Efficient Building Materials

Aluminium
Composite Panels
Life Cycle Assessment

Roopa Iyer
Semester 11: TAE114 – E11
Rachana Sansad’s Institute of Environmental Architecture
YCMOU
 CONTENTS

SR.NO DESCRIPTION PAGE

Acknowledgement
1. Introduction to Aluminum Composite panel sheet
2. Introduction to chosen brand
3. Raw material :
• Introduction
• Processing
• Properties
• Source
4. Process of ACP sheet
5. Methods of installation
6. Properties of ACP
7. Energy consumption calculation table:
• Primary Energy
• Transportation
• Total embodied energy
8. Labour
9. Applications
10. Maintenance
11. Cost
12. Environmental impact
13. Modes of reducing the impact
14. Alternative material:
• Clay tile cladding
Bibliography
Efficient Building Materials LCA

ACKNOWLEDGEMENT

This assignment would not have been possible without the help of my guides
Prof. Roshini Udyavar, Prof. Ashok Joshi.

I would also like to thank Mr. Mehul Joshi, technical manager of Eurobond Industries Pvt. Ltd, &
Mr. Vineet (Fabricator) for helping with the collection of data.

I am Thankful to Ar. Chirag Jain (Partner), UCJ architecture & environment, for helping with data
access & information.

I am grateful to my family for their patience.

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INTRODUCTION

Today our cityscape consists of these buildings - MODERN BUILDINGS!!!

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Aluminium Composite Panel (ACP) is a widely-

used term, describing flat panels that consist
of a non-aluminium core bonded between two
aluminium sheets. Aluminium sheets can be
coated with PVDF or Polyester paint. 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 its light weight. Due to the
ability of painting the aluminium in any kind of colour, ACPs are produced in a wide range of
metallic and non-metallic colours as well as patterns that imitate other materials, such as wood
or marble.

Applications of ACPs are not limited to external building cladding, but can also be used in any
form of cladding such as partitions, false ceilings etc. Aluminium Composite Panels are also
widely used within the signage industry as an alternative to heavier, more expensive substrates.

The idea of this ACP came out form the sandwich panel was made for big refrigeration area such
as rooms, the thickness was not less than 10cm and also it is used in big roof bulidings in the area
of the Arabic gulf , The ACP main idea is to have good looking surface along with good isolating
material , as most of ACP's inside layer is made of low density Polyethylene .

Aluminium Composite Panel (ACP) sheet also known as sandwich panels consists of low density
polyethylene (LDP) core sandwiched between two aluminium foils.

The entire panel consists of the following layers:

1. Top Aluminium foil

2. Low density Polyethylene Core
3. Bottom Aluminium foil

The top Aluminium sheet is coated with either Polyester or PVDF paint
The Core is either Low density Polyethylene or a Fire resistant core which is specially treated for
fire resistance
The bottom aluminium sheet comes with anti corrosive primer or (6-8 micron) backside paint

• PROTECTIVE FILM
• PVDF CLEAR COAT
• PVDF BASE COAT
• PVDF PRIMER COAT
PROTECTIVE FILM • HIGH STRENGTH ALUMINUM FOIL
• ADHESIVE FILM

• LOW DENSITY POLYETHYLENE CORE

• ADHESIVE FILM
• HIGH STRENGTH ALUMINUM FOIL
• BACK COAT
• DOUBLE PE LAYER TO BE REMOVED
AFTER INSTALLATION

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BRAND INTRODUCTION

Eurobond Aluminum Composite panels:

Eurobond Industries' Aluminum Panel Sheet lounge has a very compatible,

composite adaptable and flexible range of decorative products that have got
culminatedly the result of German technology by the names Platinum, Pearl, Ruby,
Gold, Silver, Bronze, Kohinoor, Diamond and Crystal, in their ethnic collection for the
customers.

Eurobond Aluminium panel Sheet is sandwich with top & bottom layers of aluminium, non – toxic
polyethylene cores materials. Both surface of foil coated with special baking varnish.

