PVDF (fluoropolymer)
Two- or three-coat coil coating with a high fluoropolymer resin content; the standard for exterior facades because of its colour and gloss retention. In North America, high-performance coatings are tested to AAMA 2605.
Wall panel materials guide
Aluminium Wall Panels: Choosing the Right Panel Material
Aluminium wall panels line interior walls, clad facades and form partitions because they are light, flat, durable and available in almost any colour. The four main panel types are solid aluminium sheet, aluminium composite material (ACM), aluminium honeycomb panel and insulated sandwich panel. This guide compares them for fabricators, system companies and project buyers, and explains the alloys, thicknesses, coatings and fire classes to specify.
- Panel types
- Solid, ACM, honeycomb, insulated
- Common alloys
- 3003, 3105, 5005, 5052
- Solid sheet
- Typically 1.5 – 4 mm
- Finishes
- PVDF, polyester, powder, anodised
What an aluminium wall panel has to do
A wall panel is judged on flatness, appearance over decades, fire performance, weight and how easily it can be fabricated and fixed. Aluminium scores well on all of them: a 3 mm solid panel weighs about 8 kg/m², it does not rust, it takes durable factory-applied coatings and it can be folded, routed and perforated with simple tools.
Metline supplies the aluminium that panel makers and installers work with: coil and sheet in architectural alloys, pre-painted and anodised sheet, skin coil for composite panels, honeycomb core and panels, and extrusions for sub-frames and trims. We do not fabricate or install wall systems; the guidance below explains what the panel must achieve so that you can order the right material.
Exterior facade cladding has additional structural and regulatory demands; for that angle see our pages on aluminium cladding panels and facade systems.
Four types of aluminium wall panel compared
| Type | Build-up | Strengths | Watch-outs | Typical use |
|---|---|---|---|---|
| Solid aluminium panel | 1.5 – 4 mm sheet, folded into trays, often with welded or bonded stiffeners | Best fire performance (aluminium is non-combustible), very durable, fully recyclable, can be curved and perforated | Heavier and less flat than composites at large sizes; needs stiffeners | Facades, soffits, column covers, high-traffic interiors |
| Aluminium composite (ACM) | Two thin skins (about 0.3 – 0.5 mm) bonded to a polymer or mineral-filled core, usually 3 – 6 mm thick | Very flat, light, economical, easy to rout and fold | Core choice decides fire performance; PE cores are restricted on many buildings | Signage, interiors, low-rise facades (FR or A2 cores) |
| Aluminium honeycomb panel | Aluminium skins bonded to aluminium honeycomb core, typically 10 – 25 mm | Highest stiffness-to-weight, exceptional flatness over large spans | Higher cost, edges must be sealed | Large-format feature walls, lobbies, transport hubs, stone-look panels |
| Insulated sandwich panel | Aluminium faces bonded to PIR/PU, mineral wool or EPS core | Thermal insulation and wall in one element | Foam cores need fire assessment; mineral wool is heavier | Cold rooms, industrial buildings, clean rooms, modular units |
A useful rule: if fire performance or a very long service life comes first, use solid aluminium; if flatness at low weight and cost comes first indoors, use ACM with a suitable core; if a large panel must stay perfectly flat, use honeycomb; if the wall must insulate, use a sandwich panel.
Alloys, tempers and thickness for solid panels and skins
| Alloy | Typical temper | Why it is used |
|---|---|---|
| 3003 | H14, H24 | General-purpose architectural alloy: good formability, strength and corrosion resistance; the most common solid-panel alloy |
| 3105 | H14, H24, H26 | Widely used for pre-painted coil, composite skins and trims |
| 5005 | H14, H24 | Preferred where panels are anodised, because it gives a uniform anodised colour; common in European facades |
| 5052 / 5754 | H32, H22 | Higher strength for thinner or larger panels and coastal exposure |
| 1100 / 1050 | H14, H24 | Interior panels and composite skins where formability matters more than strength |
Solid exterior panels are usually 2.5 – 4 mm, with 3 mm the most common, while interior linings and partitions often use 1.5 – 2 mm. Composite skins are much thinner because the core provides stiffness. Weight is easy to estimate: 3003 sheet weighs about 2.73 kg/m² per millimetre of thickness.
| Sheet thickness (mm) | Approx. weight (kg/m²) |
|---|---|
| 1.0 | 2.73 |
| 1.5 | 4.09 |
| 2.0 | 5.46 |
| 2.5 | 6.83 |
| 3.0 | 8.19 |
| 4.0 | 10.92 |
| 5.0 | 13.65 |
| 6.0 | 16.38 |
Coatings and surface finishes
Polyester (PE) and SMP
Lower-cost coil coatings for interiors and less exposed exteriors; AAMA 2603/2604 classes cover lower performance tiers.
Powder coating
Applied to fabricated panels after folding; tested in Europe under Qualicoat or GSB schemes; good for complex shapes and small batches.
Anodising
A metallic, non-peeling oxide surface; 5005 gives the most consistent colour. Exterior grades need adequate coating thickness and sealing.
Wood, stone and metallic effects
Printed or sublimated finishes on pre-coated sheet, plus brushed, mirror and embossed textures for interiors.
