Top 5 ACP Installation Mistakes to Avoid for Long-Lasting Cladding

Aluminium Composite Panels (ACPs) have revolutionized modern architecture. Their versatility, aesthetics, and durability make them a top choice for façades across India, from government buildings to high-rise apartments. But even the best ACPs can fail if they are not installed properly.

Many projects run into issues not because of the panels themselves but due to ACP installation mistakes. From ignoring guidelines to overlooking weatherproofing, these errors can lead to water seepage, reduced lifespan, and costly repairs. This is why understanding and avoiding ACP installation mistakes is critical. Whether it’s an architect designing a façade, a builder getting facades fabricated, or a government body investing in public projects, knowing these pitfalls ensures value for money and long-term reliability.

In this guide, we will walk you through the top 5 ACP cladding mistakes professionals often make, how to avoid them, and why careful planning is the foundation of success.

Mistake 1: Ignoring Manufacturer Guidelines

Every ACP brand provides detailed technical manuals for installation. Unfortunately, one of the most common ACP cladding mistakes is overlooking these recommendations.

Manufacturer guidelines cover aspects like panel spacing, support systems, fixing techniques, and thermal expansion allowances. Ignoring these leads to misaligned panels, compromised safety, and faster wear and tear. When teams ignore these directions, panels may warp, joints may fail, and warranties can be voided. Following the manufacturer’s manual ensures that the panels perform as intended, resisting wind loads, temperature changes, and external stresses.

Best practice: Always consult the manufacturer’s instructions and involve certified installers to avoid such common ACP mistakes. Always conduct a site briefing before installation, ensuring contractors are trained on the brand-specific requirements.

Mistake 2: Using Incorrect Fasteners or Fixing Systems

Fasteners may seem like minor details, but they play a major role in façade performance. Using mismatched or low-quality screws, rivets, or sub-frames is one of the biggest ACP installation mistakes.

Incorrect fixing systems cause panels to loosen over time, especially in high-wind or seismic zones. This directly affects structural safety and aesthetics. For large-scale government projects, this error can lead to safety hazards and expensive rework. Architects and builders must prioritize tested fixing systems that comply with Indian safety standards.

Why it matters: Proper fasteners ensure the cladding remains stable and secure, even under high wind pressure or seismic activity.

Best practice: Choose corrosion-resistant fasteners approved for ACP cladding projects. Ensure compatibility between the fixing system and the panel design.

Also Read : 8 Mistakes Fabricators Do While Working with ACP Sheets

Mistake 3: Poor Weather Sealing

India’s climate brings heavy rains, humidity, and temperature fluctuations. Skipping proper sealing during ACP installation is among the most damaging mistakes to avoid when choosing ACP cladding.

Poor weather sealing leads to water ingress, corrosion of sub-structures, and even fungal growth behind panels. Over time, this undermines the panel’s strength and appearance. Good sealing practices include:

• Using high-quality, UV-resistant sealants
• Ensuring joints are smooth and uniform
• Leaving no gaps for rainwater or dust infiltration

Can ACPs be installed in rainy weather?

Yes, but it requires additional caution. Installation during heavy rain should be avoided, as moisture affects adhesive strength. If unavoidable, ensure panels are completely dry and sealants are cured properly.
Always use high-quality sealants and waterproof membranes. Proper joint sealing ensures ACP façades remain durable in coastal and monsoon-prone areas.

Mistake 4: Neglecting Thermal Expansion Gaps

ACPs are designed to expand and contract with temperature changes. Ignoring thermal expansion gaps is a frequent ACP cladding mistake that causes panels to bulge, warp, or crack.

Builders often overlook this detail in a rush to complete projects. The result is compromised façade aesthetics and functionality.
Architect’s Note: Always follow IS codes and manufacturer recommendations for expansion joint spacing to future-proof the façade.

Best practice: Follow recommended spacing for thermal expansion. A well-installed ACP façade accommodates temperature variations without distortion.

Mistake 5: Improper Handling and Storage Before Installation

ACPs are durable on the façade but sensitive during handling. Stacking panels directly on uneven ground, dragging them across surfaces, or exposing them to moisture before installation are common ACP mistakes that reduce panel quality.

Scratches, dents, or moisture damage before installation compromise both aesthetics and performance. This is one of the common ACP mistakes that seems small but leads to dents, scratches, and discolouration visible after installation.

Best practices include:

• Storing panels in a dry, shaded area
• Keeping them stacked vertically on flat supports
• Avoiding direct exposure to moisture before sealing

Proper handling ensures that panels not only look flawless but also perform as expected for decades. Store ACPs on flat, dry surfaces and handle them with protective coverings. Proper pre-installation care prevents avoidable long-term issues.

Also Read : The Perfect Installation System for Aluminium Composite Panel

Conclusion

Modern buildings demand façades that are not only beautiful but also reliable and long-lasting. While ACPs are engineered to meet these needs, incorrect installation can undo their advantages. By avoiding common ACP mistakes such as ignoring guidelines, using the wrong fasteners, neglecting weather sealing, skipping thermal expansion gaps, and mishandling panels, you can guarantee durability, safety, and aesthetics.

Whether you are building a corporate façade, a government institution, or residential towers, ACPs deliver unmatched performance when installed correctly. For policymakers and government bodies, promoting strict installation practices will help improve building quality across India.

Discover Aludecor’s advanced ACP solutions and technical support. Call 1800-102-0407 or visit aludecor.com/enquiry to consult with our experts for flawless ACP installation on your next project.

FAQs

Q1. What is the most common ACP installation mistake?
 Ignoring manufacturer guidelines is the most frequent error. It leads to misaligned panels, structural issues, and reduced panel life.

Q2. Can ACPs be installed in rainy weather?
 It is not recommended. Moisture during installation can compromise sealing and fixing systems, leading to long-term façade problems.

Q3. Do all ACP installations require weather sealing?
 Yes. Proper sealing prevents water ingress, protects sub-structures, and ensures ACP façades last longer in diverse Indian climates.

Q4. How can I ensure my ACP installation lasts for decades?
 Work with certified installers, follow manufacturer guidelines, use quality fasteners, allow thermal expansion gaps, and maintain regular inspections.