• Eurobond Industries Pvt. Ltd., established in 2002, is one of the leading manufacturing
companies in construction materials. They manufacture ‘Eurobond’ brand Aluminium Panel
Sheet, Fire resistance Aluminium Panel Sheet and so on. The manufacturing unit is in Jammu,
India. Eurobond Industries Pvt. Ltd. is an ISO 9001:2000 Certified Company.

• Eurobond imports the Aluminium foil from China. The Aluminium foil is produced within
China. They use Aluminium alloy 1100-H18. The Aluminium content for unalloyed aluminium
not made by a refining process is the difference between 100% & the sum of all other
analyzed metallic elements present in amounts of 0.010% of more each, expressed to the
second decimal before determining the sum.

• Eurobond uses 2nd grade LDPE which is one time recycled for its production. It is sourced
from local companies

• The protective film (Double PE) protects panels when cutting, transiting, grooving and folding
to avoid mechanical damage and contaminated surface. After finishing installation, protective
film should be peeled off.

• Adhesive film (protective film): EAA – ethylene crylic acid co-polymer.Eurobond panel sheets
adopt the first grade adhesive film supplied by DU Pont. Film thickness >0.07mm for 0.50mm
aluminium sheet & >0.05mm for 0.25mm aluminium sheet

• Coating: PVDF – KYNAR 500 (70% min)

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Map showing Eurobond ACP office (with stocking facilities):

Sandwiching plant location

Depots for ACP’s

Study location

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EARTH RAW MATERIAL PROCESS END PRODUCT

Alumina • ALUMINIUM • Sandwiching of Installation
FOIL Aluminium
• LDP • Product testing
• Pre-fabrication
• PVDF
• DOUBLE PE
FILM

• Aluminium foil:

Aluminium foil is aluminium prepared in thin metal leafs,

with a thickness less than 0.2 mm / 0.008 in, although
much thinner gauges down to 0.006 mm are commonly
used. Foils are commonly gauged in Mils. The foil is
extremely pliable, and can be bent or wrapped around
objects with ease. However, thin foils are fragile and
easily damaged, and are often laminated to other
materials such as plastics or paper to make them more
useful. It replaced tin foil in the mid 20th century.

Annual production of aluminium foil was approximately

800,000 tonnes in Europe and 600,000 tonnes (1.3 billion lbs) in the USA in 2003. Approximately
75% of aluminium foil is used for packaging of foods, cosmetics, and chemical products, and 25%
used for industrial applications (eg. thermal insulation, cables and electronics).

Manufacture:

Aluminium foil is produced by rolling sheet ingots cast

from molten aluminium, then re-rolling on sheet and foil
rolling mills to the desired thickness, or by continuously
casting and cold rolling.

To maintain a constant thickness in aluminium foil

production, beta radiation is passed through the foil to a
sensor the other side. The continuous casting method is
much less energy intensive

Some lubrication is needed during the rolling stages;

otherwise the foil surface can become marked with a
herringbone pattern. These lubricants are sprayed on the
foil surface before passing through the mill rolls. Kerosene
based lubricants are commonly used.

Aluminium becomes work hardened during the cold rolling process and is annealed for most
purposes. The rolls of foil are heated until the degree of softness is reached, which may be up to
340°C for 12 hours. During this heating, the lubricating oils are burned off leaving a dry surface.
Lubricant oils may not be completely burnt off for hard temper rolls, which can make subsequent
coating or printing more difficult.

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Properties :

• Aluminium foils thicker than 0.025 mm (0.001 in) are impermeable to oxygen and water. Foils
thinner than this become slightly permeable due to minute pinholes caused by the production
process.
• Aluminium foil has a shiny side and a matte side. The reflectivity of bright aluminium foil is
88% while dull embossed foil is about 80%.

World production trend of aluminium: output in 2005

In 2005, the People's Republic of China was the top producer of aluminium with almost a one-
fifth world share, followed by Russia, Canada, and the USA, reports the British Geological Survey.

Euro Source :

Aluminium foil is outsourced from China.

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• Low Density Polyethylene:

Low-density polyethylene (LDPE) is a thermoplastic made from petroleum. LDPE is commonly

recycled, and has the number "4" as its recycling symbol.

