ALUCOBOND®

ALUCOBOND®

Known across the world as ‘the original’ ALUCOBOND® has been the market leader in aluminium composite panels since 1969.

ALUCOBOND® is known for its incredible properties, such as extraordinary flatness, a large variety of colours, and perfect formability. It has been developed to be both a rigid and flexible fascia material for architecture and is extremely weatherproof, impact-resistant, and break-proof, vibration-damping, and ensures easy and fast installation.

As a light composite material consisting of two aluminium cover sheets and a plastic core, this incredibly versatile product is also preferred in areas other than architecture – such as corporate design – and is widely used in industry and transportation.

ALUCOBOND® sold over a million sq.m of cladding material worldwide and has been awarded with numerous international prizes.

PRODUCT PROPERTIES

ALUCOBOND® is a composite panel consisting of two aluminum cover sheets and a polyethylene (virgin LDPE) core. The superb properties of this material offer architecture an inspiring new range of solutions – whether your project is a private home or a public building, corporate headquarters, office, or a trading/industrial complex – everything is possible with ALUCOBOND®.

It is also used extensively by organizations planning to create a new corporate design for retail chains, car showrooms, banks, petrol stations, etc.
ALUCOBOND® perfectly adapts to a building’s contours, flowing elements. It is the combination of formability, flatness, stability, and weather resistance that characterizes this material. Due to its composite structure, ALUCOBOND® can take on many different shapes. Though both stable and flat ALUCOBOND® can be perfectly formed without any loss to its rigidity.

Lightness meets rigidity

The composite structure of ALUCOBOND® means it has an impressive strength to weight ratio, even when compared to large panel sizes. Despite its low weight – which makes ALUCOBOND® easy to transport and handle – its rigidity helps maintain its shape and flatness, even when exposed to extreme temperature changes.

Sustainability

3A Composites is the parent company of ALUCOBOND® and is recognized across the globe as one of the leaders in the field of sustainability. Its reputation is spread far and wide, including among other diversified producers and raw material processing companies around the world.

The company’s unflinching commitment to sustainability – along with taking the needs of all key groups into account – enables it to make decisions of the highest economic, social, and ecological value. 3A Composites also commits to continuous self-improvement programs for environmental protection, many of which exceed government regulations.

ALUCOBOND® Lifecycle

Over decades of use in a rear-ventilated cladding system, ALUCOBOND® protects a building from weathering and the harmful effects of industrial and environmental pollution. It also acts as a barrier against solar radiation; the ventilated space between the ALUCOBOND® panels and the wall or the thermal insulation reduces heat transmission.

ALUCOBOND® also protects the wall of a building from high and rapid temperature changes; moisture can pass through the wall, yet the building structure remains dry.

During the lifecycle of ALUCOBOND® composite panels, no substances containing CFC are set free at any time. The core material does not contain any nitrogen, chlorine, or sulfur – therefore, it is the perfect choice for projects which require environmental-friendly materials.

The major advantages

  • Lower maintenance costs
  • Long-term preservation of the building’s structure
  • During winter there are major savings in heating costs
  • In summer there are major savings in air-conditioning costs
  • Reduction of thermal expansion
  • Reduction in crack formation

Recycling

ALUCOBOND® is fully recyclable. Both the core material and the aluminum cover sheets can be used in the production of new material.

ALUCOBOND® Thickness: 3/4mm

Length (mm)2500-69992500-69992500-69992500-69992500-6999
Width (mm) 1000 1250 1500 1575 1750
Length (mm) 2000-6800 2000-6800 2000-6800 2000-6800 2000-6800
Solid Colours available available available available not available
Metallic Colours available available available available not available
ALUCOBOND® Spectra & Sparkling available available available available —
ALUCOBOND® naturAL — not available not available — —
ALUCOBOND® Legno – Premium Wood not available available available — —
ALUCOBOND® Anodized Look available available available not available —
ALUCOBOND® Design not available available available — —
ALUCOBOND® Anodized* — available not available — —

