern design on the ACP's surface.
Due to the continuous thermal composite production process, the high surface flatness of ACM panels gives ACM a flat and homogeneous appearance, which many architects appreciate.
Builders can easily cut ACM panels to fit any size, shape, or dimension, which makes them ideal for projects with difficult angles or tight spaces.
Fire Resistance and Safety Features
The IBC requires walls containing ACM panels to pass the NFPA 285, ASTM E84. and NFPA 268 fire rating tests.
U.S. manufacturers primarily offer ACM panels with a fire-retardant core in several thicknesses: 3-, 6-, and the most common and available 4-millimeter. The fire-retardant core consists of alumina trihydrate (ATH) or magnesium hydroxide (MDH) bound with a polymer base. The material's properties improve fire safety and help achieve code requirements, including NFPA 285, at no additional costs.
It is important to note that compliance with NFPA 285 significantly improves building safety during an exterior assembly fire and eliminates the risk of fatalities.
Low-Maintenance Requirements
The ACM panel's functional and decorative surface offers long-term color consistency, weather, termite, and sunlight resistance, excellent flatness, rigidity, and formability, making the product low maintenance to significantly lessen repair costs.
Thermal and Acoustic Insulation Properties
ACM panels reflect heat and light, which reduces the thermal loading on a building. In addition, using cool paint finishes can further increase the panel's reflectivity.
ACM panels provide a sound barrier by dampening vibrations, which limits sound transfer through the panel and controls noise pollution.
Eye-catching, durable, and lightweight ACP wall systems are a practical solution for enhancing the exterior and interior spaces of residential, commercial, and institutional buildings.
Exterior Cladding and Façade Systems
For new and remodeling commercial, residential, and institutional construction, ACM panel exterior claddings and facades offer architects and builders a system that improves a building's integrity, aesthetics, and sustainability. Long-lasting ACM panel exterior cladding stands up to rain, wind, UV light, flying debris, and whatever else nature sends.
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Durable wall partition ACM panels for commercial and institutional buildings will withstand heavy wear and tear daily. In addition, ACM panels easily detach, for quick relocation as space needs change.
ACM panels can endure temperature changes and resist harsh weather impacts, which makes them ideal for outdoor signage. In addition, advertisers can customize ACM panels to fit their specific outdoor and indoor needs. ACM panels can also be utilized for indoor purposes like kiosks, point-of-purchase displays, and more.
An aluminum composite material can enhance a retail or commercial business's identity by customizing the company&#;s specific branding to its building&#;s exterior. ACM panels create a modern, clean, luxurious look that will draw customers, partners, and clients toward a retail or commercial building. Using ACM panels for interiors with intricate patterns and designs can inspire creativity. Furthermore, fire-resistant, durable ACM panels mitigate expensive repairs and maintenance.
ACM panels installed on industrial (warehouses, data centers, manufacturing. etc.) and institutional buildings (schools, churches, libraries, hospitals. etc.) can create attractive, low-maintenance, and robust structures that can withstand the heavy daily use. In addition, ACM panels enhance the building's safety by not emitting toxic gasses and providing the highest fire protection.
Like all building product and method choices, architects, designers, and contractors must consider codes, environmental impacts, budget, durability, and long-term maintenance and repair expenses when choosing an ACP wall system.
In the U.S., builders and architects must comply with the International Building Code (IBC) and the NFPA Building Construction and Safety Code, issued by the National Fire Protection Association, (NFPA). Architects, designers, and engineers can find the ACM panel code and regulations in the metal composite section of the IBC (section ).
Environmental Sustainability Factors
Sustainable ACM panels offer several environmentally-friendly features that can qualify for LEED credits and tax credits (depending on the state).
Manufacturers produce ACM panels with recycled aluminum and plastic core elements. In addition, builders can recycle ACM panels at the end of their life cycle.
Long-lasting, durable ACM panels limit the use of natural resources and the need for landfill space.
