Description
Compocel AL Aluminum Honeycomb Sandwich Panel
Compocel AL is a sandwich panel built from an aluminum honeycomb core bonded between two aluminum skins with a structural adhesive. It is used where high stiffness-to-weight ratio, flatness, and dimensional stability are required. Chemical Concepts stocks Compocel AL in 5 ft x 10 ft, 4 ft x 10 ft, and 4 ft x 8 ft sheets with 0.8 mm aluminum skins, in five panel thicknesses from 1/4 in to 1 in. Custom sizes, thicknesses, skin gauges, cell sizes, core densities, adhesive systems, and finishes are built to order.
Stocked Panels
All stocked panels use 0.8 mm aluminum skins on both faces, a squared edge, and are supplied at full 5 ft x 10 ft, 4 ft x 10 ft, or 4 ft x 8 ft. Cell diameter is listed per panel.
| Panel Size | Panel Thickness | Skin Thickness | Cell Size | Sheet Weight | SKU |
|---|---|---|---|---|---|
| 5 ft x 10 ft | 1/4 in (6.4 mm) | 0.8 mm | 3/8 in (9 mm) | 55 lb | CEL-CC-A08-08-09-05×10-1-0640 |
| 5 ft x 10 ft | 3/8 in (9.5 mm) | 0.8 mm | 3/8 in (9 mm) | 57 lb | CEL-CC-A08-08-09-05×10-1-0950 |
| 5 ft x 10 ft | 1/2 in (12.7 mm) | 0.8 mm | 3/8 in (9 mm) | 59 lb | CEL-CC-A08-08-09-05×10-1-1270 |
| 5 ft x 10 ft | 3/4 in (19 mm) | 0.8 mm | 3/8 in (9 mm) | 62 lb | CEL-CC-A08-08-09-05×10-1-1900 |
| 5 ft x 10 ft | 1 in (25 mm) | 0.8 mm | 3/8 in (9 mm) | 65 lb | CEL-CC-A08-08-09-05×10-1-2540 |
| 5 ft x 10 ft | 1 in (25 mm) | 0.8 mm | 1/2 in (12.7 mm) | 62 lb | CEL-CC-A08-08-13-05×10-1-2540 |
| 4 ft x 10 ft | 1/4 in (6.4 mm) | 0.8 mm | 3/8 in (9 mm) | 44 lb | CEL-CC-A08-08-09-04×10-1-0640 |
| 4 ft x 10 ft | 1/2 in (12.7 mm) | 0.8 mm | 3/8 in (9 mm) | 47 lb | CEL-CC-A08-08-09-04×10-1-1270 |
| 4 ft x 8 ft | 1/2 in (12.7 mm) | 0.8 mm | 3/8 in (9 mm) | 38 lb | CEL-CC-A08-08-09-04×08-1-1270 |
5/8 in (15.9 mm) panels are available in all sizes as a special order. Contact us for lead time.
Panel Construction
 |
A: Aluminum skins
B: Structural adhesive
C: Aluminum honeycomb core
|
Technical Characteristics
| Construction | Aluminum honeycomb core, aluminum skins both faces |
| Core material | Aluminum alloy 3003 / 3005 / 3103 / 3104, hexagonal cell |
| Skin material | Aluminum, 1000 / 3000 / 5000 series |
| Standard skin thickness | 0.8 mm (0.031 in). 0.5 mm and 1.0 mm on request, up to 5.0 mm |
| Stocked cell size | 3/8 in (9 mm) on most panels, 1/2 in (12.7 mm) on one 1 in thick 5 ft x 10 ft panel |
| Stocked panel thicknesses | 1/4 in (6.4 mm), 3/8 in (9.5 mm), 1/2 in (12.7 mm), 3/4 in (19 mm), 1 in (25 mm) |
| Stocked panel sizes | 5 ft x 10 ft, 4 ft x 10 ft, 4 ft x 8 ft, squared |
| Thickness tolerance | ±0.3 mm (±0.012 in) |
| Dimension tolerance | ±30 mm (±1.18 in) on manufacturer mill-size panels. Stocked panels are supplied squared to the sizes listed above |
| Planarity | ±1 mm/m (approximate) |
| Skin elastic modulus (E) | 68,000 to 70,000 MPa (9.9 to 10.2 x 106 psi) |
| Peel resistance (ASTM D1781-98) | > 280 N / 76 mm (approx. 63 lbf / 3 in), or 40 Nmm/mm |
| Maximum service temperature | -40 to +60 °C (-40 to +140 °F) standard. +80 °C, +100 °C, and +150 °C constructions available to order |
| Thermal expansion coefficient | 2.3 x 10⁻⁵ per °C (1.3 x 10⁻⁵ per °F) |
| Skin surface options | Rough, primer, polyester, PVDF, anodized |
| Protective film | Available on made-to-order panels. Contact us for cost and lead time |
| Manufacturer panel sizes | 1250 x 2500 mm, 1250 x 3000 mm, 1500 x 3000 mm standard, up to 2000 x 7000 mm on request. CEL publishes metric mill sizes. Panels stocked by Chemical Concepts are supplied in the imperial sizes listed above |
Honeycomb Core Properties by Cell Size
Core density and compressive strength change with both cell diameter and foil thickness. Use this table when specifying a custom panel.
