Composite panels for the facade

Composite panels for facades have grown in popularity among architects and builders as a way to improve both the external appearance and usefulness of a building. These panels are adaptable, blending various materials to achieve a harmony between robustness, thermal regulation, and aesthetic appeal. Composite panels are practical and stylish at the same time. They are usually made of bonded layers of metal, wood, or plastic.

The ability of composite panels to resemble natural materials like stone or wood without the upkeep issues that come with it is one of its main advantages. They are therefore perfect for both contemporary architectural designs and remodeling projects that aim for a chic, new look. The panels can be customized to match the desired aesthetic of any building facade because they are manufactured in a variety of colors, textures, and finishes.

In addition to their visual appeal, composite panels have practical advantages like weather resistance and thermal insulation. Good thermal performance from the layered structure helps control interior temperatures and lower energy expenses. These panels are also made to withstand inclement weather, such as wind, rain, and UV rays, which guarantees their durability and low maintenance over time.

Another factor contributing to composite panels’ popularity in facade construction is their ease of installation. When compared to conventional building materials, they are lighter, which facilitates handling and installation. This quality lowers labor costs and permits quicker construction schedules, both of which are important for keeping project budgets and deadlines on track.

Buildings can have their functional and aesthetic appeal improved with the help of composite panels for facades, which are a flexible and contemporary option. These panels, which are made up of several layers and frequently include materials like fiberglass, wood, or aluminum, give architects and homeowners a customizable choice that strikes a compromise between durability and creative freedom. Composite panels are made of a variety of materials that can be combined to create a wide range of textures, colors, and patterns. This allows for creative architectural expression and provides advantages like weather resistance, thermal insulation, and ease of maintenance. Composite panels, whether utilized in residential or commercial contexts, offer a modern approach to facade design that combines innovative aesthetics with functional functionality.

What are composite panels

When multiple heterogeneous materials are combined to form a single whole, the term "composite" is used. This results in the acquisition of enhanced properties by the new material, which greatly outperform the qualities and quantities of its constituent parts. Any composite consists of a filler layer that acts as reinforcement and a plastic matrix base.

Structure of Goldstar composite panels

Because the composite panels also have extra layers for finishing material decoration and protection, as well as metal plates (usually made of aluminum), their structure is more intricate. The filler’s composition, the number of layers, and the type of coating may vary amongst manufacturers, but the general features—low weight with high rigidity and strength, durability, and resistance to adverse conditions—remain constant.

Panels made of aluminum composite "Alumor"

The panels are made of thin, square- or rectangular-shaped metal plates with a heat-insulating layer on the outside. Special paints and varnishes in a variety of colors that produce a glossy and matte effect are applied to the front side of the panels. Higher-end alternatives feature a laminated covering that mimics the textures of both synthetic and natural materials. Any building’s facade can be completely changed with a range of colors and textures, regardless of the structure’s size, layout, or architectural style.

The structure of Winbond composite panels

Characteristics and types of panels

The structure of a typical composite panel is as follows:

• protective film;
• varnish layer;
• aluminum sheet;
• glue layer;
• filler;
• glue layer;
• aluminum sheet;
• Anti -corrosion coating.

Bildex aluminum composite panels

Manufacturing of composite aluminum panels

The panels are manufactured in standard lengths of 2.40, 3.20, and 4 meters, and widths ranging from 1 to 1.5 meters. It’s true that a lot of manufacturers allow customers to choose the material based on building parameters rather than specifying a set length. The panel has a thickness of 2–6 mm and weighs no more than 8 kg per square meter, meaning that the supporting structures will only need to support a small amount of weight. However, because of the structure’s small thickness and other features, this type of decoration is not used as a heat-insulating material because it does not retain heat well.

Dimensions of aluminum composite panels

The panels are resistant to corrosion and microbes, and they can tolerate temperature swings between -58 °C and +80 °C as well as high wind loads. They also effectively absorb sounds and put an end to vibrations. For instance, the addition of composite panel facade cladding doubles the soundproofing of concrete walls. Regarding fire safety, the indicators are also excellent: the panels are made of weak, difficult-to-flammable materials that don’t detect much smoke. Furthermore, a growing number of producers are using antipyrene supplements in their product lines, which lowers the possibility of a fire-free incident during a building fire.

Two factors are used to categorize the panels: the kind of external coating and the filler composition.

Type of filler	Basic properties
Mineral	Multicomponent composition, including foamed polyethylene and a large number of antipyreins. It has a low combustibility class – G1, does not distinguish caustic smoke, does not spread when melting. In German production products, a filler is used on the basis of aluminum hydroxide, which is even less prone to fire. Mineral layer panels are designed for facade finishes
Polymeric	It is made of cellular polypropylene and foamed polyethylene. Such a filler provides lightness of the facing material, which allows you to use it when facing thin partitions and structures with weak bearing capacity. Panels with a polymer layer are used mainly indoors
Aluminum	As a filler, very thin aluminum plates are used, collected in honeycombs or nets. This provides the greatest ease of cladding and the highest stiffness. Such panels withstand huge wind loads, and therefore are ideal for decoration of high -rise houses

It is important to note that panels with aluminum filler cost significantly more than cladding with mineral and polymer filler, absorb sounds much worse, and do not retain heat at all. Use them to complete a private residence is therefore improper.

