Alukobond – aluminum composite panels as a material for the facade

Modern architectural design has been revolutionized by aluminum composite panels, also marketed under the brand name Alucobond. This is especially true of facade applications. Two thin aluminum sheets are fused to a non-aluminum core, usually composed of polyethylene, to form these panels. Because of their construction, Alucobond panels offer a special blend of toughness, portability, and aesthetic appeal.

Alucobond panels’ remarkable durability is one of their main benefits. The outer layers of aluminum offer strong defense against environmental factors like sunlight, rain, and temperature changes. Because of their extreme resistance to fading, corrosion, and warping over time, they provide a durable facade solution that needs little upkeep.

Alucobond panels are highly valued for their lightweight design, which provides important advantages for structural integrity and installation as well as longevity. The panels require less labor and installation time because they are simple to handle and manipulate on site. Compared to heavier facade materials, their light weight also puts less strain on the building’s structure while maintaining superior strength and rigidity.

Alucobond panels are preferred by designers and architects due to their aesthetic versatility. These panels give facade designers a great deal of creative freedom because they come in an extensive array of hues, textures, and finishes. Alucobond panels provide a multitude of choices for achieving the desired architectural style, whether it’s simulating natural materials like wood or stone or creating a sleek, modern look with metallic finishes.

What is alukobond?

Alukobond is a facade panel composed of coatings, artificial filler, and aluminum plates. A composite is a mixture of materials with various characteristics. Panel arrangement:

• aluminum sheets up to 0.5 mm;
• polymer (most often polyethylene foam);
• anti -corrosion layer (usually sodium hydroxide);
• decorative layer (polyester or fluoroplast);
• Laminated film.

The technology is well-developed and has been around for more than 50 years. Originally developed in Germany, the term "Alukobond" is currently used to refer to the entire class of composite panels featuring aluminum sheets. It was only a matter of time until the resulting facade model was distributed because it was so successful. In Russia, alukobond production has been established.

Because each layer enhances the aluminum panel in a different way, the following are some of Alukobond’s primary benefits:

• Light weight – this minimizes the load on the foundation;
• Durability – less costs to maintain the facade in working condition;
• Flexibility – with deformations of the facade, both appearance and functionality are preserved;
• quick installation;
• absorption of vibrations;
• Good climatic resistance.

The final feature is particularly intriguing for people who select facade materials for northern climates or, on the other hand, southern climates. Alukobond perfectly demonstrates its resistance to frost while maintaining its original properties even after prolonged exposure to intense UV light. Therefore, aluminum composite panels are a great choice for the middle strip’s climate.

Production technology and main stages

Composite aluminum panels are made by manufacturers as ready-made cassettes or standard-size sheets. The sheets need to be pre-processed before installation, which includes milling, flexion, and cutting into cards of a specific size. Another name for the resultant blanks is cassettes. Because specific facade solutions may not always accommodate standard sizes, factory finished goods are utilized less frequently.

Technology for producing alukobonds:

1. Dried material for a polymer filler passes through an extruder;
2. The molten mass is placed between aluminum ribbons;
3. rolling shafts form a workpiece of standard sizes without irregularities, with neatly cut ends;
4. Hot cylinders under pressure firmly connect the elements of the composite panel, sinter aluminum tapes and polymer, and also additionally align products;
5. The composite tape passes the cooling section and the final molding;
6. The front part of the workpiece receives a protective coating;
7. The inside of the product is marked;
8. The finished aluminum composite tape is cut into separate panels.

Specifications

Although the aluminum layer in composite panels can range in thickness from 0.21 to 0.5 mm, the final product is typically 3–4 mm. Alukobond panels, which are standard for facade decoration and advertising structures, have become firmly established in the interior. Each layer’s thickness has an impact on the technical properties:

• weight (kg/m2) 4.5-7.6;
• width (mm) 1000-1500;
• Bending strength (MPA) 125-240;
• combustibility of g1-g4;
• flammability B1-B4;
• The formation of smoke d1-d3.

The price per square meter will vary considerably when appropriate Alukobond panels are chosen based on the intended operating conditions and requirements. Selecting options with low indicators of smoke formation, combustibility, and ignorance is preferable for facades.

The Alukobond panels’ length is decided based on the project’s specifications, but it cannot exceed 6 meters. According to the ordered sizes, the composite-aluminum tape will be broken up into pieces. Standards for width: 1-1.5 m.

Varieties

Three brands are included in the classification of aluminum composite panels that are collectively referred to as Alukobond:

The best markers of ignorance and combustibility are found in the first brand, A2. In terms of fire safety, these composite alukobond panels are as secure as they get. 125 mm in width. The title’s initial letter A denotes that the composite product’s filler is made of minerals.

When cost is the primary consideration, the B2 brand is appropriate. These aluminum panels are less expensive than Alukobond brand A2, but they are less flexible when bent. This is a result of the plastic filler’s properties. It is just 100 mm wide.

The Plus brand has increased weight, thickness, and width (150 mm), as the name would imply. These composite aluminum panels also have a greater bending strength than B2 and A2. This brand of alukobond is marginally less fire-resistant than A2.

Composite panels come in a variety of color options and textures, including matte, mirror, and wood-like imitation.

