ALUMINUM COMPOSITE PANELS

1. ALUMINUM COMPOSITE PANELS
Aluminium composite panel (ACP) also Aluminum composite
material(ACM) is atype of flat panel that consistsof two thin Aluminum
sheets bonded to a non-aluminum core.
Also known as Sandwichpanel, it is a structuremade of three layers:
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Low density core inserted in between
two relatively thin skin layers.
This sandwich setup allows to achieve excellent mechanical
performance at minimal weight.
The very high rigidity of asandwich panel is achieved thanks to
interaction of its components under flexural load applied to the panel.
Core takes the shear loads and creates a distancebetween the skins which
take the in-plane stresses,one skin in tension, the other in compression.
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AIM:
To gain knowledge about the prevailing practices and importance of A.C.P. as
a covering material for building.
OBJECTIVE:
To analyze its appearance on exterior walls.
To analyze its effect on the functioning of a building internally or externally.
Ambiance
HYPOTHESIS:
The factor included in covering the building envelope consists of various
materials. Aluminum composite panels are widely used in today’s
architecture. This study will explain various aspects of A.C.P. which includes
fixing details, color, texture, properties, advantages, disadvantages, sizes, etc.
This study will also explain its advantages over other traditional cladding
practices.
NEED IN ARCHITECTURE:-
It incorporates :-
New styles, varieties of colors & different shapes and textures
Used in exterior of buildings.
In interior design elements
Low thermal movement
Durability/long life
Low maintenance
Light weight

2. BASIC DEFINITION:-
Aluminum Composite Panel Cladding (ACP) is a widely-used term,
describing flat panels that consist of thermoplastic core bonded between
two aluminum sheets.
ACPs are frequently used for external cladding of buildings (building
facades). The main advantage of ACP is that, it is very rigid and strong,
despite of its light weight.
Due to the ability of painting the aluminum in any color, ACPs are
produced in a wide range of metallic and non-metallic colors as well as
patterns that imitate other materials, such as wood or marble.
Applications of ACPs are not limited to building’s external cladding; they
can be used in any cladding application, partitions, false ceilings etc.
ACP sheet are excellent in finish and are PVDF coated which is up to 35
micron.
It can be bent, cut, drilled, punched and easily shaped into complex
shapes. Easy installation and fabrication save cost and time periods of
construction.
ALUMINUM COMPOSITE PANELS

3. Properties of ACP:
Aestheticallypleasing: Other means of making astructurecannot
deliver the result as Aluminum Composite Panel does.
Good Insulation Material: Thermal and acoustical
Dead weightof the Compositematerialis very low.
Is resistant to heatup to a temperatureas highas of 113 degreeCelsius
after whichit starts deforming in the first placeand then fails.
Aluminum can be paintedin any kindof color,and ACPs are producedin
a wide range of metallic andnon-metallic colors as well as patterns that
imitate other materials, suchas wood or marble.
Fireproof and water resistant, excellent heat and sound insulation
Excellent surface flatness and smoothness
Superior weather, corrosion and pollutant resistance
Even coating, various colors
Super peeling strength
Superior impact resistance
Lightweight and easy to process
Easy to maintain
ACP as a constructionmaterial:
ACP is mainly used for external and internal architectural cladding or
partitions, false ceilings, Sign trays, Individual logos, Column cladding,
Counter cladding, Grilles and screens, Machine parts and covers, Display
panels etc.
Advantages of ACP overother building Materials:
Adding truebeauty to a structure
An economical option
Easily andquickly processed
Long lasting durability
Excellent weather resistance
Outstanding thermal comfort
Improved sound dampening
Least maintenance required
ALUMINUM COMPOSITE PANELS

4. Manufacturing of ACP:
The very first stage of the production process is the selection of raw
materials through rigorous tests.
Firstly, the Plastic Granules are sent for 'Oven Test', where the density and
strength of the granules (LDPE shape) are accessed.
Alongside, is done the checking of Aluminium Coils in Spectrometer so as
to confirm its thickness, coating quality and aluminium grade as per
international standards.
Now, matching of colors to avoid all possible chances of color variation
follows.
This stage is completed by testing the Adhesive Film from Resins, having
the thickness of 50- 70 microns.
Once each production material is repeatedly checked and tested to
ensure flawless manufacture, the actual process commences.
In the beginning, the LDPE and HDPE Granules are mixed in accurate
ratio.
The mixture is processed in the Dryer and later in the Extruder, where the
Granules melt and culminate into PE core.
Correct temperature is maintained in the Extruder to give the accurate
shine and flow to the PE core.
The tested Adhesive film is now pasted on both sides of the core, and
they are forwarded into the Compounding Roll. At a particular high
temperature, colored coils are now fixed on both sides of the core, inside
the compounding roll.
This process assures optimum strength. After the compounding the
'Quality Inspector' checks the quality of the ACP sheets being
manufactured to assure defect-free production.
This is followed by the Cooling Process and soon after, a Protective film is
pasted on the ACP sheets. This film provides is a safeguard against
transportation and installation damages. And finally, after satisfactorily
passing through different hard tests for ensuring tensile strength, peeling
strength and more, the ACP sheets are cut in appropriate required sizes
and are dispatched.
COMPOSITION:
Two sheets of aluminum sandwiching a solid core of extruded Non-
combustible mineral core material formed in a continuous co extrusion
process with no glues or adhesives between dissimilar materials.
The core material shall be free of voids and/or air spaces and not contain
foamed insulation material.
Exterior / Face panel is Aluminum Sheet Coated with PVDF and interior /
Rear side of Panel will be available Mill Finish / Polyester Service Coat /
Chromate.
ALUMINUM COMPOSITE PANELS
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5. PROCESSING TECHNIQUES:
Sawing and Cutting
Aluminium Composite Panel can be sheared easily by using a carbide tip
saw. Also guillotine shears can be used (Figure 2). However, shearing by
using guillotine shears may cause a slight tilt at an approximate angle of
1° - 1, 5°, in the shearing process at the point of shear.
Jointing Angles
Aluminium Composite Panels can be easily bent and shaped by single roll
press machine. Bending angle is determined by the mould width, roll
radius, stroke force and stroke distance. Front opening of the mould must
be smooth and in a specific radius.
The two ends of shaping mould must not be sharp cornered but rather
rounded at a specific radius. Besides a soft buffer material can be placed
to prevent crushing. The ideal mould width is calculated using the formula
below. Bending radius is 40-55 mm with press and 200-300 mm with
three roller machine.
Removing Edges and Folding
Initially, it is started by opening V shaped canals at 25 mm distance from
panel sides. Panel corners are removed and bent towards the dyed side
and a 25 mm deep cassette formed then panel corners are reinforced by
either riveting or bonding of aluminium pieces.
After Jointing, Aluminium Composite Panel can be folded and shaped on a
smooth and straight surfaced desk. Recommended temperature is
between 20°C and 35°C. Folding process must be done under 10°C or
lower temperatures otherwise cracking of dye can be possible.
ALUMINUM COMPOSITE PANELS

6. •LOCATION – LOTUS PARADISE, C-3, MAHAL YOJNA, GONER ROAD,
JAIPUR, 302017
•CLIMATE - COMPOSITE
•PROJECT TYPE - COMMERCIAL COMPLEX
•PROJECT STATUS - UNDER CONSTRUCTION
•ORIENTATION - EAST FACING
Joinery details in construction:-
ALUMINUM COMPOSITE PANELS
CASE STUDY:- LOTUS PARADISE MALL