Composite panels made of aluminum

Different coating options for panels

Type of coating	Main characteristics
Polyester paints and varnishes	The most inexpensive type of coating. Forms a strong and elastic film with a pleasant glossy shine. Has good resistance to burnout and moisture. It is recommended to use panels with such a coating for interior decoration, since outside they lose external attractiveness after 5-6 years
PVDF paints and varnishes	Coatings of this type have dirt -repellent properties, high resistance to mechanical damage and ultravioletus. The average service life is 20-25 years without losing its original type. This coating panels are great for external cladding
Oxide films	Coating formed as a result of electrochemical processing of aluminum. It creates reliable protection against corrosion, ultraviolet radiation, negative effects of precipitation and mechanical damage, gives the surface a mirror effect. The average service life of such a coating is 15-20 years
Laminating films	These synthetic coatings perform both protective and decorative functions. They create a skillful imitation of various textures: marble, granite, polished metal, various wood species. Laminated panels are more expensive than the rest, but they look most spectacular. The service life of these coatings is 15-20 years

The best manufacturers

Few businesses produce composite panels because they are not as widely used as siding or corrugated board yet. About thirty manufacturers whose products meet the required standards are present on the domestic market and deserve attention. Furthermore, the majority of them are joint ventures between Chinese and Russian businesses. The market leader, however, is still the German-Swiss company "Alukobond," whose composite panels were the first to be introduced into Russia.

Alukobond

Aluminum composite panels, or Alucobond

Because of their exceptional strength and flexibility, this brand’s composite panels are simple to install on curved surfaces. Their length ranges from 3.20 to 8 meters, and their width is between 1 and 1.5 meters. A square meter of cladding can weigh up to 7.7 kg. The panels’ color spectrum is very broad, and beneath the stone are several imitation models and a tree in different tones. The material has a roughly 50-year lifespan on average.

Goldstar

Composite panels "Goldstar"

The material is produced in Russia, has excellent quality, fully meets the accepted standards. In the manufacture of panels, a polymer and mineral filler is used, the coating is used – PVDF. The range is very wide, a large selection of shades on the RAL scale. The manufacturer offers several spectacular series with imitation of various materials: “Vologda” – panels for wood, “Mirror” – imitation of a mirror surface, polished metal, gold and silver; "Palermo" – imitation of natural stone. Panels of the Chameleon series are in high demand, which change color from different angles of vision. The thickness of the material of this brand is 3-4 mm, the width is 1.22, 1.25 and 1.5 m, length 2.44 and 4 m.

Alluxe

Composite panels manufactured in China are not less superior to those made in the country. The best Western technologies are used to make the products, which also have all the required quality certifications. The coating is PVDF, and the layer consists of a polymer and mineral filler. Panels with maximum length of 5.70 m, standard width of 1.25 m, and thicknesses of 3 and 4 mm. There are twenty-three choices in the panels’ color scheme, with both a glossy and matte finish.

Composite panels made of aluminum alloy Alluxe

Products from well-known brands like Winbond, Alcotek, Yaret, and Dibond are also well-liked. They must only buy them from authorized dealers because there is a chance they will purchase a fake.

Composite Yaret panels similar to "Alukobond"

Prices for composite panels

Composite panels

Video – manufacture of Alukobond panels

Facing technology with composite panels

Although this kind of facing is highly costly, the outcome is worthwhile. First of all, you get a sturdy structure that is unaffected by wind, silt, or extremely high or low temperatures. Second, a decoration like this stands out profitably among the siding or plastered houses, looking incredibly spectacular and stylish. Everything can be done on your own as long as you follow the directions exactly.

Facades with ventilation made of composite panels

Composite panel cladding for columns

Tools and materials

Mounted on a metal frame subsystem are composite panels. Thus, you will also need to buy fasteners, a galvanized profile, two-stage aluminum drills, drill, and construction level in addition to facing material.

Brief two-stage exercises

Metal panels are cut with scissors, a manual jigsaw, or a disk saw; rivets or galvanized screws are used to secure the skin to the subsystem.

An installation tool

• insulation (preferably in the form of plates);
• waterproofing membrane;
• primer for walls;
• roller;
• punch;
• marker.

Prices for Popular Puner models

Perforators

Preparation of walls

Composite panel facing is appropriate for any kind of wall, including aerated concrete, brick, wooden, and so forth. It is necessary to clean and repair the surface before putting the frame under the cladding. It is not permitted to have crumbling, cracking, or mold that has been impacted by mold. Consequently, all defects found must be fixed, filled in with a mixture of cracks and wide voids, and the walls may need to be redone if needed.