Properties:

• LDPE is defined by a density range of 0.910 - 0.940 g/cm³.

• It is unreactive at room temperatures, except by strong oxidizing agents, and some solvents
cause swelling.
• It can withstand temperatures of 80 °C continuously and 95 °C for a short time. Made in
translucent or opaque variations, it is quite flexible, and tough but breakable.
• LDPE has more branching (on about 2% of the carbon atoms) than HDPE, its tensile strength is
lower, and its resilience is higher.
• Its density is lower.
• LDPE contains the chemical elements carbon and hydrogen.

Chemical resistance:

• Excellent resistance (no attack) to dilute and concentrated acids, alcohols, bases and esters
• Good resistance (minor attack) to aldehydes, ketones and vegetable oils
• Limited resistance (moderate attack suitable for short-term use only) to aliphatic and aromatic
hydrocarbons, mineral oils, and oxidizing agents
• Poor resistance, and not recommended for use with Halogenated hydrocarbons.

Euro Source :

LDPE sourced from a local company.

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• PVDF:

Polyvinylidene Fluoride or PVDF is a highly non-reactive and pure

thermoplastic fluoropolymer.

Processing:

PVDF may be synthesized from the gaseous VDF monomer via a

free radical (or controlled radical) polymerization process.

This may be followed by processes such as melt casting, or

processing from a solution (e.g. solution casting, spin coating, and
film casting).

A quantitative defluorination process was described by mechanochemistry (Zhang , 2001), for

safe eco-friendly PVDF waste processing.

KYNAR 500 PVDF:

Kynar 500® is a premier finish for colorful metal buildings. Originally specified by many architects
for long life finishing on metal curtain walls for tall buildings and large industrial parks, Kynar 500
has grown in use for painted aluminum extrusions such as windows and storefronts.

KYNAR 500 paint haS extremely good gloss and color retention, and they have been used on
many prominent buildings around the world, e.g. the Petronas Towers in Malaysia and Taipei 101
in Taiwan, as well as on commercial and residential metal roofing.

Euro Source :

PVDF sourced from a local company.

• Double PE protective film:

Polyethylene film is a resinous material with thermoplastic

properties that is synthesized by inducing oxidative
polymerization of ethylene gas.
While the polyethylene is still supple, the tube is closed off at
one end and then blown to inflate and stretch the film into the
desired length and thickness.
The thickness of polyethylene film can be as thin as .0004 inch (10.16 microns).
Polyethylene or polythene (IUPAC name polyethene or poly(methylene)) is the most widely
used plastic, with an annual production of approximately 80 million metric tons.

Properties:

• Polyethylene film has ability to self-seal under controlled heat.

• Polyethylene sheets can be sewn or stapled together, or even bonded with glue.
• This material also helps to prevent the escape of moisture and heat.

Euro Source :
Double PE is sourced from DU PONT.

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Efficient Building Materials LCA

EARTH RAW MATERIAL PROCESS END PRODUCT

Alumina • Aluminium Foil • SANDWICHING Installation
• LDP OF
• PVDF ALUMINIUM
• Double PE film • PRODUCT
TESTING
• PRE-
FABRICATION

1. Sandwiching of Panel:

• The raw materials used in

EUROBOND APS production are
Aluminium sheet (0.50mm,
0.30mm, 0.25mm & 0.21mm) of
thickness in the form of coils, Low
density Polyethylene & special
adhesive in the roll form.

• The melted thermoplastic is

blended with special adhesive &
passes between the two
aluminium foils.

• With qualified high molecular film,

proper technology & strict quality
control, composite panel is
produced.

• The three parts (two aluminium

sheets & adhesive along with
polyethylene) are highly
compressed within the rolls
resulting in panel sheet.

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2. Product testing (@ Jammu plant):

The test includes :

• 180◦ peeling strength
• Dynamic character of raw materials by electronic universal tester,
• Colour difference,
• Boiling water resistance,
• finish coating thickness,
• Impact resistance,
• Gloss test,
• Adhesion test,
• Peel off Strength,
• Pencil hardness etc.

