Many customers find that problems like color fading and sheet cracking often arise even before the warranty period ends while bending ACPs. The main causes include low-quality materials, unsuitable coatings, and poor installation methods. For a brand like Reynoarch, openly discussing these factors helps build customer trust. It also aids customers in choosing the right ACPs and properly maintaining them.
Why does color fading happen early?
Impact of UV and Weather: One major factor is exposure to UV rays and changing weather conditions. Regular exposure to sunlight, rain, and temperature changes causes the pigments and binders in lower-quality coatings to break down. This leads to color fading, spotting, and a loss of gloss. Panels on sun-exposed facades or in hot, humid cities like Delhi deteriorate faster.
Concerning underperforming coatings, particularly those made with polyethylene (PE), some manufacturers use polyester-based coatings that break down when exposed to high levels of UV radiation and heat. This results in rapid color fading, the appearance of a white powdery film, and cracking. Such coatings are not suitable for the harsh weather conditions typically found in India.
Additionally, consumers or contractors sometimes install ACP panels meant for indoor use on outdoor structures. Since these panels are not designed to endure UV exposure, moisture, and pollution, their color changes quickly and significantly.
Why do sheets crack when bending?
What causes sheets to crack when they bend?
1. The reason for that crack on this sheet is the aluminum layer thickness is not thick enough. So the bond strength and weak intensity are poor, and it will cause it to crack when it is being bent or heated.
2. When a rough tool is used for cutting and excessive bending is carried out near the bending line, then it can weaken the surface as well as the core of aluminum, which results in small cracks, and over a period of time, these cracks will extend to a major crack. People usually do not see these problems until after the panel has been installed or its first heating cycles.
3. Temperature Changes and Wrong Installation: ACP panels behave differently when there are temperature changes. When the panels are too tightly contrained because of little or no space or flexible joints, internal stress builds up. When this occurs, paint layer or core cracks may manifest, especially at bends and corners. Failing to follow the repair instructions given by the manufacturer may void the warranty and cause visible damages.
Environmental and Misuse Factors: Pollution, humidity, and salty air in coastal or industrial zones accelerate corrosion, peeling, and color fading. In polluted cities, panels without strong protective coatings deteriorate more quickly. Dust, moisture, and acidic pollutants can all shorten the lifespan of ACP panels.
Handling and storage before installation also play a role. If panels are stacked poorly, dragged over rough surfaces, or stored in damp conditions, they can suffer dents, scratches, or moisture damage. These defects may later appear as fading or cracking, though customers might mistake them for manufacturing issues.
Cause problems
1. Thickness of aluminum coils supplied is insufficient.
When the supplied aluminum coil is under the specified thickness (for example, it is sold as 0.25 mm but actually measures 0.12-0.15 mm), the complete panel is made structurally weaker. This significantly increases the risk of cracking, oil canning, and early decay.
2. The “under-puff” coating that is low-quality paint or thin paint leads to color fading.
Applying an ‘under-puff’ (thin-layer or inferior-quality) coating causes degradation of the pigment and resin quickly because of UV rays, heat, and pollution. The surface takes on a chalky white color, a white powdery substance is released, and the color fades too quickly.
3. Inferior quality caused cracks in panels.
If the core is of poor quality or improperly manufactured, it becomes easily broken, resulting in a weak bond with the aluminum layers. The layers of the material separate (delamination) when it undergoes thermal expansion, bending, and impact, causing the fine cracks once they develop.
4. Providing B1-grade ACP instead of A2-grade is a misgrading or fraud situation.
If a manufacturer pretends to supply A2-grade fire-retardant ACP (FR-A2) while in reality supplying cheaper B1-grade or standard PE-core ACP, it is a case of misrepresentation. This can lead to fraud, particularly when the exteriors (facades) of a building are marketed as 'fire-resistant.'
How Brands Like Reynoarch Can Prevent This
They use weather-resistant coatings like PVDF or HDP that withstand UV rays and maintain color stability for years, even in harsh conditions. Improved coating processes also reduce tiny cracks and chalking.
They enhance core materials and bonding methods to prevent delamination and maintain flexibility without breakage, meeting warranty standards.
They offer clear installation and handling instructions. Providing detailed guides on proper fixing methods, allowing for thermal expansion, and on-site care support contractors in avoiding stress cracks and early failures. Brands that offer thorough training and reliable warranty support earn trust from architects and builders.
Conclusion
When ACP panels fade and crack, it is rarely merely a “manufacturing defect." Usually a result of poor-quality material, poor choice of coating, or incorrect manufacturing and installation. Selecting high-quality ACPs with weather-resistant coatings and following proper handling and installation procedures will ensure superior long-term performance. For brands like Reynoarch, focusing on quality and educating users is the best way to provide durable and visually appealing facades.
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