Aluminium Composite Panel || ACP sheets design

Aluminium composite panel (ACP) is a flat panel made of two thin aluminium sheets bonded to a non-aluminium core. Aluminium Composite Panel offers a lightweight, durable, and aesthetically pleasing solution for building exteriors, interiors, signage, and cladding. It resists weather, corrosion, and UV rays, making it ideal for long-term use. Builders and designers prefer ACP for its easy installation, modern look, and variety of colors and finishes. ACP also provides insulation and soundproofing benefits. Manufacturers design ACP sheets to meet different structural and design needs. Thanks to its flexibility and strength, the aluminium composite panel is widely used in both commercial and residential construction. ACP continues to shape modern architecture with its performance and visual appeal.

​In this article, we explore the production process features, benefits, and applications of aluminium composite panels (ACP), highlighting their significance in modern construction and design.

What is an Aluminium Composite panel cladding ?

​Aluminium composite panels (ACP) originated in the late 1960s, initially developed for signage and advertising purposes. Their lightweight, durable, and aesthetically versatile nature quickly garnered attention in the construction industry. By the 1980s and 1990s, ACPs became a preferred choice for architects and builders worldwide, particularly for commercial buildings, skyscrapers, and high-traffic public spaces. Today, they are a staple in modern facade design, offering energy efficiency, design flexibility, and sustainability, significantly influencing contemporary architectural practices

Aluminium composite panels (ACP) consist of two aluminium sheets bonded to a non-aluminium core, typically polyethylene or a fire-retardant material. This configuration provides a lightweight yet durable material ideal for various applications. Aluminium Composite Panel’s versatility makes it suitable for external cladding, interior partitions, signage, and more. Its smooth surface allows for diverse finishes, including metallic, matte, and woodgrain, catering to aesthetic preferences. Beyond appearance, ACP offers thermal and acoustic insulation, enhancing building energy efficiency. Its resistance to weathering and corrosion ensures longevity with minimal maintenance. The ease of fabrication and installation reduces construction time and costs. Moreover, ACP’s Recyclability aligns with sustainable building practices, making it a preferred choice in contemporary architecture

​Due to aluminium’s relatively low melting point, aluminium composite panels with combustible polymer cores are more susceptible to fire, restricting their application in areas prone to fire hazards.

​To enhance fire resistance, polymer cores should undergo special treatment, or a non-combustible mineral fiber core comprising over 90% of the panel’s composition should be used, sandwiched between two aluminium skins. To protect and preserve ACP sheets, coatings such as polyvinylidene fluoride (PVDF), fluoropolymer resin (FEVE), polyester, and others are applied. Standard aluminium composite panel thicknesses include 2 mm, 3 mm, 4 mm, and 6 mm.

Types of Aluminium Composite Panels (ACP)

Depending on the usage and fire rating standards ACP sheets are classified into two categories

• Non fire rated grade
• Fire rated grade

Fire-Retardant (FR) ACP

Fire-retardant ACPs incorporate a mineral-filled core, typically comprising about 70% non-combustible materials. This composition significantly enhances their resistance to fire, making them suitable for high-rise buildings and structures requiring stringent fire safety standards. In the event of a fire, FR ACPs are designed to self-extinguish when the heat source is removed, thereby reducing the risk of flame spread. They are often mandated by building codes for constructions exceeding certain heights or in areas with strict fire regulations.​

Depending on the core composition, fire-rated Aluminium Composite panel can withstand fire for up to 2 hours. The core materials are the fundamental distinction between ACP sheets that are fire-rated and those that are standard. While the fire-rated ACP has a specially formulated fire-resistant mineral core, the standard ACP uses LDPE/HDPE as its core material. Fire resistant mineral core uses Magnesium hydroxide as core for enhanced fire retardant qualities. As the name suggests, Fire Grade Aluminium Composite Panels have the unique capability to withstand extreme temperatures. The highest grade ACP is fire retardant ACP (A2 GRADE), which contains over 90% inorganic material content.

️ Non-Fire-Retardant (PE Core) ACP

Non-fire-retardant ACPs feature a core made of polyethylene (PE)low-density polyethylene (LDPE) , a combustible material. While these panels are lightweight, cost-effective, and easy to install, their flammability poses significant fire risks, especially in high-rise applications. The use of PE core ACPs has been linked to rapid fire spread in several incidents, leading to increased scrutiny and regulatory restrictions in many jurisdictions. They are generally recommended for low-rise buildings or interior applications where fire risk is minimal.​

Selecting the appropriate type of ACP is crucial for ensuring building safety and compliance with local fire safety regulations.

Coating options got Aluminium composite panel

PVDF Coating (Polyvinylidene Fluoride)

A high-performance thermoplastic resin coating offering exceptional UV resistance, chemical stability, and durability. Commonly used in architectural cladding and aerospace applications for its long-lasting finish. ​

FEVE Coating (Fluoroethylene Vinyl Ether)

A fluoropolymer-based resin providing superior weatherability and UV resistance. Ideal for applications requiring enhanced durability and color retention in harsh environments. ​

Polyester Paint:
A cost-effective coating option made from polyester resin, offering good durability and color retention. Suitable for residential and commercial buildings, but may not match the longevity of PVDF coatings

Types of Aluminium Composite Panels

Aluminium Composite Panels (ACPs) are versatile building materials comprising two aluminium sheets enclosing a non-aluminium core. They offer durability, aesthetic appeal, and are widely used in both interior and exterior applications.​

PE Core ACP

PE (Polyethylene) Core ACPs are cost-effective panels with a polyethylene core sandwiched between two aluminium sheets. They are lightweight and easy to install, making them suitable for interior applications like false ceilings and partitions. However, they have limited fire resistance compared to other types.​

