Cladding failures create expensive delays, rework, and legal exposure. Most issues are avoidable with proper oversight. Below are the top problems—and how GCs can stop them before they happen.
Water Infiltration
Water is the leading cause of cladding failure and the costliest warranty claim. Leaks typically occur at transitions—not in the field.
- Common Causes: Poor sealant prep, incompatible products, reverse laps in flashing, missing end dams, flat sills, or last-minute M&E changes requiring field cuts.
- GC Controls:
- Require mockups with ASTM E1105 water testing at design pressures—failures must be fixed in mockup, not on the building.
- Inspect flashing before panel installation begins.
- Coordinate all penetrations before fabrication. Late penetrations must include engineer-reviewed waterproofing details.
- At closeout, archive maintenance manuals with inspection and sealant replacement schedules.
Thermal Performance Failures
Thermal bridging through steel studs and fasteners can slash effective R-value by 30–50%.
- Best Practices: Use thermal break clips (min. 25 mm depth), stainless fasteners, and continuous insulation around all penetrations. Tape and seal all insulation joints.
- GC Controls:
- Demand thermal calculations and condensation risk analysis in submittals.
- Enforce pre-close-in inspections for insulation continuity.
- Include thermal imaging in QA deliverables—look for ≥10°C delta between indoor and outdoor surfaces.
Installation Defects
Poor workmanship from rushed schedules or untrained installers results in preventable defects.
- Common Issues: Over-torqued screws warping panels, sealants applied in poor conditions, and alignment issues from substrate tolerance buildup.
- GC Controls:
- Require torque-controlled tools and logged calibration data.
- Monitor weather logs during sealant application—apply only between 5–35°C and <85% humidity.
- Verify alignment using laser checks every 5 panels to avoid compound misalignment.
Maintenance Access Oversight
Design decisions made during construction affect decades of maintenance costs and safety.
- Best Practices: Include removable panels every 6–9 m, CSA Z271-compliant fall arrest anchors, and suspension points for swing stages.
- GC Controls:
- Ensure permanent access systems are in scope and installed before handover.
- Require as-built documentation showing access points, panel removal sequences, and anchor locations.
GC Checklist: Preventing Cladding Problems
- Mockups with ASTM E1105 water testing
- Pre-panel flashing inspections and M&E coordination
- Thermal calcs, insulation inspections, and IR scans
- Torque tool calibration logs and alignment checks
- Weather monitoring for sealants
- Access systems installed and as-builts delivered
- Maintenance manuals archived at turnover
