How Do Panel Sizes Affect Facade Cost and Performance?
Panel size selection is one of the earliest decisions in facade design, and one of the most consequential. The dimensions you choose affect material cost, waste percentage, installation speed, transport logistics, and the visual outcome on the building. Getting the module right early - ideally during schematic design - reduces waste and avoids surprises during procurement and construction.
The relationship is straightforward. Standard sizes cost less and arrive faster. Custom sizes cost more and take longer. Every millimetre of offcut is paid for but never installed. And panels that are too large for efficient handling on site slow installation down, which costs labour hours. The goal is to find the size that balances visual intent, structural adequacy, material yield, and buildability.
This article covers available panel sizes and module planning principles for the three primary Valmond & Gibson aluminium facade systems: interloQ interlocking rainscreen panels, element13 solid aluminium cladding panels, and 165CW unitised curtain wall.
What Sizes Are Available for interloQ Interlocking Rainscreen?
interloQ is an extruded aluminium rainscreen system with multiple profile widths available. Because it is manufactured by extrusion - aluminium alloy pushed through a die to form a continuous profile - the width of each panel is fixed by the extrusion die, while the length is determined by cutting the extrusion to size.
Length is limited by the extrusion run and practical handling constraints. Single lengths up to 6-7 metres are typical. Longer lengths may be possible depending on the profile and supplier, but transport, site handling, and thermal movement all become more challenging as panels get longer.
Width is determined by the specific interloQ profile selected. Multiple profile widths are available, each with a different visible face dimension and overall interlocking geometry. The interlocking design means different width profiles can be mixed on the same facade, creating visual variety through alternating wide and narrow panels without changing the fixing or subframe system.
Orientation matters. interloQ panels can be installed horizontally or vertically, and the orientation changes the visual read of the facade.
- Horizontal installation: the visible face width equals the profile width. Panels run left to right, interlocking vertically. The facade reads as a series of horizontal bands.
- Vertical installation: the panel length becomes the visible vertical dimension, running floor to soffit or parapet. The profile width reads as the horizontal module. The facade reads as a series of vertical blades or columns.
This flexibility means the same panel stock can produce very different visual outcomes depending on orientation. It also means that module planning needs to consider which dimension the eye reads as the “module” on the finished building - and that dimension changes with orientation.
For most projects, interloQ panel sizes do not drive significant waste because panels are cut to length from continuous extrusions. The main planning consideration is ensuring the visible module width works with the facade grid, window positions, and corner details.
What Sizes Are Available for element13 Solid Aluminium Panels?
element13 is a 3mm solid aluminium panel system. Unlike interloQ, element13 panels are cut from standard flat sheets, so understanding the sheet sizes is essential for efficient module planning.
Standard sheet sizes:
| Width | Length | Thickness | Weight |
|---|---|---|---|
| 1250mm | 3200mm | 3mm | 8.13 kg/m2 |
| 1250mm | 4000mm | 3mm | 8.13 kg/m2 |
| 1500mm | 3200mm | 3mm | 8.13 kg/m2 |
| 1500mm | 4000mm | 3mm | 8.13 kg/m2 |
These are the raw sheet sizes. Panels are then cut, folded, and fabricated to project-specific dimensions. This means every panel on the building starts as one of these four sheet sizes, and every offcut is material you have paid for but will not install.
The width threshold. This is where module planning has the biggest impact on cost. element13 sheets come in two widths: 1250mm and 1500mm. If a panel design requires a finished width of, say, 1260mm, it cannot come from a 1250mm sheet - it must be cut from a 1500mm sheet, wasting 240mm of width on every single panel. That is a 16% material loss on width alone, multiplied across every panel on the facade.
The alternative is to redesign the panel at 1240mm or split it into two narrower panels that nest efficiently within the 1250mm sheet. Ten millimetres of design adjustment can save thousands of dollars in material on a large project.
The length threshold works the same way. A panel that requires 3300mm of length cannot come from a 3200mm sheet - it needs the 4000mm sheet, leaving 700mm of offcut per panel. If the panel could be trimmed to 3180mm, it nests within the smaller sheet and the waste drops dramatically.
Nesting strategy. Nesting is the process of arranging panel cut patterns on standard sheets to maximise material yield. A well-planned nesting layout can save 10-15% on material cost compared to a naive approach. The principles are simple:
- Work back from standard sheet sizes when setting panel dimensions
- Where possible, design panels so that two or more nest side by side or end to end within a single sheet
- Account for saw kerf (cutting width), edge trims, and folding allowances in the nesting calculation
- Consider whether offcuts from one panel size can be used for smaller panels, flashings, or soffits on the same project
For element13, the module planning conversation should happen early - ideally when the architect is setting the facade grid. A small adjustment to panel dimensions at design stage can eliminate a large percentage of waste at fabrication stage.