Footnotes:
not available on request

Dimensional Tolerances

Due to manufacturing, a displacement of the cover sheets sidewise at the panel
edges up to 2 mm is possible.
Thickness: ± 0,2 mm
(mill-finish | stove lacquered | anodized)
Width: – 0 / + 4 mm
Lengths: 2500 – 400 mm; – 0 / + 6
Lengths: 4001– 6999 mm; – 0 / + 10 mm
* Exception: ALUCOBOND® naturAL Reflect is only available in ALUCOBOND® plus.
THICKNESS CODE STANDARDS UNIT 3MM 4MM 6MM
Thickness of Aluminium Layers [mm] 0.5
Weight [kg/m²] 4.5 5.5 7.3
Width [mm] 1000 / 1250 / 1500
TECHNICAL PROPERTIES CODE STANDARDS UNIT 3MM 4MM 6MM
Section modulus W DIN 53293 [cm³/m] 1.25 1.75 2.75
Rigidity E·J DIN 53293 [kNcm²/m] 1250 2400 5900
Alloy / Temper of Aluminium Layers EN 573-3 EN 515 EN AW 5005A (AIMg1) H22/H42
Modulus of Elasticity EN 1999 1-1 [N/mm²] 70’000
CORE CODE STANDARDS UNIT 3 MM 4 MM 6 MM
Polyethylene, Type LDPE [g/cm³] 0.92
SURFACE CODE STANDARDS UNIT 3MM 4MM 6MM
Lacquering Coil Coating Fluorocarbon based (e.g. PVDF)
Gloss (initial value) EN 13523-2 [%] 30-80
Pencil Hardness EN 13523-4 HB-F
ACOUSTICAL PROPERTIES CODE STANDARDS UNIT 3MM 4MM 6MM
Sound Absorption Factor αs ISO 354 0.05
Sound Transmission Loss Rw ISO/DIS 717-1, EN ISO 140-3 [dB] 25 26 27
Loss Factor d EN ISO 6721, Frequency range 100-3200 Hz 0.0072 0.0087 0.0138
THERMAL CODE STANDARDS UNIT 3MM 4MM 6MM
Thermal Resistance R DIN 52612 [m²K/W] 0.0069 0.0103 0.0172
Heat Transition Coefficient U DIN 4108 [W/m²K] 5.65 5.54 5.34
Temperature Resistance [ºC] -50 to +80

Wind load and permissible panel sizes

ALUCOBOND® A2 3 mm
ALUCOBOND® A2 4 mm
The graphs for 3 mm and 4 mm thick ALUCOBOND® A2 indicate the maximum permissible panel length (σ = 53 N/mm²) (without having to add a stiffener) based in applicable design wind load and panel width. Values apply to 4-side supported panels. Values for other systems on request.

Tray panels suspended

on stainless steel bolts / vertical panel layout

Tray panel screwed

for vertical panel layout

Tray panels SZ-20

tongue and groove design / horizontal panel layout

Glued

for vertical / horizontal panel layout

Riveted / screwed

on omega carrier section for vertical panel layout

Riveted / screwed

on vertical profiles for vertical panel layout

Clamped / screwed

double “top-hat”sections

Riveted weather boarding

on aluminium substructure
Country Approval Name Approval Authority
Belgium UBATc 99/2368 ALUCOBOND® Cassettes; Bardage rapporté UBATc, Bruxelles
Czech Republic c.216/C5a/2009/0148 ALUCOBOND® PAVUS a.s., Praha
France n° 2/09-1372 ALUCOBOND® Riveté CSTB, Paris
France n° 2/09-1371 ALUCOBOND® Cassettes CSTB, Paris
Country Approval Name
EU EN 13501-1 Class D
Germany DIN 4102-1
DIN 4102-7		 Class B2 passed
France NF P 92-501
NF F 16-101		 Class M1
Class F0
To avoid possible reflection differences (for metallic, special effect, naturAL, and spectra colours), it is recommended to install the panels in the same direction as marked on the protective peel-off-foil. Colour variations may occur between panels originating from different production batches. To ensure colour consistency, the total requirement for a project should be placed in one order.
Dimensional tolerances
Thickness ±0.2 mm
Width -0 / +4 mm
Lengths 1000 – 4000 mm -0 / +6 mm
Lengths 4001 – 8000 mm -0 / +10 mm
Due to the production process, a displacement of the cover sheets of max. 2 mm to one side may occur along the longer sides of the panels if not specially trimmed.

Protective foil

  • To avoid residuals of glue sticking to the surface of the panels due to UV radiation, it is recommended to remove the protective foil as soon as possible after the installation.
  • The protective foils and the panel surfaces must not be marked using ink (marker), adhesive tapes or stickers, as the lacquered surfaces could be damaged by solvents or plasticizers.
  • Make sure to remove the protective foil as soon as possible after installation as weathering for a longer period could make the foil difficult to remove.
  • Cleaning and maintenance

Cleaning and maintenance

The frequency of cleaning depends on the design and the degree of soiling. For further information, please refer to our brochure.

ALUCOBOND®

Download our Alucobond processing manual
  Download as PDF [4.23 MB]

Storage / Handling

  • Protect ALUCOBOND® pallets during storage against rain, penetration of moisture and condensation.
  • Only pallets of identical size should be stacked, with a maximum of 6 pallets stacked on top of each other.
  • Storage exceeding 6 months should be avoided, as it may become difficult to remove the protective foil.
  • When stacking the panels nothing should be placed in between them, as this could produce marks on the panels.