| Cell Diameter | Foil Thickness | Core Density | Compressive Stabilized Strength |
|---|---|---|---|
| 1/4 in (6 mm) | 50 micron | 56 to 59 kg/m³ (3.5 to 3.7 lb/ft³) | 3.0 to 3.5 MPa (435 to 508 psi) |
| 1/4 in (6 mm) | 70 micron | 80 to 83 kg/m³ (5.0 to 5.2 lb/ft³) | 4.3 to 4.6 MPa (624 to 667 psi) |
| 3/8 in (9 mm) | 50 micron | 39 to 40 kg/m³ (2.4 to 2.5 lb/ft³) | 1.4 to 1.95 MPa (203 to 283 psi) |
| 3/8 in (9 mm) | 70 micron | 54 kg/m³ (3.4 lb/ft³) | 2.5 to 2.6 MPa (363 to 377 psi) |
| 1/2 in (12 mm) | 50 micron | 29 to 30 kg/m³ (1.8 to 1.9 lb/ft³) | 0.8 to 0.95 MPa (116 to 138 psi) |
| 1/2 in (12 mm) | 70 micron | 40 to 42 kg/m³ (2.5 to 2.6 lb/ft³) | 1.41 to 1.5 MPa (205 to 218 psi) |
| 3/4 in (19 mm) | 50 micron | 20 to 21 kg/m³ (1.2 to 1.3 lb/ft³) | 0.4 to 0.6 MPa (58 to 87 psi) |
| 3/4 in (19 mm) | 70 micron | 27 to 29 kg/m³ (1.7 to 1.8 lb/ft³) | 0.85 to 0.9 MPa (123 to 131 psi) |
Panel Performance Data
Values below are published by CEL for panels with 0.5 + 0.5 mm and 1.0 + 1.0 mm skins over a 1/4 in (6 mm) 56 kg/m³ honeycomb core. Stocked panels use 0.8 mm skins over a 3/8 in cell core, so treat these as reference brackets. Contact us for values on a specific stocked SKU.
| Property | Test Method | Skins 0.5 + 0.5 mm | Skins 1.0 + 1.0 mm | |||||
|---|---|---|---|---|---|---|---|---|
| Panel thickness | 6 mm | 10 mm | 15 mm | 10 mm | 15 mm | 20 mm | 25 mm | |
| Panel weight | 3.8 kg/m² 0.78 lb/ft² |
4.0 kg/m² 0.82 lb/ft² |
4.3 kg/m² 0.88 lb/ft² |
6.7 kg/m² 1.37 lb/ft² |
7.0 kg/m² 1.43 lb/ft² |
7.3 kg/m² 1.50 lb/ft² |
7.6 kg/m² 1.56 lb/ft² |
|
| Compressive stabilized strength | ASTM C365-365M | 2.9 MPa (421 psi) | ||||||
| Maximum load | ASTM C393 | 190 N 43 lbf |
340 N 76 lbf |
520 N 117 lbf |
600 N 135 lbf |
1,000 N 225 lbf |
1,350 N 304 lbf |
1,700 N 382 lbf |
| Deflection at maximum load | ASTM C393 | 14 mm | 8 mm | 6 mm | 8 mm | 6 mm | 4 mm | 3 mm |
| Moment of inertia (I) | 7,600 mm⁴/m | 22,000 mm⁴/m | 52,000 mm⁴/m | 40,000 mm⁴/m | 98,000 mm⁴/m | 181,000 mm⁴/m | 288,000 mm⁴/m | |
ASTM C393 sample dimension is 540 x 50 mm on four support points, 500 mm between lower points and 250 mm between upper points. Compressive strength, maximum load, peel resistance, service temperature, and thermal expansion values are tested by CEL internal laboratory. Physical and mechanical properties are provided as a basis for comparison. Verify performance against your specific application requirements before design use.