What Are the Key Dimensions for 165CW Unitised Curtain Wall?
165CW is a unitised curtain wall system - meaning panels are factory-assembled as complete units (glass, frame, seals, and all) and hung on the building as finished modules. The dimensions of each unit are set by the facade grid, which is typically driven by the building’s structural grid and floor-to-floor height.
Key frame dimensions:
| Component | Dimension |
|---|---|
| Frame depth | 165mm (internal) |
| Mullion width | 86mm (including 10mm nominal gap) |
| IGU glazing capacity | 24mm to 40mm |
| Stack head movement | plus or minus 25mm |
| Mullion movement | plus or minus 10mm |
Module width for 165CW is typically 1200-1800mm, set by the facade grid. The mullion-to-mullion dimension defines the clear glazing or spandrel zone within each unit. Wider modules mean fewer mullions and fewer joints on the facade, but they also mean heavier units and larger glass sizes - which affects crane requirements, installation speed, and glass procurement.
Module height is typically floor-to-floor, minus the structural zone required for the slab edge and stack joint. The stack head movement of plus or minus 25mm is a critical design parameter - it accommodates floor deflection under load, concrete creep, and construction tolerances. The curtain wall must move with the building without transferring load between floors.
The mullion movement allowance of plus or minus 10mm accommodates horizontal thermal expansion and construction tolerances. Together, the stack and mullion movement allowances mean the curtain wall is a live system - it is designed to move, and the module dimensions must account for that movement without compromising weather performance or visual alignment.
For 165CW, module planning is less about material yield (as with element13) and more about coordinating with the building structure, achieving the architectural intent, and keeping individual unit weights within handling limits. V&G provides a LogiKal by Orgadata database developed specifically for 165CW, which supports estimating, cutting optimisation, AutoCAD export, and CNC machine control.
What General Principles Apply to Facade Module Planning?
Regardless of the system, several principles apply to facade module planning across all aluminium cladding types.
Start with standard sizes. Every system has standard or preferred dimensions. Designing within those dimensions keeps costs down, lead times short, and waste low. Moving outside standard sizes introduces custom manufacturing, longer lead times, and higher per-unit costs.
Account for joints and fixings. The visible panel dimension is not the same as the coverage dimension. Joints, overlaps, interlocks, and fixing zones all consume material that does not contribute to visible facade area. Make sure coverage calculations account for these - a common source of quantity errors during estimating.
Consider transport and handling. Panels over certain sizes need special packaging, larger vehicles, or additional labour on site. For element13, panels fabricated from 4000mm sheets are manageable but require care during transport and handling to avoid edge damage. For interloQ at lengths approaching 6-7 metres, site logistics and access need to be considered - a 7m panel cannot be carried up a standard stairwell.
Factor in colour and lead time. For element13, stock colours - Salt, Carbon, Silver, Charcoal, and others - are available with no minimum order quantity, which means short lead times and flexibility to order what you need. Non-stock colours require minimum order quantities and 10-12 week lead times from manufacturing. This matters for module planning because it affects how much design flexibility you have late in the project. If the colour is non-stock, the panel sizes and quantities need to be locked earlier.
Engage your supplier early. The most effective module planning happens when the facade supplier is involved during design development, not after the specification is locked. A conversation about panel sizes, sheet yields, and module coordination at the right time can save significant cost and programme time downstream. V&G regularly advises architects, specifiers, and installers on optimal panel sizing for specific projects - that early conversation is one of the most valuable things a supplier can offer.
The Short Version
Panel size selection is a design decision with direct cost and programme consequences. For interloQ, the key is choosing the right profile width and orientation for the visual intent. For element13, the key is designing panel dimensions that nest efficiently within 1250mm or 1500mm x 3200mm or 4000mm standard sheets. For 165CW, the key is coordinating module width and height with the building grid, structural movement, and unit handling limits. In all cases, working with standard sizes, planning for yield, and involving the supplier early produces the best outcome.
Related Reading
- element13 Specification Guide
- Aluminium Cladding Lead Times: What to Expect and How to Plan
- How to Order Aluminium Cladding: A Guide for Installers
- Aluminium Facade Waste Management and Recycling
Last updated: 4 April 2026