Recladding - removing combustible ACP and replacing it with non-combustible cladding - sounds straightforward. It is not. The projects that run into trouble usually share the same handful of avoidable mistakes, from underestimating structural loads to leaving combustible insulation behind the new facade. Here are six of the most common, and how to get ahead of them.
Is the existing subframe suitable for the replacement cladding?
Often, it is not. The subframe behind the removed ACP was designed for a specific cladding weight and fixing pattern. The replacement product will almost certainly have different loads, different fixing centres, and different deflection characteristics.
Before specifying the new cladding, get a structural assessment of the existing support system. This means engaging a facade or structural engineer to confirm whether the existing framing, brackets, and anchors can handle the replacement. Skipping this step is one of the fastest ways to blow a programme and a budget.
Does the replacement weigh the same as what was removed?
Rarely. A typical aluminium composite panel weighs 3 to 5 kg/m2. Solid aluminium at 3mm - like element13 - weighs 8.13 kg/m2. That is a meaningful increase, and the structure may need reinforcement to carry it.
The reverse can also apply. If the new product is lighter, existing fixings may be over-engineered. That is not a safety concern, but it affects cost estimating - you may be pricing for more capacity than you need.
Either way, the weight comparison needs to be explicit in the design documentation. Do not assume equivalence.
Is the compliance documentation product-specific?
The entire purpose of a recladding project is to remove a compliance problem. The replacement product must have clear, product-specific, NATA-accredited test reports that demonstrate non-combustibility under AS 1530.1.
Generic data sheets or manufacturer assertions are not enough - especially in the post-crisis regulatory environment where certifiers are scrutinising documentation more closely than ever. The test report needs to name the product, reference the standard, and come from a NATA-accredited laboratory.
Valmond & Gibson provides CSIRO test reports for both element13 (report FNC12545) and interloQ (report FNC12595). Both tested non-combustible under AS 1530.1.
What about the rest of the wall assembly?
Removing the ACP exposes everything behind it - insulation, membranes, sarking, and the subframe itself. If the insulation is combustible (polystyrene is common in older buildings), replacing only the outer cladding does not solve the fire safety problem.
The whole wall assembly needs to be assessed. Combustible insulation, non-compliant membranes, and degraded fire barriers all need to be identified and addressed. Replacing the cladding while leaving combustible materials in the cavity is not remediation - it is a partial fix that may not satisfy the fire safety order.
Have you programmed for occupant disruption?
Recladding an occupied building is a different proposition to cladding a new build. Residents or tenants are living and working behind the facade while it is being removed and replaced.
That means noise management, dust control, privacy considerations (particularly on residential towers), restricted access to balconies and common areas, and staged work that limits the extent of exposed building at any one time. These are not afterthoughts - they are programme items that belong in the tender.
Underestimating disruption leads to complaints, work stoppages, and scope changes mid-project. Price it and programme it from the start.
Are you budgeting for make-good?
Removing cladding panels disturbs everything around them - window head and sill flashings, penetration seals, sealant joints, and waterproofing details at balcony edges and parapets. Every one of these interfaces needs to be reinstated to maintain the building’s weather integrity.
A recladding budget that only covers remove-and-replace will fall short. Make-good of disturbed elements is a real cost item and should be a separate line in the estimate, not buried in contingency.
Which products are used for recladding?
element13 is the standard product for ACP remediation projects - 3mm solid aluminium, non-combustible, with a proven track record across government-funded and privately managed recladding work. For projects that need a different aesthetic or want a rainscreen look, interloQ offers an interlocking panel option that is also tested non-combustible.
The recladding market continues to grow, supported by government programs including NSW Project Remediate, Victoria’s Cladding Safety Victoria, and Queensland’s Safer Buildings program.
Valmond & Gibson provides compliance documentation, product data, and technical support for recladding projects across Australia. If you need test reports or product information for a remediation project, get in touch.
Related Reading
- Preparing a Recladding Tender: What to Include
- Recladding with Solid Aluminium: A Guide for Building Owners and Project Teams
- element13 Specification Guide: Solid Aluminium Cladding for Australian Projects
- Combustible Cladding Bans by Australian State: 2026 Update
Last updated: 4 April 2026