Performance in Production
- Aluminum honeycomb core provides high stiffness at low panel weight, which reduces handling, transport, and support structure loads compared to solid sheet of comparable stiffness.
- Panel stiffness increases sharply with thickness at the same skin gauge. Compare the moment of inertia and maximum load columns when selecting panel thickness for a span.
- Cell diameter and foil thickness drive core density and compressive strength. A larger cell reduces panel weight and cost but lowers compressive strength, which matters where fasteners, inserts, or point loads bear on the core.
- Aluminum skins bond readily with structural adhesives and are used as a substrate for stone, laminate, and veneer lamination.
- Aluminum construction is dimensionally stable and does not absorb water, which supports use in humid and exterior environments.
- Confirm the skin surface condition before specifying an adhesive. Panels ship with skins in one of several conditions (rough, primer, polyester, PVDF, or anodized), and surface condition can differ face to face. Anodizing increases corrosion and wear resistance and improves adhesion for paints, primers, and adhesives.
- Service temperature is set by the lamination adhesive, not the aluminum. Standard construction is rated -40 to +60 °C. Higher temperature constructions are made to order.
- Standard Compocel AL is not supplied with fire certification. Fire classified panels are supplied as Compocel AL FR and must be requested in advance.
Common Applications
- Backing and reinforcement for natural stone, marble, semi-precious stone, mosaic, and porcelain slabs
- Ventilated facades, cladding, and architectural panel systems
- Elevator cabin walls, ceilings, and floors
- Marine interiors, partitions, bulkheads, furniture, and flooring
- Railcar partitions, ceilings, floors, and tables
- Cleanroom and bio-containment walls, doors, floors, and ceilings
- Countertops, worktops, tables, seats, and separating walls
- Lightweight structural panels and tooling plate where stiffness-to-weight ratio governs
- Acoustic and air deflection panels
Custom Panel Configurations
Stocked panels cover one construction: 0.8 mm aluminum skins over a 3/8 in cell 3000 series core. Compocel AL is built to order across a much wider range. If your specification falls outside the stocked build, send it to us and we will confirm feasibility with the manufacturer before quoting.
| Variable | Documented Range |
|---|---|
| Panel size | Up to 2000 x 7000 mm |
| Panel thickness | 1/8 in (3 mm) through 1 in (25 mm) standard, 5/8 in (15.9 mm) included. Thicker on request |
| Skin thickness | 0.5 mm to 5.0 mm |
| Skin alloy | 1000, 3000, or 5000 series |
| Core cell diameter | 3 mm to 19 mm |
| Core foil thickness | 50 or 70 micron |
| Core density | 20 to 163 kg/m³ (1.2 to 10.2 lb/ft³) |
| Adhesive system | Two-component polyurethane, two-component epoxy, epoxy film, thermoplastic film |
| Service temperature | +80 °C, +100 °C, or +150 °C constructions on request |
| Skin finish | Anodized, powder or liquid paint, PVDF, FEVE, serigraphy. Antibacterial and dissipating paints on request |
| Processing | Cut to size, cut to shape, milling, drilling, folding, edging, inserts, veneering |
Made-to-order constructions carry a minimum order quantity that varies by specification. Higher temperature and non-standard core builds generally have a higher minimum than standard panels. Tell us your quantity along with the specification and we will confirm the minimum up front.
Need panel data for a specific application? Send us the SKU along with your span, load, and support condition and we will get you the panel data from CEL. For custom sizes, thicknesses, cell diameters, core densities, skin gauges, adhesive systems, or finishes, tell us the target specification and we will confirm feasibility before quoting.
