Define Project Performance Goals

When you begin looking into the best aluminum extrusions for your building’s facade, it’s important to start by defining clear project performance goals. These goals are like your roadmap—they guide your material selection, design, and installation decisions from start to finish. Taking the time to really understand the unique needs of your building, the environment it’s in, and how it will be used helps ensure your final choice meets both immediate needs and long-term expectations. Setting these objectives early on helps everyone involved—from the owner to the installer—stay focused, whether we’re talking about the initial plans or the final touches.

Typically, these project performance goals cover:

Durability
Overall look and aesthetics
Energy efficiency
Compliance with safety standards

For example, if you’re working on a sleek office building downtown, you might care more about a modern appearance and strong thermal performance. On the other hand, a school or hospital may place higher value on impact resistance and easy maintenance. It’s worth considering input from everyone involved—architects, engineers, building owners, and facility managers—when you’re setting these goals, so that no important detail gets overlooked.

Climate, exposure, and building height

Something you should keep in mind is that local environmental conditions play a big role in choosing aluminum extrusions for facades. Factors like temperature swings, humidity, and how much rain or snow you get can speed up corrosion and affect how the material expands or contracts. Aluminum naturally forms an oxide layer that helps protect it, but if your project is near the coast with salty air, or in a city with lots of pollution, that protection can wear down faster. In these cases, it’s a good idea to look for extrusions made from alloys that resist corrosion or to add protective surface treatments.

Building height is another key detail. The taller your structure, the more it’s exposed to wind and pressure differences. Facade systems on high-rises, for example, need stronger extrusions with thicker walls and sturdy anchoring to handle those forces and keep everything safe and secure. The combination of your local climate and how exposed each side of the building is will help you decide on the right type of extrusion, wall thickness, and anchoring methods.

Also, don’t forget about solar exposure. South- and west-facing walls tend to get more sun, which can heat up the building and impact comfort and energy use. Choosing the right aluminum extrusion and finish can help reflect sunlight, reduce heat absorption, and keep your energy bills in check.

Fire, impact/wind, acoustic, and thermal targets

It’s important to know that your project’s performance goals should also address both regulatory and practical needs:

Fire resistance: Especially critical for taller or public buildings. The aluminum extrusion and its finish need to comply with fire safety codes and should not contribute to spreading flames. Many places require that facade systems pass tests like NFPA 285, and finishes often need to be non-combustible or only minimally combustible.
Impact and wind resistance: Building codes require that facades can handle impact and wind—this is even more important in areas prone to tornadoes or hurricanes. Systems have to pass standardized tests, such as ASTM E330 for structural performance and ASTM E1886/E1996 for impact resistance.
Acoustic performance: If your building is close to a busy road or airport, you’ll want to think about acoustic performance too, making sure the extrusion system can support sound-dampening features like gaskets or insulation.
Thermal targets: Aluminum extrusions should be compatible with thermal breaks and insulation to meet codes like the International Energy Conservation Code (IECC) and keep occupants comfortable.

Select Alloy, Temper & Profile Geometry

After you’ve nailed down your project goals, your next step is to select the right alloy, temper, and profile geometry for your aluminum extrusion. Most facades use alloys from the 6000-series, such as 6061 and 6063. These offer a great mix of strength, corrosion resistance, and workability.

Temper, which refers to how the aluminum is heat-treated, affects both strength and flexibility:

T6: Stronger, used where more weight support is needed.
T5: More flexible, helpful for intricate shapes.

Profile geometry is another factor that’s worth careful consideration. Custom profiles can give you the best strength-to-weight ratio, include spaces for gaskets, and create the look you want. For example, extrusions with internal chambers can add rigidity without unnecessary weight. It’s always a smart move to work closely with experienced aluminum systems manufacturers so your profiles are engineered for solid, reliable performance. Early collaboration can also help you spot opportunities to save on materials or streamline installation, which is never a bad thing.

Evaluate Attachment & Subframing

How you attach the aluminum extrusion to your building matters a lot for the durability and performance of your facade. The attachment system determines how well the facade can handle movement, resist loads, and avoid damage over time. You have options here—direct fixing, clip systems, or rail-based subframes—each with its own pros and cons depending on your building’s structure, facade type, and the look you’re going for.

A good attachment system also makes it easier to maintain or replace facade elements down the road. If you can remove and swap out individual panels or profiles, you’ll save on repair costs and minimize disruption for people inside the building. It’s a good idea to coordinate with structural engineers and facade consultants to make sure your attachment approach works for both performance and constructability.

Fixed vs. sliding points; bracket spacing

Fixed points: Keep things anchored firmly in place.
Sliding points: Let the system expand or contract with temperature changes.

Striking the right balance here helps prevent stress from building up in the extrusion, which reduces the risk of warping or failure. For larger facades, it’s common to use sliding points at regular intervals.

Bracket spacing is another detail you can’t overlook. It’s determined by the weight of the facade, wind loads, and the characteristics of your Extruded Aluminum profiles. Closer bracket spacing can increase stability, but it may also bump up material and labor costs. Following recommendations from manufacturers and relying on solid engineering calculations will help you get the spacing just right. Don’t forget that these calculations should account for both dead loads and live loads, like wind or accidental impacts, to make sure your system is safe in the long run.