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3. Pre – fabrication:
The process of designing is mainly subjected to geometrical sizes of building & local wind load
etc. to calculate the parameters of the geometrical size of the single panel the density of the
reinforcement & the span of the column.

Ordinary Aluminium processing & wood working machines and tools can be used for fabrication
of the panel.

o Saw cutting: Usually vertical saws, of good quality

are being used. Even portable circular saws equipped
with a system of guides can be used, so as to ensure
straight-line cuttings.

o Shearing: Shear cutting can also be used for sizing a large

quantity of panels. Some shear drop may be observed at
the cut edge.

o Grooving:

Hand operated router machine: These tools are consisted of

routers that are available in the market and are used for wood
processing. If they are equipped with special routing bits-carbide
tipped cutter – the hand operated router can be used for a limited
number of processes. In this case the stability of the tool and the
guide - system considerably affect the quality of the routing.

Circular routing blades & router bits: Details of various types of

circular blades & router bits are shown in the figure. The supplier
of vertical panel saw offer special circular blades for the routing process of composite
aluminium panels.

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o Bending: Grooved panels can be bent with jig. Press brake or

plate punch.

o Bending with brake press: While bending the panel with press
brake, use of top die having desired radius

o Bending with 3 – Roller bender: Eurobond panels are bent in 3 –

roller bending machine for large size bending radius.

o Fastening / Riveting & Bolting: Eurobond panels can be faster together or joined to
aluminium extruded elements with rivets which are quite common to aluminium construction
works.

o Welding: Eurobond panel edges can be joined by

welding the core with the help of hot jet gun.

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EARTH RAW MATERIAL PROCESS END PRODUCT

Alumina • Aluminium Foil • Sandwiching of INSTALLATION
• LDP Aluminium
• PVDF • Product testing
• Double PE film • Pre-fabrication

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PROPERTIES OF ACP SHEET

Panel thickness Units 3mm 4mm 6mm

Panel Dimensions
Alumnium mm 0.25 0.50 0.50
thickness
EUROBOND Kg/m2 3.8 5.6 7.4
weight
Max. standard mm 1220, 1550
width
Standard Length mm 2440, 3050, 3660
Panel Dimensions Tolerances
Panel Thickness mm + 0.20
Panel width mm + 2.0
Panel length mm + 4.2
+ 3.0
Mechanical characteristics of Aluminum
Tensile strength N/mm2 145
tolerances (Rm)
Yield strength N/mm2 120
(Rp0.2)
Elongation (AS) % 5%
Modulus of N/mm2 70000
elasticity
Rigidity KNm 0.11 0.25 0.60
Alloy Al.1100 H18
Surface paint characteristics
Visible surface 3 layers & 2 layers PVDF 70% KYNAR - 500
layers
Temperature behaviour
Behavior in From -50 C to + 80 C
temperatures
Thermal 1.4mm per liner meter for temperature difference of 60 C
expansion
Thermal Insulation
Thermal W/m2K 0.29
insulation of LDP
Sound Insulation
Average Db 24 25 26
airborne

Panel thickness Units 3mm 4mm 6mm

Visible surface protection
Surface covered with self – adhesive Film thickness of 80 microns, film to be removed within
film, for protection against damage 45 days after installation
from handling and placing of the
material

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ENERGY CONSUMPTION CALCULATIONS

Primary energy:

ALUMINUM FOIL 204 MJ/KG 20.1MJ/KG (RE-CYCLED)

LDPE 103 MJ/KG

PVDF 90.4 MH/KG

DOUBLE PE FILM 85.9 MJ/KG

ACP SHEET 1.92 MJ/KG

PRE - FABRICATION 0.018MJ/KG

INSTALLATION 0.002MJ/KG

TOTAL PRIMARY ENERGY = 485.24 MJ/KG

TOTAL PRIMARY ENERGY(re-cycled aluminium)

= 301.34 MJ/KG

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Transportation energy:

CHINA JAMMU 89.88 MJ/KG

AL FOIL PLANT 3210km

JAMMU MUMBAI 5.65 MJ/KG

ACP DEPOT 1982 km

SHEET

ANDHERI MALAD 0.022 MJ/KG

DEPOT PRE - 8 km
FAB

MALAD SITE 0.071 MJ/KG

PRE - INSTALL 25 km
FAB

TOTAL TRANSPORTATION ENERGY = 95.623 MJ/KG

TOTAL EMBODIED ENERGY = PRIMARY + TRANSPORTATION

580.863 MJ/KG

TOTAL EMBODIED ENERGY = PRIMARY + TRANSPORTATION

396.963 MJ/KG

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LABOUR

Assuming installation of ACP sheet for a building of 30,000sq.ft.