ACM panels do not emit harmful toxic gasses.
Budget and Cost Considerations
Installing aluminum composite panels ranges from $40-$55 per sq. ft., including materials and installation. However, the cost of ACM panels depends on the core type, color and finish, panel size, project complexity, panel size, and structural properties.
ACM fire-retardant panels cost more than panels with PE cores.
Applying a customized color, texture, or company logo to an ACM panel will increase the overall cost.
The aluminum composite panel's width, length, and thickness will impact the construction and transportation costs.
Structural properties of aluminum composite panels can affect the prices, like: including protective film over the panel installers remove after installation, adding primer, adhesive film, and service coating to the ACM panel, applying PDVF coating to protect against color fading, and design teams can specify coatings rigorously tested and rated by the Fenestration and Glazing Industry Alliance&#;s rating, American Architectural Manufacturers Association (AAMA) , which ensures the best resistance to ultraviolet (UV) degradation, corrosion, and chemical exposure.
Manufacturers pre-paint and pre-treat ACM panels with a protective layer to prevent corrosion and rust. In addition, ACM panels resist attacks from water, sunlight, termites, etc., which further reduces maintenance and repairs. Cleaning an ACM panel&#;s surface typically only requires water, soap, and a mild cleaner.
Lightweight ACM panels offer many features that ensure their long-term durability.
ACM panels' fluorocarbon coatings make them resistant to extremely high temperatures, flying debris, wind, rain, sun, harsh weather, wear and tear, and pollution.
ACM panels offer dimensional stability and high tensile strength to resist damage when bending.
A growing number in the building community are turning to aluminum composite panel technology for its continuing innovations towards improved fire-, UV-, and abrasion resistance, and enhanced aesthetics. Research predicts the ACP market size will hit $7.93 billion (USD) by at a CAGR of 6.8 percent between (&#;). Future trends and innovations in aluminum composite material panel technology aim to improve the quality and traits of signage boards and residential, commercial, and institutional building exterior and interior spaces.
Combining solar panels with aluminum composite panels will contribute towards net-zero-energy buildings, to save building owners money and energy and protect the environment.
Incorporating 3D designs with ACM panels will expand the limits of creativity, to enhance the aesthetic possibilities for architects and designers.
Smart machines allow for advanced cutting technology in laser and waterjet modes and enhance designers' abilities to customize and create more complex building designs.
Graphic designing and computer software will allow the exact matching of brand colors to ACM panels.
The future of designing and constructing buildings points towards incorporating sustainable and eco-friendly materials and methods as a matter of standard practice, like using ACM panels.
Building long-lasting, weather- and disaster-resistant structures with ACM panels contributes towards conserving the ecology.
Energy-efficient ACM panels reduce the need for heating and cooling systems, which lessens energy use and cost.
Manufacturers use recycled material to make reusable ACM panels.
ACM panels limit harmful toxins, lower habitat risk and help preserve and promote biodiversity in urban settings.
ACM panels offer the building community a lightweight, easy-to-install, long-lasting, fire-resistant, and low-maintenance composite panel system for new and renovation retail, commercial, industrial, institutional, and residential construction projects and signage applications. In addition, ACM panels improve the thermal and acoustic properties and allow architects and designers extensive aesthetic versatility.
Installing ACM panels can help designers stay on budget, achieve building code and sustainability requirements, and create a durable, low-maintenance structure. The ongoing innovations of ACM panels point towards improving the safety and durability of future projects, making them a superior choice for enhancing aesthetics and creating sustainable structures.
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Many buildings today are clad with aluminum skins, crisp metal panels in both simple and complex shapes, with limitless color options. Aluminum doesn&#;t rust, and its light weight makes it easy to install.
