ACP Installation — A Step-by-Step Guide for Contractors

Correct installation is as important as the quality of the ACP panel itself. A poorly installed panel can buckle, leak or fail — even if the panel specification is excellent. This guide covers the complete ACP installation process for facades.

Step 1 — Substrate Preparation

Ensure the substrate structure is plumb, level and structural sound. For concrete or masonry walls, apply a waterproof membrane. For steel or aluminium framing systems, verify galvanization or anodizing of all components.

Step 2 — Setting Out

Mark panel joint lines on the substrate at 1200mm (or design) centres horizontally and vertically. Check for plumb and level at every storey. Install horizontal and vertical guide lines.

Step 3 — Sub-Frame Installation

Fix horizontal and vertical aluminium sub-frame members (T or Z sections) to substrate at marked positions. Use stainless steel fasteners. Ensure all fixings are plumb and level. Minimum fixing centres per structural engineer design.

Step 4 — Panel Routing & Folding

ACP panels must be routed to form a return fold at edges for fixing and weathering. Use a V-grooving router set to leave 0.3–0.5mm of core intact. Fold carefully to the designed return width (minimum 15mm). Never cut through the full depth of the panel at a fold.

Step 5 — Panel Fixing

Fix panels to sub-frame using concealed rivets, screws or clip systems per design. Leave a minimum 10mm joint gap between panels. Do not over-torque fixings — allow for thermal expansion. Apply joint backing rod and weatherproof sealant to all exposed joints.

Step 6 — Sealant & Finishing

Use a neutral-cure silicone sealant compatible with PVDF coatings. Apply consistently at designed joint widths. Remove protective film from panel face only after sealant is cured and site works are complete. Clean with mild detergent and water — never solvents or abrasives.