Labour required for fabrication : 6nos.

Labour required for fixing : 4nos.
4 x 4 ft panel installation would take : 30 mins.

COST

Transportation Cost:

CHINA JAMMU 4000 Rs/MT

JAMMU MUMBAI 33,000 Rs/Truck

ANDHERI MALAD 1000 Rs/Truck

MALAD SITE 2500 Rs/Truck

Market Cost: (After Pre – Fabrication)

4mm(0.50mm) – 200 to 250 per sq. ft.

Labour Cost:
450 Rs. /day

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APPLICATIONS

Externally ACP is used as a cladding material.

1. Exteriors of Multi storey apartment
2. Curtain wall
3. Industrial & commercial construction
4. Wall cladding
5. Fascias & Soffit
6. Canopies
7. Elevators
8. Sign boards
9. Kitchen units
10. Display unit
11. Shop fronts

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MAINTENANCE

• Routine cleaning of the APS surface is recommended. It may be washed with solution of water
& detergent, followed by clean water rinse.
• The frequency with which the cleaning is to be carried out and the choice ofsuitable
cleaning agent depends largely on the position of the building being cleaned and
degree of contamination.
• The cleaning procedure involves the following steps:
o Machine cleaning
o Pre cleaning
o Soil removal
o Clean detergent & solutions
o Operation sequence
o Coating protection
o Scratch prevention

• Frequency of washing for various building types:

Rural area : 1-2 times/ year
Urban area : 2-3 times/ year
Low rainfall/coastal area : 3-4 times/ year
Heavy industrialized area : 6-8 times/ year

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ENVIRONMENTAL IMPACT

• ACP sheet is a composite material which is made up of high embodied raw materials.
• Waste produced during manufacturing process is approximately 10% of the material
produced. The waste produced is sent to Landfill sites or Incinerated.
• The Double Polyethylene film is to be removed after application, recycling the same involves
high energy & is difficult to re-cycle.
• The energy spent on importing & transportation of the material is 16% approx. of the total
embodied energy.
• Transportation cost is very high due to import of raw material from China.
• Material is manufactured & pre-fabricated in an enclosed, supervised environment. No
harmful gases are produced during the manufacturing process.
• Economic considerations:
o The high cost of Aluminum making process because of the huge amounts of electricity it
uses.
o The end product cost is very high.
• The individual raw material production has a huge impact on the environment:
o Environmental problems in mining and transporting the bauxite:

Loss of landscape due to mining, processing & transporting the bauxite.

Noise, water & air pollution involved in the operation.

Disposal of red mud into unsightly lagoons.

Transport of the finished aluminium.
• The life of the material is approx 12 – 20 yrs. As compared to almost lifetime of a
conventional material used building.
• The building would require a lot of maintainance energy, as given in the section above,
resulting in wastage of water.
• The main problems with aluminium are the very high energy costs when using virgin material,
and the unnecessary use of polyester powder coatings to colour the sheets.
• Once the life of the building is over, the panels cannot be recycled due to its composite
nature, where it becomes difficult to separate each raw material. Separation of the material
is a high energy involved process, even then the energy only 10 – 15% of the material can be
recycled & reused, and the energy involved is high.