Recycling

ALUCOBOND® can be fully recycled, i.e. both the core material and the aluminium cover sheets can be recycled and used for the production of new material.

Cutting

Punching

Contour Cutting

Bending

Roll Bending

Routing & Folding

Riveting

Screwing

ALUCOBOND® can be cut with a vertical panel saw, circular saw, or jigsaw. Carbide tipped (CT) saw blades.
Blade geometry Tooth thickness approx. 2 - 4 mm, tapered to the inside to prevent jamming
Tooth geometry Trapezoid tooth / flat tooth
Pitch t 10 - 12 mm
Clearance angle α 15°
Rake angle γ 10° positive
Maximum cutting speed v 5000 m/min
Maximum feed s 30 m/min
Carbide tipped (CT) saw blades for HOLZ-HER and Striebig circular panel saws. Trapezoid/flat tooth saw blade, flat teeth 45° chamfered for burr-free edges.
Saw blade-Ø D = 300 mm (for Striebig vertical panel saw Standard II)
Number of teeth t = 72 (for cuts of up to 5 panels) LEUCO Code No. 181724 t = 96 (for single cuts without burrs) LEUCO Code No. 181725
Saw blade-Ø D = 250 mm (for Holz-Her vertical panel saw 1255 ALUCOBOND®)
Number of teeth t = 60 (for cuts of up to 5 panels) LEUCO Code No. 181726 t = 80 (for single cuts without burrs) LEUCO Code No. 181727
Bore ø D = 30 mm
Tooth thickness 3.2 mm
Clearance angle α 15°
Rake angle γ 10 ° positive
 

ALUCOBOND® panels of any thickness can be punched using conventional sheet punching machines.
  • For clean cuts use sharp tools and dies with minimal cutting clearance (0.1mm). Punching will cause a slight deflection at the cut edge of the impact side.
  • Holes having a minimum diameter of 4mm can be punched.
  • Distance between the adjacent hole edges should not be less than 4mm.
  • Please ask for detailed information on how to perforate ALUCOBOND® before proceeding.
ALUCOBOND® can be cut to shape using jigsaws, a CNC machine, and a waterjet machine.
  • While using a jigsaw, use saw blades that are used for cutting wood and plastic material.
  • Cut abrasively while using a waterjet cutting machine. Predrilling of panels is required before commencing.
  • While using a waterjet, a cut is needed in the middle of the panel as it is not possible to drill through using a waterjet.
  • CNC machining centres should use a one edge cutter.
ALUCOBOND® can be bended using a bending press.
  • The minimum required radius is r = 10 x t (t = panel thickness).
  • The spring-back effect of ALUCOBOND® is greater than that of a solid aluminium sheet.
  • The die edges should be rounded and smooth.
  • To prevent damage to the panel surface, protective foil must not be removed during bending.
  • Additionally, the visible surface can be protected by using plastic pads of 1-2mm thickness
  • Ideal die width: 2 x t + 2 x protective foil thickness + punch diameter + 15mm
  • Before scaled-up production, testing on the sample panels is recommended.
 

A = punch

B = protective foil

C = die

D = die width

r = radius

  • ALUCOBOND® can be bent using a roll bending machine (3 or 4 rollers). Make sure that the feeder does not exert too much pressure. Bending rollers which are also used for bending other metals must be thoroughly cleaned from swarf before processing ALUCOBOND®. Make sure to use only polished rollers free of dents and other defects.
  • To prevent damage caused to the panel surface, the protective peel-off foil must not be removed during bending. Additionally, the visible surface can be protected by using plastic pads of 1–2mm thickness.
  • Before scaled-up production, testing on the sample panels is recommended.
Important: When bending ALUCOBOND® with an anodised surface, the bent area is brighter.
ALUCOBOND® composite panels can be shaped using a very simple processing method. The technique –called the routing and folding method – enables a fabricator to produce shapes of various kinds and sizes. A V-shaped or rectangular groove is routed on the reverse side of the ALUCOBOND® composite panel using a disk or end milling cutter. A thin layer of the core material should be left at the base of the groove, i.e. on the inside of the outer cover sheet. The untouched outer cover sheet can now be bent manually, giving an exact and clean folding line which follows the routed groove. The outer radius of the folded edge depends on the shape of the groove and its depth. We recommend that routing should be done using a vertical panel saw equipped with ALUCOBOND® grooving accessories, CNC machines, a portable sheet milling machine or handheld router. Routing and folding can be done on all the standard surface and finishes of ALUCOBOND® composite panels
Important: When folding ALUCOBOND® with an anodised surface, the folded edges are brighter. Advantages The convincing advantages of this unique technique are:
  • Low investment cost
  • Simple fabrication technique
  • Folding can be done on site, saving transportation cost
  • Low-cost fabrication of shaped components used in fascia and wall cladding, roof edgings, column cladding, flashings, etc.
  • Flexibility in creating shapes
  • Very economical
  • Shapes are not limited by machine capacity
Benefits
  • The fabrication of shaped components using ALUCOBOND® only requires a minimal investment outlay.
  • Hand routers and sheet milling machines are inexpensive and can be used either in the workshop or on site.
  • The fabrication of shapes in larger quantities is particularly economical using vertical panel saws equipped with ALUCOBOND® grooving accessories.
90° V-groove for folds up to 90° routing_21
135° V-groove for folds up to 135° routing_21
Rectangular groove for folds up to 150°, depending on panel thickness. Not suitable for ALUCOBOND® A2. routing_21
Riveting is possible using solid or blind rivets with conventional riveting tools. For exterior applications allow for thermal expansion and use a rivet attachment jig if necessary. ALUCOBOND® panels can be fastened together or joined to other materials using rivets commonly used in aluminium construction. For outdoor use and for use in areas of high humidity, make sure to use aluminium blind rivets with stainless steel mandrels to prevent unpleasant corrosive edges. When using aluminium blind rivets with steel mandrels, the mandrel should drop out after riveting (detachable version). Countersunk rivets are suitable for indoor use only.

