Quality control during aluminium facade installation prevents costly rework and ensures the system performs as it was tested and designed to perform. The best QC approach is not complex - it is consistent checks at the right stages, documented properly. Most defects we see on Australian projects are picked up too late, when fixing them means removing panels that are already installed.
What should you check before installation starts?
Pre-installation QC catches problems before they get built in:
- Verify delivered materials match the specification. Check product type, colour code, and quantity against the order and the facade engineer’s drawings. A mismatched colour batch or wrong profile is much easier to resolve before it goes on the wall.
- Inspect panels for transport damage. Look for scratched finishes, dented edges, and bent extrusions. Document anything with photographs and notify Valmond & Gibson immediately.
- Confirm the subframe is complete, plumb, and within tolerance. A subframe that is out of plumb will produce a facade that is out of plumb - no amount of panel adjustment fixes a bad subframe. Check against the engineer’s specified tolerances before you start hanging panels.
- Check waterproofing and membranes. The waterproofing layer behind the cladding zone needs to be installed and inspected before panels go on. Once panels are fixed, access to the membrane is limited to removing those panels.
What should you monitor during installation?
This is where most defects originate. Consistent checking during installation is more effective than a single inspection at the end:
- Panel alignment. Check plumb, level, and consistent joint widths regularly - not just on the first few panels. Alignment drift is cumulative and easier to correct early.
- Fixing type and spacing. Verify that fixings match the facade engineer’s specification. The type, size, and spacing of fixings are structural - they are not interchangeable without engineering approval.
- Proper engagement. For interloQ, confirm the interlocking profile is fully engaged along the full length of each panel. For element13, check that rivets or screws are at the correct torque - not over-driven and not loose.
- Flashings at junctions. Head flashings, sill flashings, corner flashings, and flashings around penetrations all need to be installed as the facade progresses. Retro-fitting flashings after panels are in place is difficult and rarely looks right.
- Protective film. If a protective film has been applied, it needs to come off within the manufacturer’s recommended timeframe. UV exposure degrades the adhesive, making the film extremely difficult to remove and potentially damaging the coating underneath.
What gets inspected after installation?
Post-installation QC is your final check before handover:
- Visual inspection from ground level and close-up. Ground-level checks confirm the overall appearance - consistent colour, straight lines, no obvious defects. Close-up inspection confirms fixings, flashings, and junctions are complete.
- Completeness. All flashings and trims are installed, all penetrations are properly finished, and all fixings are in place.
- Damage from other trades. Concrete splatter, welding sparks, impact from scaffolding - facade damage from other trades is one of the most common problems on multi-trade sites. Inspect before scaffolding comes down, not after.
- Document with photographs. A dated photographic record of the completed facade is your best evidence if a certifier or building commissioner queries something six months later.
- Clean the facade. Mild detergent and warm water with a soft cloth. No solvents on powder coat. No pressure washers at close range.
What are the most common facade installation defects?
These are the defects that generate the most rework on projects we supply:
- Panels not fully engaged in the interlocking system. On interloQ, a panel that is not fully clicked in will rattle in the wind and creates a potential water entry point. It is not always visually obvious from the ground.
- Missing or misaligned flashings. Top, bottom, corners, and penetrations all need flashings. Missing flashings are the single most common defect we see in facade inspections.
- Over-driven or under-driven fixings. Over-driven fixings leave visible dimples in the panel face. Under-driven fixings leave panels loose. Both are fixable, but both require rework.
- Protective film left on too long. After prolonged UV exposure, the film bonds to the coating. Removing it tears the finish or leaves adhesive residue that requires chemical cleaning - sometimes with mixed results.
- Damage from other trades. Welding sparks burn permanent marks into powder coat. Concrete bonds aggressively to coated aluminium. Plan the trade sequence to minimise exposure, and cover installed panels when wet trades are working nearby.
Does QC documentation matter for compliance?
Yes. Under the NSW Design and Building Practitioners Act, building compliance declarations require evidence that installation matches the regulated design. A QC record - photographs, checklists, inspection sign-offs - supports that evidence trail. Similar requirements apply in other states under their respective building reform legislation.
V&G provides detailed installation guidance for interloQ, element13, and 165CW. These documents set out the installation requirements that QC checks should verify against.
Photograph every stage. Check fixings and flashings as you go, not just at the end. Catch alignment drift early. The time spent on QC during installation is a fraction of the time spent on rework after it.
Need installation documentation or technical support for your project? Get in touch with our team.
Related Reading
- Aluminium Cladding Storage and Handling on Site
- Measuring for Aluminium Cladding: Tolerances and Best Practice
- DBPA NSW: What Facade Suppliers and Installers Need to Know
- Aluminium Facade Repair and Panel Replacement
Last updated: 4 April 2026