Infill Panels: Tips for a Successful Installation Process

Installing factory-glazed infill panel systems is an efficient and cost-effective way to help your project stay on schedule and budget. However, contractors should always follow the manufacturer’s best practices for infill panel installation to ensure project success.

The importance of accurate measurements and correct alignment of the panels can not be overstated, and following proper techniques will help you avoid common installation mistakes to ensure the panels last for years to come. 

Pre-Installation Preparation

The installation of infill panels really starts with pre-installation prep work. Don’t skip this step in an attempt to get the job done more quickly. If mistakes are made, they could result in costly replacements or fixes later on.  

The best way to avoid issues is to perform checks at every step of the installation process.

Site Assessment

The pre-installation process should always start with a thorough site assessment. Make sure that the substrate or framing where the panels will be installed is plumb, level and structurally sound. Make sure the glazing pocket is clean and free of debris, ensuring the weep system is not blocked and the panel can be adequately sealed within the pocket.

Finally, cross-check the site dimensions against shop drawings to catch any discrepancies. 

Selecting the Right Materials

Replacing infill panels is a big and expensive job, so it’s important to choose the right materials the first time. 

Selecting the correct materials for infill panel installation begins with understanding the project’s structural and environmental demands. You’ll need to choose panels based on specs like fire rating, thermal insulation, impact resistance and aesthetics.

Make sure the framing system is compatible with the panel thickness and weight, and ensure the sealants and weather barriers are appropriate for the condition.

Additionally, pay close attention to the requirements for wind loads, water intrusion, thermal movement and the local climate.

Tools and Equipment

While contractors should have most of the tools required for installing infill panels, some specialized equipment may be necessary. 

If panels need to be cut on-site, a carbide-tipped saw blade is recommended to maintain clean edges and prevent damage to the panel surface. Common tools used for this are circular saws, reciprocating saws or routers.

Lifting equipment is advised when appropriate.

Infill Panels: The Installation Process

After the pre-installation prep is done, the actual installation process can begin. 

Addressing Sizing and Alignment, Then Installation Begins

Once you’ve confirmed that the framework is level and plumb in the prep steps, it’s now time to check the sizing, alignment and positioning of the panels. 

Dry-fit the panels first to confirm that the sizing and alignment are correct. Securely glaze the panels into the framing, and seal both sides of the panels (interior and exterior) to maintain their weather resistance.

Post-Installation Checks

When the infill panels have been installed and the alignment is consistent, some post-installation checks can be done to make sure the panels are secure.

Inspecting the Fit and Finish

The first thing that needs to be done after the panel installation is an inspection of the fit and finish of the panel.

Start by making sure that there are no signs of warping, bowing or oil-canning throughout the panels. Then, check that there’s no damage caused by the removal of the panel’s protective film. If there’s any adhesive residue, be sure to clean it.

Weatherproofing and Sealing

To check the weatherproofing and sealing of infill panels, start by inspecting all seams and penetrations. Make sure that the sealants are continuous, properly tooled and free of gaps, bubbles or separation.

Final Quality Control

At this point, the panels should be properly aligned and sealed. A visual inspection to check for any damage done during the installation should be the final quality control check.

Common Installation Challenges and Solutions

The installation of infill panels is relatively straightforward, but challenges do occur. Fortunately, these issues can usually be solved without completely reinstalling panels.

Misalignment Issues

Never try to force a panel into alignment. Take the time to remove the panel and reposition it carefully. Losing a little time is preferable to breaking the panel or redoing an entire panel system.

Weather Conditions

Weather conditions can have a big impact on the installation process.

Rain or high humidity can interfere with sealant adhesion and trap moisture behind panels, leading to long-term issues like corrosion or mold. Wind can make it dangerous to lift and position large panels, as it risks damage and injuries.

Cold temperatures may cause sealants to stiffen and fasteners to become brittle, while heat can affect expansion tolerances. 

If the weather is extremely hot or cold or if rain is predicted, put off the installation until the weather is more temperate. 

Panel Damage During Installation

Infill panels can get damaged on the job site from improper handling, poor storage or contact with tools and equipment. Scratches, chips and warping are common when panels are stacked unevenly, dragged across rough surfaces or left exposed to the elements.

The best way to protect panels from damage is by storing them carefully. It’s also recommended to use heavy equipment to move panels so they aren’t dropped or damaged while being shifted around the job site.

If the panels do get damaged, replace them — you never want to install a damaged panel. 

Find The Right Solutions For Your Next Project

Mapes offers high-quality, reliable and efficient panels for every project. 

Our commercial architecture panels have been specified by professionals for over 60 years, and we are dedicated to delivering innovative solutions to meet the challenges of the ever-evolving construction industry. 

Browse our available panels or check out the Mapes Selection Guide to find the solution that best fits your project needs.

If you need more help, reach out to us directly to get immediate assistance from one of our panel experts.