Fabrication and Processing
Compocel AL is processed with standard CNC equipment. CEL also performs finished processing to customer drawings.
- Cutting to size, milling, drilling, and cutting to shape
- Panel folding, including V-groove and rectangular grooving along fold lines without cutting the outer skin, followed by adhesive bonding
- Panel edging, insert installation, painting, and veneering
Joining and Fastening
- Panel to panel with visible or blind rivets and screws
- Self-tapping screws with sealing washers, aluminum or stainless steel, matched to the substructure
- Drilling screws
- Threaded inserts set into the honeycomb core for repeatable mechanical attachment
Edging Options
- Flat edging (applied edge). Extrusions in aluminum, laminate, PVC, or ABS, including color matched to the panel skin, bonded with a tear-resistant adhesive.
- C-profile edging. Applied with adhesive after milling the panel core.
- T-profile edging. Applied with adhesive after milling the panel core. The combination of milling and adhesive increases hold and perimeter rigidity. Smallest available T-profile is 25 mm.
- Folded skin edge. The outer skin is lightly scored, folded over, and bonded until it covers the panel thickness.
Matching a C-Profile to Panel Thickness
C-profiles wrap the full panel including both skins, not just the honeycomb core. The panel must be thinner than the profile height by the thickness of the profile walls. Check this before ordering panels and profiles together.
| C-Profile | Required Panel Thickness | Finished Edge Height |
|---|---|---|
| 15 x 15 x 1.5 mm | 10.4 mm (0.41 in) | 15 mm |
| 20 x 15 x 1.5 mm | 14.4 mm (0.57 in) | 20 mm |
Stocked panel thicknesses do not match these profiles directly. If your project needs a C-profile edge, the panel thickness needs to be specified to suit. Contact us and we will work the profile and panel thickness together.
Surface Finishing
Finishes are selected for indoor or outdoor service. High quality polymeric paints including PVDF and FEVE are available on request. Specific finishes and colors require an overall order so that all aluminum sheets are produced in one batch without pigment variation.
- Anodic oxidation. Increases corrosion and wear resistance and improves adhesion for paint, primers, and adhesives.
- Painting. Powder or liquid paint. Antibacterial and dissipating paints available on request for indoor and outdoor use.
- Serigraphy. High resolution digital printing with UV resistant inks.
- Protective film. Available on made-to-order panels where the skin surface needs protection through fabrication and installation.
How to Read the Part Number
Example: CEL-CC-A08-08-09-05×10-1-1270 is a Compocel AL panel, 0.8 mm aluminum skins, 3/8 in cell, 5 ft x 10 ft, squared, 1/2 in (12.7 mm) thick.
| Position | Meaning | Codes |
|---|---|---|
| Series | Panel family | CC = Compocel AL, AS = Alustep, CS = Clearstep |
| Skin | Skin material and thickness | A05-05 = 0.5 mm aluminum, A08-08 = 0.8 mm aluminum, A10-10 = 1.0 mm aluminum |
| Cell size | Honeycomb cell diameter, rounded mm | 6 = 1/4 in (6 mm), 8 = 5/16 in (8 mm), 9 = 3/8 in (9 mm), 13 = 1/2 in (12.7 mm), 19 = 3/4 in (19 mm) |
| Size | Sheet size | 04×08 = 4 ft x 8 ft, 04×10 = 4 ft x 10 ft, 05×08 = 5 ft x 8 ft, 05×10 = 5 ft x 10 ft |
| Finishing | Edge condition | 1 = Squared, 2 = Unsquared |
| Thickness | Total panel thickness | 300 = 1/8 in (3 mm), 640 = 1/4 in (6.4 mm), 950 = 3/8 in (9.5 mm), 1270 = 1/2 in (12.7 mm), 1590 = 5/8 in (15.9 mm), 1900 = 3/4 in (19 mm), 2540 = 1 in (25 mm) |
Frequently Asked Questions
What sizes and thicknesses of aluminum honeycomb panel are in stock?