Additionally, it has a competitive price point compared with other claddings and is readily available from multiple manufacturers. Being the metal cladding of choice by both designers and contractors, aluminum controls the lion&#;s share of the metal cladding market. It is an economic material with a proven record of success. To install it in a code-compliant manner, however, requires understanding the various types of aluminum skin and their restrictions.
There are two basic types of aluminum panels: solid plate and metal composite material (MCM). Solid plate is exactly what it sounds like &#; a single thickness of aluminum plate, no fillers or preservatives, just simple, solid metal. It comes in a variety of thicknesses. I&#;ve used it at thicknesses from 0.062 inches (1/16&#;) to 0.125 inches (1/8&#;). MCM is composed of two very thin sheets of aluminum laminated to a polyethylene plastic core. The laminated metal on both faces is approximately 0.019 inches (1/64&#;) thick and the plastic core is approximately 0.125 inches (1/8&#;) thick, for an overall panel thickness around 0.16 inches (5/32&#;).
For solid plate, the building code has very few restrictions to its use. Table .2 requires a minimum thickness of 0.019 inches (1/64&#;). I don&#;t know of any aluminum material currently on the market that doesn&#;t meet or exceed this minimal thickness. Other than the thickness requirement, there are no other code restrictions for solid plate. Another benefit is the durability of the solid plate. Depending on the thickness, solid plate can take substantial abuse from wind, impact, and basic vandalism with minimal damage. It is durable, and the finish may be able to be repaired without replacing the panel. One simple downside to using aluminum plate is that it really wants to stay in a flat plane. Bending it in one direction along a straight fold is what the material likes. To get complex geometries or curves requires careful cutting and/or welding. It can be done, but not easily and at a higher price.
The building code has a specific section for MCM in Chapter 14: Section , METAL COMPOSITE MATERIALS (MCM). In simple terms, the code allows MCM to be installed on buildings less than 40 feet in height with very few restrictions. Once the panels are installed at a height above 40 feet from grade, the requirements vary depending on the version of the code being used. In both the and the code, an NFPA 285 assembly test is required for installations above 40 feet from grade. However, the edition has several exceptions under section .11 that provide an escape from the NFPA 285 requirement. [For an explanation on NFPA 285 and issues with compliance to the tested assemblies, please refer to What Is NFPA 285? and The Loophole in NFPA 285.] In the edition, those exceptions have all been removed, and compliance with NFPA 285 is mandatory. A tested NFPA 285 assembly is required because MCM panels have a flammable polyethylene plastic core. Even the panels marketed as Fire Resistant are still flammable under certain circumstances. The exceptions have likely been removed from the edition due to the Grenfell Towers fire and other façade fires around the globe. The installed height is the most critical factor in using MCM. Using above 40 feet from grade requires careful compliance with NFPA 285 and the specific details and limitations associated with the tested assembly. Below 40 feet from grade, there are fewer restrictions from the code standpoint.
Another concern with MCM is the softness of the material. Because it is made with a very thin aluminum skin and a plastic core, it is susceptible to damage from wind-blown debris or general vandalism if installed at a height accessible to pedestrians. Consideration should be given to where it is installed near grade and if it could be accessed/damaged by the public.
On the plus side, it is easily formed into complex shapes and geometries. I have detailed it with compound curves and folds and diamond shapes that can&#;t be matched by the solid plate material. It&#;s also lightweight, so large panels are easily handled by one or two installers.
Additionally, some manufacturers are coming out with MCM panels that have honeycombed aluminum cores. Vitrabond &#; G2 manufactured by Fairview Architectural is one such panel. These panels are non-combustible and would eliminate the need for an NFPA 285 assembly. While the IBC and IBC do not specifically address these newer panels, I would expect the code to require compliance under the solid plate material section instead of the MCM section. These newer panels are as lightweight as the MCM and similar in installation. The downside is they don&#;t like to be curved. The aluminum honeycomb core is not as malleable as the plastic core. It makes the panel rigid, like the plate material.
In summary, I offer the following thoughts for the two materials.
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