For outdoor use please note:

  • Use aluminium blind rivets that have been approved for construction with a 5mm shaft diameter and an attachment head diameter of 11mm or 14mm.
  • Please take the thermal expansion of the panel into account (2.4 mm/m/100°C). To avoid jamming, the hole in the panel must be large enough to allow for expansion.
  • With the shaft of the rivet fitting closely to the edge of the hole, the attachment head must cover 1mm of the area surrounding the hole.
  • Multi-step drills or sleeves with corresponding diameters are used for centrically drilling holes into the panel and the substructure for centrically fitting the rivet.
  • Rivet attachment jigs are used for fitting blind rivets without jamming, allowing for a tolerance of 0.3mm.
  • Make sure to use rivet attachment jigs and rivets from the same manufacturer, as the height of the attachment head according to DIN 7337 may vary.
  • The clamping thickness results from the thickness of the material to be riveted plus an additional value of 2mm to ensure that the closing head is perfectly formed. In accordance with this clamping thickness the corresponding shaft length is determined in the tables provided by the rivet manufacturers. (Lmin = 14 mm).
Important: During riveting many factors influence exact tolerance of the rivets of 0.3mm (e.g. rivet head tolerance). We recommend testing on the fascia panels before commencing. Always remove the protective foil from the riveting surface area before riveting.
riveting1_021

Threaded fasteners for outdoor use

For outdoor use make sure to take the thermal expansion of the panel into account. To avoid jamming, the hole diameter in the panel must allow for the expansion. Fastening without jamming is possible using fascia screws made of stainless steel with sealing washer (Fig. 1) that have been approved for construction. The screws must be suitable for the corresponding substructure (please note the information given by the manufacturer). The screws should be tightened with a torque wrench or screwdriver so that the sealing washer is placed on the panel for sealing the bore hole without exerting pressure to the panel. Multi-step drills or sleeves with corresponding diameters are used for centrically drilling holes into the panel and the substructure, and for centrically fitting the rivet. Important: Make sure to remove the protective foil only from the screwing area prior to screwing.

Threaded fasteners for indoor use

Screws for sheet metal and wood with different head shapes can be used for indoor application (Fig. 2). They do not normally allow for any panel expansion. Countersunk screws can be inserted by the usual countersinking method or by depressing the aluminium surface into the panel. When depressing the aluminium surface, the hole diameter in the panel must be larger than the screw diameter.

Threaded fasteners for outdoor use

For outdoor use make sure to take the thermal expansion of the panel into account. To avoid jamming, the hole diameter in the panel must allow for the expansion. Fastening without jamming is possible using fascia screws made of stainless steel with sealing washer (Fig. 1) that have been approved for construction. The screws must be suitable for the corresponding substructure (please note the information given by the manufacturer). The screws should be tightened with a torque wrench or screwdriver so that the sealing washer is placed on the panel for sealing the bore hole without exerting pressure to the panel. Multi-step drills or sleeves having corresponding diameters are used for centrically drilling holes into the panel and the substructure and for centrically fitting the rivet. Important: Make sure to remove the protective foil in the screwing area prior to screwing.

Threaded fasteners for indoor use

Screws for sheet metal and wood with different head-shapes are suitable for indoor use (Fig. 2). They do not normally allow for any panel expansion. Countersunk screws can be inserted by the usual countersinking method or by depressing the aluminium surface into the panel. When depressing the aluminium surface, the hole diameter in the panel must be larger than the screw diameter.