Perforation
Round, square or slotted patterns for acoustic absorption (with backing fleece and cavity) or ventilated facades.
Coil-coated sheet to EN 1396 is painted before fabrication, which gives the most consistent colour; specify the coating system, film thickness, colour reference and gloss together, and order all panels for one elevation from the same batch.
Fire classification of aluminium wall panels
Fire regulations now drive panel choice on many buildings. Aluminium metal itself is non-combustible, so solid aluminium panels and honeycomb panels with an aluminium core achieve the highest reaction-to-fire classes. With composites and sandwich panels the core and adhesive determine performance.
| Panel type | Typical reaction-to-fire result | Comment |
|---|---|---|
| Solid aluminium with inorganic coating | Best classes (non-combustible or A1/A2) | Organic coatings are thin; confirm the class with the coating supplier |
| ACM with polyethylene (PE) core | Combustible | Restricted or banned on facades of tall and many other buildings in several countries |
| ACM with fire-retardant (FR) core | Typically B-s1,d0 | Check national rules for building height and use |
| ACM with A2 mineral core | A2-s1,d0 | Used where combustible cladding is not permitted |
| Honeycomb with aluminium core | Typically A2-s1,d0 | Depends on adhesive and skins |
| Sandwich with mineral wool core | A1/A2 achievable | PIR/PU cores need system testing |
European classes refer to EN 13501-1. In the US, exterior wall assemblies are commonly tested to NFPA 285 and surface burning to ASTM E84. Always use the classification document for the exact product and system.
How wall panels are fixed and what that means for the material
- Hook-on or pin-and-hook trays: folded solid or ACM cassettes hang on a sub-frame; panels can be removed individually. Requires accurate folding and corner notching.
- Concealed clip and Z-clip: clips on the panel back engage rails; common for interior linings and partitions.
- Exposed fixing: screws or rivets through the face; simple and cheap for industrial walls, trailers and garages.
- Structural bonding: adhesive tapes and silicones bond panels to sub-frames; needs clean, primed surfaces and compatible coatings.
- Sub-frames: extruded aluminium rails, brackets and helping-hand brackets carry the panels and allow thermal movement.
Design for thermal movement: aluminium expands about 2.4 mm per metre for a 100 °C change, so a 4 m panel moving between −10 °C and 70 °C changes length by roughly 7.5 mm. Slotted holes, floating fixings and open or sealed joints of suitable width prevent buckling. Check wind-load deflection for large panels and add stiffeners where needed.
Where aluminium wall panels are used
- Commercial interiors: lobbies, feature walls, lift lobbies, retail and hospitality interiors
- Public and transport buildings: airports, stations and hospitals, where cleanability and fire class matter
- Facades and soffits: rainscreen cladding, column covers, canopies and fascias
- Industrial and cold-chain buildings: insulated walls, cold rooms and clean rooms
- Partitions and modular rooms: offices, control rooms and laboratories
- Vehicles and modular units: trailer and container walls, site cabins
References and standards
- EN 13501-1 – Fire classification of construction products and building elements: reaction to fire
- EN 1396 – Aluminium and aluminium alloys: coil coated sheet and strip for general applications
- AAMA 2605 – Superior performing organic coatings on aluminium extrusions and panels
- NFPA 285 – Fire test method for exterior non-load-bearing wall assemblies
- ASTM B209 – Aluminum and Aluminum-Alloy Sheet and Plate
Aluminium (aluminum) wall panels: FAQ
What thickness of aluminium sheet is used for wall panels?
Solid exterior panels are typically 2.5 – 4 mm, most often 3 mm. Interior linings and partitions commonly use 1.5 – 2 mm. Composite panels are usually 3 – 6 mm overall with skins of about 0.3 – 0.5 mm.
Which aluminium alloy is best for wall panels?
3003-H14/H24 is the general choice for painted solid panels; 5005 is preferred when panels are anodised; 5052 or 5754 suit larger or coastal panels that need more strength; 3105 is common for pre-painted coil and composite skins.
Are aluminium composite panels safe on facades?
It depends on the core. Polyethylene-core ACM is combustible and is restricted on many buildings. Fire-retardant (FR) and A2 mineral-core panels, solid aluminium and aluminium honeycomb panels are used where higher fire classes are required. Always check local regulations.
How long do coated aluminium wall panels last?
Properly specified PVDF-coated or anodised panels routinely give decades of service outdoors; coating warranties vary by system and exposure. Interior panels last essentially indefinitely with simple cleaning.
Are aluminium wall panels recyclable?
Yes. Solid aluminium panels and honeycomb panels are fully recyclable, and aluminium can be remelted repeatedly without losing its properties. Composite panels are recycled by separating the skins from the core.
Does Metline install wall panel systems?
No. Metline supplies the aluminium sheet, coil, composite skins, honeycomb and extrusions used to make wall panels, cut and finished as required, to fabricators and project buyers worldwide.
Sourcing aluminium for wall panels?
Tell us the panel type, alloy, thickness, finish and quantities. We will quote the sheet, coil or panel material delivered to your site or factory.
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