FR Core ACP

FR (Fire Retardant) Core ACPs feature a mineral-based core that enhances fire resistance. These panels are ideal for high-rise buildings and areas requiring stringent fire safety standards. They offer improved safety without compromising on aesthetics.​

High-Pressure Laminate (HPL) ACP

HPL ACPs combine the durability of high-pressure laminate with the versatility of ACPs. They are resistant to scratches, heat, and moisture, making them suitable for both interior and exterior applications. HPL ACPs are available in various textures and finishes, offering a wide range of design possibilities. ​

Nano ACP

Nano ACPs are advanced panels coated with a nano-coating that provides self-cleaning properties. These panels resist dirt and water, maintaining their appearance with minimal maintenance. They are ideal for areas exposed to harsh environmental conditions.​

Brushed ACP

Brushed ACPs have a textured surface that mimics the appearance of brushed metal. This finish adds a modern and sophisticated look to buildings. Brushed ACPs are commonly used in commercial facades and signage.

Mirror ACP

Mirror ACPs feature a reflective surface that creates a mirror-like finish. These panels are used to enhance the visual appeal of buildings, making them appear more spacious and luminous. They are often used in interior applications like wall cladding and ceilings.​

Advantages of Aluminium Composite Panels

Aluminium Composite Panels are widely used nowadays because of their countless unique properties. Let’s highlight a few of its unique features that set it apart from other panelling materials.

Light weight

When compared to other building materials like steel, Aluminium Composite Panel is lightweight. This significantly reduces the design loads on the structure with big spans and vast areas involved. Lifting and erecting ACP sheets is simple. This, in turn, minimises labour and construction costs while maintaining the schedule.

Flexible

The ACP sheet is flexible and very simple to use. The installation process is quick and simple, and the fixing framework construction is uncomplicated.

Availability and colour choices

This composite panel has exceptional flexibility because to the vast range of finishes it supports. Aluminium composite board can be textured, solid, mirror, or wood type to meet any architectural concept. The colour and feel of real stone and wood are effectively replicated on aluminium.

Environmental friendly

ACP is an environmentally friendly material that is composed of 85% recycled aluminium. ACP’s cover sheets and core material are both recyclable.

Dimensional stability

Aluminium composite panels got high dimensional stability and the material can remain stable for a long period without changing the dimensions.

Smooth and elegant

The exteriors of buildings can have a pleasant and attractive appearance because to the smooth, elegant ACP surface.

Cost

ACP sheet is the most economical panelling option when compared with other panelling materials. The cost depends on the core materials. The fire grade materials are costlier than standard non fire rated ACP.

Weather resistant and Durable

ACP panels are UV resistant and chemical resistant. They are unbreakable stain-resistant, weather-resistant, termite resistant, moisture resistant, and anti-fungal.

Applications of Aluminium Composite Panels

Building Facades & Cladding

ACP sheets are widely used for exterior cladding, providing weather resistance, insulation, and aesthetic appeal to commercial and residential buildings.

False Ceilings

Lightweight and moisture-resistant, ACPs are ideal for creating modern false ceilings in interiors, enhancing aesthetics and concealing utilities. ​

Interior Partitions

ACP panels serve as durable and customizable partitions, dividing spaces in offices and homes while offering sound insulation and visual appeal. ​

Signage & Branding

Due to their durability and printability, ACPs are commonly used for outdoor signage, hoardings, and branding displays, ensuring longevity and vibrant graphics. ​

Furniture & Modular Kitchens

In interior design, ACPs are employed for making sleek furniture, wardrobes, and modular kitchen units, offering water resistance and easy maintenance. ​

Column & Balcony Cladding

ACPs are used to cover structural columns and balconies, providing protection against weather elements and enhancing the building’s exterior aesthetics. ​

Cleanrooms & Laboratories

In industrial settings, ACPs are utilized for cladding cleanrooms and laboratory cabinets, offering chemical resistance and ease of maintenance. ​

Exhibition Stalls & Booths

ACPs are favored for constructing exhibition stalls and booths due to their lightweight nature and ease of fabrication, allowing for creative designs. ​

Acoustic Panels

ACP sheets can be used as acoustic panels in interiors, helping to reduce noise levels and improve sound quality within a space. ​

Green Building Solutions

With their thermal insulation properties, ACPs contribute to energy efficiency in buildings, supporting sustainable and eco-friendly construction practices.

ACP sheet is mainly used for a wide range of applications due to its extraordinary qualities. Major uses of the ACP sheet are as follows.

• External and internal architectural cladding 
• Internal partition
• False ceilings
• Signage
• Machine coverings
• Container construction

External and internal architectural cladding/partitions

For exterior cladding/façade applications, ACP sheets are used, thanks to their versatile qualities like UV resistance, fire resistance, and durability. ACP sheets come in a wide range of colours to match any architectural style. ACP sheet is the material of choice for facades and partitions because of its lightweight characteristics, simple fixing procedures, and quick construction.

Internal partitions

Aluminium Composite Panels in combination with aluminium, UPVC etc are used for office cabins and internal partitions. Partitions can be done with minimal space wastage.

Signage

ACP is used to render a wide variety of flexible exterior signs, as signage and hoardings are being used for exterior applications and must survive changes in temperature or weather

Interior work

ACP sheets are used for interior applications such as wall coverings, false ceilings, cupboards, portable kitchen cabinets, tabletops, column covers, and more.

Conclusion

ACP sheets are Green and environmentally friendly, easy to clean, and can shorten the construction period. ACP panels are resistant to corrosion, prevents acid and alkali, and other types of corrosion. Due to these versatile properties, ACP sheets are one of the popular choices in the construction sector.

Summarize the key points.

• Reiterate the importance of selecting the right type of ACP for specific applications.​