Thermal breaks, cavity ventilation, and drainage paths

Thermal breaks: Insulating strips placed between the interior and exterior aluminum parts to prevent heat transfer and condensation. Systems that follow standards like AAMA 1503 can help you avoid issues with cold spots or condensation.
Cavity ventilation: Helps prevent moisture from building up inside the facade, which can cause corrosion or mold. Well-designed aluminum cladding systems include paths for ventilation and drainage, such as weep holes.
Drainage paths: Ensure any water that does get inside is directed out, protecting the building and extending the facade’s lifespan.

Proper detailing here is crucial. If thermal breaks, ventilation, or drainage aren’t designed or installed correctly, you could end up with long-term headaches like water leaks, poor insulation, or early material failure. It’s always wise to work with experienced facade engineers and consult technical standards from the Aluminum Association or similar groups.

Pick Durable Finishes

The finish you choose for your aluminum extrusions affects both how your building looks and how well it stands up over time. The two most common finishing methods are:

Anodizing: Creates a tough oxide layer that boosts corrosion and abrasion resistance, available in a range of metallic shades. Great for consistent color and a matte or satin look.
Powder coating: Offers more color options and produces a durable, uniform finish that resists chipping and fading. Some powder coats can even mimic the look of wood or stone.

Both methods can be specified to meet standards like AAMA 2603, 2604, or 2605, which set the bar for color retention, gloss, and resistance to chalking.

When deciding on a finish, think about your local environment. In areas with a lot of sun or industrial pollution, it’s smart to use finishes certified by the American Architectural Manufacturers Association (AAMA) for long-term durability. If your project is near the ocean, a high-performance powder coat or a thicker anodized layer can really extend the life of your facade. Remember, a durable finish doesn’t just protect the aluminum underneath—it also keeps your building looking its best.

Verify Code Compliance & Testing

Every aluminum extrusion system for facades needs to meet the right building codes and pass the necessary tests. Codes often reference ASTM International standards for:

Structural strength (ASTM E330)
Fire safety
Weather resistance (ASTM E283, ASTM E331)

Depending on your location, you might also have to meet requirements for earthquakes or energy use.

Tests usually cover:

Air and water infiltration
Structural loads
Impact resistance
Fire performance

Manufacturers or third-party labs should be able to show documentation that their products comply with these standards. It’s worth taking the time to review these records before you specify or sign off on a system—you want to be sure your facade is up to code and safe. Sometimes, mockup testing is done to see how the system performs in simulated real-life conditions.

Working with manufacturers who provide clear documentation and third-party certifications can make the approval process much smoother and help you avoid compliance issues. Since codes and standards can change, it pays to stay updated so your project doesn’t run into any surprises.

Balance Cost, Lead Time & Sustainability

When you’re weighing costs, remember it’s not just about the price per foot of aluminum extrusion. The full cost includes:

Subframing
Finishes
Labor
Future maintenance

Choosing standard profiles and finishes usually keeps costs down and lead times short, while custom solutions may require more engineering and longer waits. Starting conversations with your suppliers early can help you find opportunities to use off-the-shelf parts or modular systems, which often saves both time and money.

Lead time is especially important for projects with tight schedules. By planning ahead, you can spot supply chain hiccups and make adjustments to your material choices or design as needed. Sometimes, global events or local shortages can affect the availability of certain alloys or finishes, so being flexible in your specs can help you avoid delays.

Sustainability is becoming more and more important. Many aluminum systems use a high percentage of recycled material, which reduces their environmental impact and can help you earn points towards certifications like LEED or Green Globes. Choosing durable solutions that require less maintenance and last longer is good for both your budget and the planet. If you want to compare the environmental impact of different options, lifecycle assessments are a helpful tool.

Submittals, Mockups & Quality Control

The steps of submittals, mockups, and quality control are key to making sure your aluminum extrusion system performs as planned.

Submittals: Typically include drawings, specs, and test results from the manufacturer, so the project team can review and confirm that the proposed aluminum panels, attachment methods, and finishes meet all requirements. Thorough submittals often include finish samples, hardware, and code compliance certifications.
Mockups: Full-scale installations of part of the facade, allowing for visual inspection, color and finish confirmation, and the chance to test installation techniques. Sometimes, project specs or local authorities require mockups for design approval and to verify performance. In addition to a visual check, mockups can be tested for water infiltration, structural strength, and impact resistance to see how they’d hold up in real-world conditions.
Quality control: During fabrication and installation ensures everything meets the right tolerances and the finished product is free from defects. This process includes factory and on-site inspections, as well as clear documentation of installation steps. Keeping lines of communication open between the project team, fabricators, and installers helps catch and fix any issues quickly.

Staying in sync with designers, manufacturers, and contractors helps you avoid common pitfalls and makes sure your facade looks great and performs well. If you want to dig deeper into related aluminum systems, it’s worth checking out resources on aluminum siding, aluminum cladding, and aluminum panels. Regularly reviewing industry best practices and learning from similar projects can also help you get the results you want and steer clear of costly mistakes or delays.

aPlank https://www.aplank.com/

Alloy	Strength	Surface Finish	Typical Use Cases
6061	Higher	Good	Structural components
6063	Moderate	Excellent	Visible facade elements

How to Choose the Right Aluminum Extrusion for Facades