mineral / Metallic / Non-Ferrous Metals
Aluminum Alloy Sheet
Lightweight aluminum alloy sheets for cladding, roofing, and facade applications with corrosion resistance
Atlas code
MIN-MET-ALY-002
At-a-glance signals
Lightweight aluminum alloy sheets for cladding, roofing, and facade applications with corrosion resistance
Overview
Executive summary
Aluminium alloy sheet is a lightweight, corrosion-resistant metal cladding and roofing material manufactured from rolled aluminium alloys, primarily 3003, 5052, and 5251 series for architectural applications. With a density approximately one-third of steel (~2680-2730 kg/m3) and excellent corrosion resistance from its natural oxide layer, aluminium sheet is widely used in building facades, roofing, rainscreen cladding, soffits, fascias, and decorative architectural elements. Solid aluminium sheet (as distinct from aluminium composite panels with polyethylene cores) is classified as non-combustible when tested to AS 1530.1, making it fully NCC-compliant for external wall cladding on Type A and Type B buildings. Available finishes include mill finish, anodised (various colours), powder-coated (PVDF or polyester), and pre-painted coil. In Australia, major suppliers include Capral, Ullrich Aluminium, and various fabricators. While aluminium has high embodied energy due to energy-intensive smelting (~14-16 MJ/kg primary), it is 100% recyclable with recycling requiring only 5% of the energy of primary production, and products with >90% recycled content are available.
Best when…
- Lightweight - approximately one-third the weight of steel (2680-2730 kg/m3)
- Excellent natural corrosion resistance from oxide layer
- Non-combustible per AS 1530.1 (solid sheet) - full NCC compliance
- 100% recyclable with recycling requiring only 5% energy of primary production
- Excellent formability for complex architectural profiles
- Wide range of finishes (anodised, PVDF, powder coat, mill)
- Long lifespan (40-60+ years with quality coating)
- Low maintenance - wash down annually
- High strength-to-weight ratio
Top advantages
- 01 Lightweight - approximately one-third the weight of steel (2680-2730 kg/m3)
- 02 Excellent natural corrosion resistance from oxide layer
- 03 Non-combustible per AS 1530.1 (solid sheet) - full NCC compliance
- 04 100% recyclable with recycling requiring only 5% energy of primary production
- 05 Excellent formability for complex architectural profiles
Top limitations
- 01 Very high embodied energy and carbon for primary aluminium (8,300-12,460 kg CO2e/tonne)
- 02 High thermal conductivity creates thermal bridging issues requiring thermal breaks
- 03 Susceptible to galvanic corrosion when in contact with dissimilar metals
- 04 Higher material cost than steel or fibre cement cladding
- 05 Poor acoustic performance as solid sheet (NRC <0.10) - highly reflective
Technical
Physical ·9
- Density
- 2680-2730 kg/m3 3003 alloy: 2730 kg/m3. 5052 alloy: 2680 kg/m3. 5251 alloy: 2690 kg/m3. Approximately 1/3 of steel. Source: Atlas Steels Australia data sheets, MatWeb
- Specific gravity
- 2.68-2.73 Aluminium alloys
- Porosity
- 0 % Solid rolled metal - zero porosity
- Water absorption
- 0 % Zero - impervious metal
- Hardness
- 2.5-3.0 Mohs Aluminium alloys. Brinell hardness: 3003-H14 ~40 HB, 5052-H32 ~60 HB, 5251-H22 ~60 HB
- UV resistance
- Excellent (material), coating-dependent (finish) Bare aluminium unaffected by UV. Coating durability depends on type: PVDF/Kynar 25-30+ years, polyester 15-20 years, anodised indefinite. Source: coating manufacturer data
- Chemical resistance
- Good (atmospheric), Poor (strong acid/alkali) Good resistance to most atmospheric conditions and many chemicals. Poor resistance to strong acids and alkalis. Excellent in marine environments (5052 alloy). Susceptible to galvanic corrosion with dissimilar metals (copper, steel)
- pH tolerance
- 4-9 pH Aluminium corrodes in strongly acidic (<4) and strongly alkaline (>9) environments. Oxide layer stable in neutral to mildly alkaline range
- Surface roughness
- 0.4-5.0 um Mill finish ~0.4-1.6 um Ra. Anodised varies. Powder coated ~1-5 um Ra. Brushed ~0.5-2.0 um Ra
Mechanical ·7
- Tensile strength
- 150-320 MPa 3003 (H14): 150-200 MPa. 5052 (H32): 228-282 MPa. 5251 (H22): 200-260 MPa. Source: Atlas Steels Australia, Cumberland Metals, Wikipedia
- Compressive strength
- 130-220 MPa Similar to yield strength in compression for ductile metals. Thin sheet buckling is the governing failure mode, not material compressive strength
- Flexural strength
- N/A (governed by yield strength) MPa Sheet metal - flexural behaviour governed by yield strength and section properties (thickness, profile). Not measured as an intrinsic material property for thin sheet
- Shear strength
- 70-138 MPa 3003-H14: ~70 MPa. 5052-H32: ~125 MPa. 5251: ~125 MPa. Source: Atlas Steels, MatWeb
- Poisson's ratio