Remodeling wall

The solution must be allowed to dry completely before priming the base. For wood, use antiseptic soil and apply it in two to three layers; for plastered walls, use a deeper penetration of soil. Small imperfections don’t need to be removed because the hinged facade will completely cover them.

Wood primer antiseptic

Deep penetration prices

A primer of deep penetration

Installation of the crate

Step 1: Mark the brackets with fasteners. Markings are made vertically because the frame guides should be installed vertically. After retreating from an angle of ten to fifteen centimeters, the vertical is established by the level, and on this line, they place the point with a step that is the panel’s width wide. The lines are spaced 50–60 cm apart.

Step 2: Drill the holes for the markings using a perforator or drill, depending on the walls of the walls. After that, dust them off and insert the dowels. Following that, they gather brackets and screw them to the wall in turn.

Boring holes to be marked

Dust off the holes by blowing on them.

Bracket installation (dowel installation)

A hammer has jammed the dowels, and the bolts are twisted.

Attaching extension cables to brackets

Step 3: Using slabs of mineral wool, outline the areas beneath the bracket slots on the wall. Making the slots with a sharp mounting knife is simple. Install the insulation on the wall once more and tie off any protruding fasteners. The remaining plates are installed in a similar manner, firmly fastening them to one another and inevitably shifting the seams vertically.

Make perforations in the insulation.

Put in insulating slabs

Step 4: Mineral wool is covered with a waterproofing membrane, and bracket slots are cut into it. From the bottom up, the membrane is secured with horizontal stripes that overlap by at least 10 cm.

Step 5: Drill holes in the center of each plate and at two to three points in the corners, then insert plane dowels to secure the insulation and membranes.

Step 6: The P-shaped form’s guide profile is then mounted. Unique spacer slopes are formed into the profile cavity. These are tiny, movable plates that serve as a hook for panels. Virtually attach the profile to the brackets, drill a hole in the side, and fasten it with two rivets for each bracket. The profiles are joined at the junction by a fastener bus that is likewise secured with rivets.

As of right now, the frame’s installation is finished. Ensure that every component is fixed firmly and on a single plane. When you apply pressure with your hand, the frame shouldn’t sway or creak.

Installation of cladding

Step 1: The first panel is horizontally and leveled along the lower edge and applied to the guides in the lower portion of the crate. Attach its upper corners using self-tapping screws to the guide profile.

Hand rofile prices

Manual rivets

Step 2: They slide the slide to the panel’s upper side bracket and secure it to the profile with a self-tapping screw. Additionally, the sluts are reinforced on the opposite side of the panel and at the lower bracket in the same manner.

Step 3: Install the other panel. The gaps between the panels should not be wider than 12 mm at their junction. Therefore, a ruler is required for installation. The panel is positioned correctly, and self-tapping screws are used at the corners to secure the brackets to the pre-fixed sluts.

Panels following the movie’s filming

The horizontal and width gaps are controlled by the same mounting method for the upper panels. Two techniques are used to design the corners: either the curved panels are mounted to give a semicircular or traditional corner shape, or the panels are joined precisely at the corners of the facade, leaving a gap throughout its height. A table, a clamping plate, a clamp, and a metal pipe with the required diameter make up a basic bending machine. Because the clamping plate is made of hard metal, it is covered with a felt gasket that protects the panels when they are flexible.

Utilizing aluminum composite panels for facade cladding

Video – installation of gaskets

Video – gluing a decorative film on the panel

Modern and adaptable, composite panels provide an excellent way to improve the appearance and usability of building facades. These panels are made up of layers, usually made of aluminum sheets sandwiched between two metal sheets with an insulating core. Excellent durability and thermal efficiency are provided by this construction, which also offers a variety of design options.

The lightweight nature of composite panels lowers structural load and facilitates installation, making it one of their main benefits. Because of this feature, they are especially well suited for new construction as well as renovations where speed and ease of assembly are critical requirements. Furthermore, composite panels are well-known for their resistance to weather and low maintenance needs, which lower long-term costs and promote sustainability.

Composite panels provide architectural designers a range of design options. They enable architects and designers to create a variety of visual effects because they can be produced in a broad spectrum of hues, textures, and finishes. These panels allow structures to stand out while still being functional, whether they replicate the appearance of natural materials like stone or wood or have striking, modern colors.

Furthermore, by improving a building’s thermal performance, composite panels aid in energy efficiency. By reducing heat gain in the summer and loss in the winter, the insulation core enhances indoor comfort and may even reduce energy use. Because of their thermal efficiency, composite panels are a sustainable option for facade solutions because they meet current building standards and regulations.

Video on the topic

Alucobond® Easy Fix // Benelux

Volumetric cassettes from composite panels

Beautiful facade of DPPs and composite panels. Features of installation and operation.

Milling and cutting composite panels

Cutting aluminum composite panels

Non -standard use of aluminum composite panels Aluminstroy.