3A Alucore®
The Lightweight Aluminium Panel That Holds Its Shape
There’s a specific problem in contemporary facade design that Alucore® is built to solve. Large-format aluminium panels, the kind that give a commercial or institutional building its clean, considered appearance, need to stay flat. Perfectly, consistently flat. Over decades of thermal cycling, UV exposure and wind loading. On panels that may be 1500mm wide and 9000mm long.
Alucore®’s corrugated aluminium core delivers that. The corrugation runs through the full depth of the panel, creating a structural geometry that resists bowing and deflection in a way that flat cores can’t match. And crucially, the core is aluminium, not thermoplastic or polymer fill, which gives Alucore® fire performance credentials that conventional aluminium composite panels simply don’t have.
CSP Architectural supplies Alucore® and processes every panel in-house alongside our Alucolux® range.
Technical Specifications
Panel thickness
4 mm (standard), 6 mm available
Core
Corrugated aluminium – no thermoplastic, no polymer fill
Cover sheets
Aluminium alloy – 5005 H24 marine-grade alloy available for coastal applications
Surface coating
PVDF/FEVE to AAMA 2605 – UV-stable, long-term weathering performance
Panel widths
Up to 1500mm
Panel lengths
Up to 9000mm – continuous manufacturing process
Weight advantage
Significantly lighter than solid alternatives at equivalent flexural rigidity
Processing
In-house CAD, cut, roll and route – CSP Architectural facility
Compatible subframe
Nvelope rainscreen subframe system – supplied by CSP
Key applications
Commercial facades, Institutional buildings, Interior ceiling systems, Balconies, Canopies, Mixed-use developments
What the Corrugated Core Actually Does
The engineering principle behind Alucore® is straightforward: a corrugated core structure, like a corrugated cardboard box, provides far greater rigidity in the direction of the corrugations than a flat core of the same thickness and material. This allows Alucore® to span larger distances between fixing points without deflecting and to resist the constant micro-movement caused by thermal expansion and contraction without losing its surface flatness over time.
Superior flatness across large spans
The corrugated core resists the bowing and oil-canning that can affect flat-core panels on wide spans, particularly visible on large commercial facades with raking light.
Lightweight at equivalent rigidity
Alucore® achieves high panel stiffness at lower weight than solid alternatives. Lighter panels mean simpler subframe design, lower loads on the structure and faster installation.
Marine-grade alloy available
The 5005 H24 aluminium alloy option provides enhanced corrosion resistance for coastal and waterfront projects where salt air and moisture are ongoing factors.
Standard equipment processability
Alucore® is designed to be fabricated using common processing methods; bending, routing, cutting and forming don't require specialist tooling. Complex facade profiles are achievable without exotic fabrication requirements.
Where Alucore® Belongs
Alucore® sits in the specification between standard aluminium composite panels (which have thermoplastic cores and fire performance limitations) and solid aluminium panels like Alucolux® (which are heavier and have a different structural profile). It’s the right choice when the design brief calls for lightweight, large-format aluminium with strong fire credentials and a surface quality that responds to light.
Commercial and institutional facades
Large-format commercial buildings where span, weight and appearance consistency over decades are all critical. The corrugated core maintains flatness across wide panels and through years of thermal cycling.
Factories and industrial buildings
Large-format industrial and manufacturing buildings where the facade needs to span wide bays, handle the mechanical vibration typical of production environments and perform without maintenance across decades of heavy use.
Interior ceiling systems
Large-format interior ceiling and feature ceiling applications where consistent flatness, lightweight installation and a premium surface finish are the brief. The PVDF coating performs in interior applications as well as exterior ones.
Mixed-use and multi-residential developments
Projects where the facade specification needs to cover a range of orientations, exposures and aesthetic requirements within a single material system. Alucore®’s broad colour range and processability handle complex facade geometries.
Featured Projects with Alucore®
Frequently Asked Questions
What is the core material in 3A Alucore®?
Alucore® uses a corrugated aluminium core; there is no thermoplastic, polyethylene or polymer fill in the panel. This distinguishes it from standard aluminium composite panels (ACP) that use a polyethylene or mineral-filled core. The all-aluminium construction of Alucore® gives it fire performance credentials that conventional ACP products with polymer cores cannot achieve.
Is Alucore® non-combustible under the NCC?
Alucore® contains no thermoplastic or polymer core material and has strong fire performance credentials as a result. For specific NCC compliance classification, particularly for Type A and Type B buildings, contact our team for the relevant technical and fire certification documentation. Where the NCC requires a fully non-combustible classification, 3A Alucolux® solid aluminium is the appropriate product.
What is the maximum panel size available in Alucore®?
Alucore® panels are available in widths up to 1500mm and lengths up to 9000mm, manufactured through a continuous process that allows very large panel formats. Panel dimensions for specific projects are processed to the required size by CSP’s in-house team; contact us with your project requirements.
Can Alucore® be used in coastal environments?
Yes. Alucore® is available with 5005 H24 marine-grade aluminium alloy cover sheets, which provide enhanced corrosion resistance for coastal and waterfront applications. The PVDF/FEVE surface coating also provides protection against UV degradation and atmospheric pollutants, making Alucore® suitable for Australian coastal conditions.
Does CSP process Alucore® panels to custom dimensions in-house?
Yes. We process all Alucore® panels in-house; CAD drawing, cutting, rolling and routing all happen at our facility. Custom panel sizes, radius elements, routed joints and bespoke facade profiles are handled before delivery. Nothing is sent to a third-party fabricator.