- 0.33 Aluminium alloys. Source: material property databases
- Impact resistance
- Moderate J Good energy absorption through plastic deformation. Denting occurs at moderate impact energy. Thicker sheet (2-3mm) and 5052 alloy offer better impact resistance
- Creep resistance
- Good Good creep resistance at ambient temperatures. Creep becomes significant above 150 degC
Sustainability & Health
Embodied carbon & energy ·7
- Embodied carbon
- 0.5-12.5 kg CO2-eq/kg Primary aluminium: 8.3-12.5 kg CO2-eq/kg (global average ~12.46). Recycled aluminium: ~0.5-2.0 kg CO2-eq/kg. Low-carbon options: Capral LocAl ~6.0 kg CO2-eq/kg. Source: MECLA, ScienceDirect, Capral LocAl data, ICE database
- Carbon footprint
- 3-74 kg CO2-eq/m2 Per m2 of 2mm aluminium cladding (~5.4 kg/m2). Primary: ~67-74 kg CO2/m2. Recycled: ~2.7-10.8 kg CO2/m2. Source: Abodo comparison study, MECLA
- Embodied energy
- 8-230 MJ/kg Primary aluminium: ~170-230 MJ/kg (very high). Recycled: ~8-12 MJ/kg (95% reduction). Source: ICE database, MECLA low-emissions aluminium report
- Water footprint
- 10-30 L/kg Primary aluminium production has moderate water consumption for cooling and power generation. Recycled aluminium significantly lower
- Recycled content
- 35-90+ % Market standard ~35% recycled scrap content. Products with >90% recycled content available. Aluminium is infinitely recyclable without quality loss. Source: Greenspec, net zero carbon guide
- Renewable content
- 0 % No renewable content - 100% mineral metal. However, smelters powered by renewable energy (hydro) significantly reduce carbon footprint
- Circular score
- 8.5 /10 Aluminium is a model circular economy material - 100% recyclable without quality loss, infinite recycling cycles, high scrap value ensures recovery. Current global recycling rate ~75%. Source: Aluminium Association, MECLA
Compliance & Fire
Fire performance ·6
- Combustibility class
- Non-combustible (A1) Non-combustible per AS 1530.1. Solid aluminium sheet (as distinct from PE-core ACP) meets NCC requirements for non-combustible external cladding on Type A and Type B buildings. Source: NCC, Network Architectural, Probond PROMINIUM CodeMark
- Fire resistance level
- 0 (loses structural integrity at 660 degC) minutes Solid aluminium sheet alone has no FRL - melts and fails structurally at ~660 degC. Non-combustible classification means it does not contribute to fire load. Fire resistance of wall system depends on complete assembly. Source: NCC, ABCB advisory note
- Ignition temp
- N/A - non-combustible degC Aluminium does not ignite under normal conditions. Melts at ~660 degC. Thin foil can ignite in powder form but solid sheet does not burn
- Flame spread index
- 0 Zero flame spread - non-combustible metal. Source: AS 1530.1 testing
- Smoke dev. index
- 0 Zero smoke from aluminium metal. Meets AS/NZS 1530.3 smoke developed requirements
- Heat release rate
- 0 kW/m2 Zero - solid aluminium is non-combustible. No organic content to burn. Coating contributes negligible heat release
Cost & Lifecycle
Capex & lead time ·6
- Material cost (range)
- 14-65 AUD/m2 Mill finish sheet: $14-25/m2. Powder coated: $25-55/m2. Anodised: $30-60/m2. PVDF coated: $35-65/m2. Source: Sculptform cost guide, ServiceTasker, Ecospecifier
- Material cost (per unit)
- 30-55 AUD/m2 Typical architectural cladding: powder-coated 2mm 5052 or 5251 sheet. Source: industry pricing estimates
- Lead time
- 3-30 days Standard sheet/coil from stock: 3-7 days. Cut-to-size and fabricated panels: 2-4 weeks. Custom powder coat colours: 3-6 weeks. Source: Australian fabricator estimates
- Lifecycle cost
- 100-400 AUD/m2 High initial cost offset by long lifespan and low maintenance. Scrap value at end of life (aluminium recycling). 40-60 year lifecycle
- Annual maintenance
- 1.00-5.00 AUD/m2/year Annual wash-down. Very low maintenance for quality coated finishes. No painting required for PVDF or anodised
- Market availability
- Excellent Widely available in Australia. Domestic smelting and rolling (limited). Major distributors: Capral, Ullrich Aluminium, Metalcorp, Atlas Steels. Extensive fabricator network in all capital cities
Service life & durability ·3
- Expected lifespan
- 40-60+ years Solid aluminium cladding with quality PVDF or anodised finish: 40-60+ years. Bare aluminium in benign environments: 60-100+ years. Source: industry data, Sculptform
- Maintenance interval
- 1-5 years Annual wash-down recommended to maintain appearance and prevent buildup of atmospheric contaminants. Inspect fixings every 5-10 years. Recoating typically not required with PVDF finish
- Warranty period
- 10-25 years PVDF coating warranty: 20-25 years colour retention. Anodised: 10-25 years depending on grade. Structural warranty: 10-20 years. Source: coating and cladding manufacturers
Layer D
Where it's used
External wall cladding
Metal roofing
Decorative screening
Fascia and soffit
Rainscreen cladding