AlucobondStandandartcolors (standard colors of alukobond panels)

The most common choices for standard colors are black, white, cream, beige, red, and other hues in a limited palette of just 14 shades. These aluminum composite panels are advantageous for M2, as is the case with any standard offer; however, the customer’s options are restricted to a limited palette of colors.

Alucobond Natural Colors ("Aluminum")

The alukobond panels from this series will create an intriguing facade, and metal surfaces work well with the urbanist theme. There are four variations of composite panels available, each with a different texture on the aluminum surface.

Alucobond Metallic Colors ("Metallic")

There are thirteen options in this color collection, such as gold, copper, and bronze. The facades featuring panels from the Metalik series have a rigid appearance that emphasizes respectability. Glass elements look great with this finish.

Alucobond Wooden Design

There are situations when the building’s facade needs to blend in quietly with the surrounding architectural style. A range of wood-like composite alukobond panels can be successfully used for certain styles. There are five options in this variety.

Alucobond Sparkling Colors (sparkling colors)

These Alcohobond panels come in three colors: black, blue, and red. Their surface is well-polished. The facade, which is trimmed with composite panels from the "sparkling colors" series, will stand out among the surrounding structures and draw attention.

Alucobond Spectra Colors ("Chameleon")

Similar to the previous series, the Hameleon series is appropriate for building facades, which ought to be highlighted. Alukobond materials come in nine different varieties, and what sets them apart from the others is a color game that changes based on the lighting and viewing angle.

Alucobond Anodized Look ("under the anodizing")

The surface of composite panels with an anodized metal effect is matte. Alukobond, in contrast to a prototype, can be bent and processed in the necessary ways, making it a successful solution for buildings that need to have a precise and orderly appearance. Additionally, there won’t be any conflict with the facade’s decorative solution when the project uses anodized doors or frames.

Aluminum panel installation technology

Alucobond composite aluminum panel installation is quick and easy. This saves time and money at large facilities, and you can handle small areas of the cladding on your own.

Materials other than the panels themselves that are needed for installation:

• thermal insulation and windproof membrane;
• facade profile and brackets;
• fasteners (plate dowels, nails, rivets);
• forests;
• screwdriver, punch;
• milling mill;
• drill on metal, concrete;
• scissors for metal, for thermal insulation material – an mounting knife;
• level.

Alukobond aluminum panel installation starts with marking, which determines where brackets need to be installed. Underneath the bracket base, paronite laying is positioned and secured with a gilse anch.

The thermal insulation is then covered, laid, and covered again with a windproof material. Make use of vapor-permeable membranes. Nails (or stopped screws) and plastered dowels are used to secure this layer. Thermal insulation is punctured using an assembly knife.

Rivets are used to secure the profile to the brackets. P-Schell, a corner, and ready-made profile systems are all utilized in the installation of alukobond. Although the first option is more expensive, it greatly simplifies installation and prevents linear expansion from deforming the finished facade. The second option will save money, but you shouldn’t let that deter you too much from the process’s expense: internal work profiles and self-tapping screw fastening are not advised. Alukobond panels can expand linearly without distorting the facade canvas thanks to rivets.

Use metal rivets that are suitable for aluminum. After installation, the protective film needs to be taken off right away because doing so later will make it more difficult.

Alukobond prepared and captured composite panel installation starts below with profile alignment. The corners must then be fixed. Installed and secured in an appropriate location, the supporting plate joins the cassette hook. The technology of the docking is also determined by the type of product: v and or grooved. Make sure to leave a maximum of 10 mm of gaps. Alcohobond panels should be installed with consideration for the marking on the incorrect side of the panel in order to prevent color heterogeneity on the completed facade.

Due to their durability and versatility, aluminum composite panels, like Alucobond, have completely changed the design of modern facades. Built with a non-aluminum core between two thin layers of aluminum, these panels provide a strong, lightweight option for building facades.

Alucobond’s visual appeal is one of its best qualities. With so many different hues, textures, and finishes to choose from, architects can design eye-catching facades that complement a variety of architectural philosophies. Alucobond panels can be customized to provide a sleek, modern appearance or a more traditional appearance, depending on the design preferences of the user.

In addition to improving a building’s aesthetic appeal, Alucobond panels are highly valued for their functional advantages. They are appropriate for both urban and suburban settings because they are low maintenance, weather-resistant, and UV-stabilized. Their lightweight design also speeds up installation and lowers the price and duration of construction.

Moreover, Alucobond panels support building sustainability objectives. They are recyclable and frequently made of recycled materials, which is in line with green building techniques. Because of this, they are a better option for projects looking to obtain green building certifications.

Aluminum composite panels, such as Alukobond, are a flexible and long-lasting material option for contemporary building facades. Because of the way it is made, which consists of two thin sheets of aluminum fused to a non-aluminum core, it is both lightweight and strong. Alukobond panels are well known for their visual appeal, offering a broad selection of colors and finishes to architects and designers to improve the external appearance of buildings. In addition to their aesthetic value, these panels are popular in modern architecture because of their practical qualities like energy efficiency, weather resistance, and ease of maintenance.

Video on the topic

What is alukobond? What is an aluminum composite?

Aluminum panels for the facade (automatic transmission)

Composite panels: weight, thickness, size, combustibility class, prices, installation and scope

Aluminum composite panels. Short review. Application

How to bend the composite correctly!