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MODES OF REDUCING IMPACT

• Use of Re-cycled Aluminum:

o Saving of raw materials and particularly electrical energy by not having to extract the
aluminium from the bauxite. Recycling aluminium uses only about 5% of the energy used
to extract it from bauxite.
o Avoiding the environmental problems in the extraction of aluminium from the bauxite.
• Transportation of raw material from long distances to be controlled or avoided completely.
• Centrally located plants, to minimize transportation energy & cost
• Use of bio- degradable plastic: Biodegradable plastics are plastics that will decompose in
natural aerobic (composting) and anaerobic (landfill) environments. Biodegradation of
plastics can be achieved by enabling microorganisms in the environment to metabolize the
molecular structure of plastic films to produce an inert humus-like material that is less
harmful to the environment.
o Bio-derived polyethylene

The basic building block (monomer) of polyethylene is ethylene. This is just one small
chemical step from ethanol, which can be produced by fermentation of agricultural
feedstocks such as sugar cane or corn. Bio-derived polyethylene is chemically and
physically identical to traditional polyethylene - it does not biodegrade but can be
recycled. It can also considerably reduce greenhouse gas emissions. Brazilian chemicals
group Braskem claims that using its route from sugar cane ethanol to produce one
tonne of polyethylene captures (removes from the environment) 2.5 tonnes of carbon
dioxide while the traditional petrochemical route results in emissions of close to 3.5
tonnes.

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ALTERNATIVE MATERIAL

Though building façade design should be such that an external cladding application is not
required. Even if required Clay tile cladding could be adopted.

Clay tiles are manufactured from kaolinite clay with various additives. The minerals are vitrified
to bind the tiles at a high firing temperature in excess of 1100°C, the higher the temperature the
longer the life of the tile. The high temperatures involved lead to a high embodied energy.

Though the embodied energy is high,toxicity issues involved in the manufacture of clay tiles is
less.

The embodied energy of a single clay tile = 5-15MJ/KG

Clay tile façade:

Alupro Building systems –
Moeding Clay tile façade
(Ventilated Clay Tile Cladding
based on the rain screen
principle.)

The Concept of Rain screen:

Rain screen system

The Rain Screen Principle is based on fundamental laws of physics

• Resists water penetration not by sealing joints, but by
eliminating pressure differentials > Pressure equalization
• Back ventilation
• Heat-insulation fitted on the outside of the building

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Various clay tile sections:

Characteristics:
Based on the excellent material properties of clay the façade comes with additional advantages
of a natural material.

• Natural Clay with good insulation properties.

• Wide Variety of colours & finishes.

• Effective water drainage, base channel and weather protection of rear wall.

• A single tile could be replaced separately.

• High resistance with uniform weathering. Non-fading, anti fungal properties, UV resistant.

• Remarkable reduced heat losses.

• Effective weather protection and drainage of moister.

• High resistance against aggressive environmental effects of any nature.

• Uniform but natural weathering.

• Long life and high cost-effectiveness.

• Resistant to frost, UV, fire and salt-water. Non-fading colours.

• Noise insulation.

• Fully recyclable.

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Technology of Clay tile façade:

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Bibliography:

1. Information from Eurobond catalogue

2. http://eurobondindia.com

3. http://en.wikipedia.org/wiki/Aluminium_composite_panel

4. http://en.wikipedia.org/wiki/Aluminium_foil#Manufacture

5. http://en.wikipedia.org/wiki/Aluminium#Production_and_refinement

6. http://en.wikipedia.org/wiki/Low-density_polyethylene

7. http://www.gganeshan.com/picture/PE_LDPE_Process.jpg

8. http://www.symonite.co.nz/alucomat_xsec.jpg

9. http://www.alustrong.com/wall.jpg

10. http://en.wikipedia.org/wiki/Kynar

11. http://www.arkema-inc.com/kynar/page.cfm?pag=979

12. http://www.wisegeek.com/what-is-polyethylene-film.htm

13. http://en.wikipedia.org/wiki/Container_ship#Specifications

14. http://www.aluproindia.com/s-moeding.htm

15. http://www.archdaily.com/32778/nbk-terracotta-facade-panels-hunter-douglas-contract/

16. Embodied Energy in Buildings by Prof. B. V. Venkatarama Reddy Department of Civil

EngineeringIndian Institute of Science, Bangalore

17. http://www.greenbuildingpress.co.uk/archive/sustainable_roofing.php

18. http://en.wikipedia.org/wiki/Bioplastic

19. http://www.chemguide.co.uk/inorganic/extraction/aluminium.html

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