Chemical Concepts stocks Compocel AL in 5 ft x 10 ft (1/4 in, 3/8 in, 1/2 in, 3/4 in, and 1 in thick), 4 ft x 10 ft (1/4 in and 1/2 in thick), and 4 ft x 8 ft (1/2 in thick). All stocked panels have 0.8 mm aluminum skins and a squared edge. 5/8 in panels are available in all sizes as a special order.
How thick are the aluminum skins?
0.8 mm (0.031 in) on both faces. This is the standard skin thickness for Compocel AL and is used on every stocked panel. 0.5 mm and 1.0 mm skins are available by special order, and CEL can supply skins from 0.5 mm to 5.0 mm.
What is the honeycomb cell size?
Most stocked panels use a 3/8 in (9 mm) hexagonal cell. One 1 in thick 5 ft x 10 ft panel uses a 1/2 in (12.7 mm) cell. Compocel AL is also built with 1/4 in and 3/4 in cell diameters on request. Cell size affects both core density and compressive strength, so specify it when requesting a custom panel.
How much does a panel weigh?
Panel weight depends on thickness, skin gauge, and core density. Sheet weights for each stocked SKU are listed in the stocked panels table above. Contact us for weights on custom constructions.
Do you stock 5 ft x 8 ft panels?
Not currently. 5 ft x 8 ft is a standard Compocel AL size and is available as a special order. Contact us for lead time and minimum quantity.
Are Compocel AL panels fire rated?
Standard Compocel AL, including all stocked panels, is not supplied with fire certification. CEL produces a certified version, Compocel AL FR, which holds IMO MED Mod. B and D, UNI EN 13501-1 A2 s1 d0, NF P92-507 M1, and UNI EN 45545 HL3 classifications. Certified panels must be requested in advance and carry a surcharge for certified materials. Contact us with the specification you need to meet.
What is the maximum service temperature?
Standard Compocel AL is rated -40 to +60 °C (-40 to +140 °F). Service temperature is set by the lamination adhesive rather than the aluminum, so higher temperature versions use a different adhesive system. CEL builds +80 °C, +100 °C, and +150 °C constructions to order, and these carry a higher minimum order quantity than standard panels. Send us your operating temperature and quantity and we will confirm feasibility and the minimum.
Can Compocel AL be cut to size?
Yes. Compocel AL is cut, milled, drilled, and shaped with standard CNC equipment. CEL also performs cutting to size, cutting to shape, folding, edging, insert installation, painting, and veneering to customer drawings. Contact us for panels processed before shipment.
What are the dimensional tolerances?
Stocked panels are supplied squared at full 5 ft x 10 ft, 4 ft x 10 ft, or 4 ft x 8 ft. Thickness tolerance is ±0.3 mm (±0.012 in) and planarity is approximately ±1 mm/m. The ±30 mm dimension tolerance published in the CEL data sheet applies to manufacturer mill-size panels rather than squared stock.
How do you bond stone or laminate to an aluminum honeycomb panel?
Aluminum skins bond with two-component structural adhesives. Chemical Concepts supplies laminating epoxies and honeycomb bonding systems selected for stone, porcelain, and laminate lamination onto aluminum honeycomb panels. Confirm the skin surface condition before selecting an adhesive, since primer, polyester, PVDF, and anodized finishes behave differently and surface condition can vary face to face.
How do you fasten aluminum honeycomb panels?
Options include blind or visible rivets and screws for panel to panel joints, self-tapping screws with sealing washers matched to the substructure, drilling screws, and threaded inserts set into the honeycomb core. Chemical Concepts stocks threaded inserts and deform nuts made for honeycomb sandwich panels.
Can I get an edge profile to match a stocked panel?
C-profiles wrap the full panel including both skins, so the panel has to be thinner than the profile height. A 15 mm C-profile needs a 10.4 mm panel and a 20 mm C-profile needs a 14.4 mm panel. Stocked thicknesses do not line up with the available profiles, so panel and profile need to be specified together. Contact us and we will size both.
Related Products
- Honeycomb panel bonding systems and laminating epoxies
- Honeycomb sandwich panel threaded inserts and deform nuts
- Alustep 500 SL fiberglass skin honeycomb sandwich panel
- Clear-Step translucent sandwich panel for backlit stone
See the Compocel AL technical data sheet for complete manufacturer specifications.
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