Facades - Common Mistakes and How to Avoid Them

Introduction

In modern architecture, facades and curtain walls form the captivating faces of our buildings, defining not just their appearance, but also their performance and longevity. As the boundaries between structural innovation and artistic expression blur, these elements have evolved from mere envelopes to sophisticated systems that dictate light, thermal comfort, and energy efficiency. However, the complexity of facades and curtain walls often leads to a host of avoidable mistakes—each with the potential to undermine aesthetics, safety, or function. This article will guide you through the most common pitfalls and offer practical solutions, ensuring your next project stands tall and timeless.

Recognising these factors and addressing them is often compromised by the professional and commercial team promising results and timelines that cannot be met within budget. Early input from the façade specialist can assist in avoiding these common pitfalls.

Understanding Facades and Curtain Walls

Before exploring common mistakes, it’s essential to distinguish between facades and curtain walls. The term facade refers broadly to the exterior face of a building, often emphasising the front or most prominent side. A curtain wall, on the other hand, is a non-structural outer covering, typically comprising lightweight materials such as glass, aluminium, or composite panels, attached to the structural frame. Curtain walls serve as both aesthetic and functional shields, providing protection from the elements while allowing for creative design.

Common Mistakes in Façade and Curtain Wall Design and Installation

Even the most experienced teams can fall prey to errors during facade and curtain wall design, fabrication, or installation. Here are some of the most frequent missteps and tips to steer clear of them.

1. Inadequate Early-Stage Coordination

Mistake: As mentioned above, many projects suffer from a lack of early and ongoing coordination between architects, structural engineers, facade consultants, contractors, and manufacturers. Misalignment at this stage can result in design clashes, installation problems, and costly rework.

·       Design intent may not align with structural realities.

·       Lack of clarity around connections, loading, and tolerances.

How to Avoid:

·       Engage all key stakeholders early in the design process.

·       Facilitate regular multidisciplinary coordination meetings.

·       Utilise Building Information Modelling (BIM) for integrated planning and clash detection.

2. Poor Material Selection

Mistake: Choosing inappropriate materials—whether due to cost-cutting, lack of knowledge, or aesthetic bias—can have disastrous consequences. Inferior materials may fail under weather exposure, cause thermal bridging, or lack fire resistance.

·       Glass that is not adequately toughened or insulated.

·       Aluminium that corrodes or discolours in harsh environments.

·       Sealants and gaskets that deteriorate prematurely.

How to Avoid:

·       Specify materials based on climatic conditions, building function, and desired performance.

·       Insist on third-party certifications and performance testing.

·       Consult manufacturers about long-term durability and maintenance.

3. Neglecting Thermal and Moisture Performance

Mistake: Substandard design or installation can result in thermal bridging, condensation, and water ingress—leading to discomfort, mould, and costly repairs.

·       Lack of continuous insulation in the facade system.

·       Poor detailing of joints, sills, and parapets.

·       Improper installation of vapour barriers or drainage systems.

How to Avoid:

·       Incorporate thermal breaks and continuous insulation.

·       Pay meticulous attention to weatherproofing details.

·       Test mock-ups for air and water infiltration prior to full installation.

4. Overlooking Structural Movement and Loading

Mistake: Buildings move—whether due to thermal expansion, live loads, settlement, or seismic events. Facades and curtain walls must accommodate these movements without cracking, leaking, or detaching.

·       Rigid or improperly detailed fixing systems.

·       Failure to allow for differential movement between facade and structure.

How to Avoid:

·       Design flexible anchorages and movement joints at strategic locations.

·       Work closely with structural engineers to predict movement patterns.

·       Conduct performance testing to validate design assumptions.

5. Ignoring Fire Safety Requirements

Mistake: Non-compliance with fire regulations can put lives at risk and invite severe legal ramifications. Common lapses include using combustible materials, failing to compartmentalise floors, or overlooking firestopping details.

·       Improper selection of insulation and cladding materials.

·       Lack of tested fire barriers at slab edges and penetrations.

How to Avoid:

·       Stay updated on local and international fire codes.

·       Specify only tested and approved fire-rated components.

·       Engage fire consultants during design and sign-off phases.

6. Deficient Detailing and Documentation

Mistake: Incomplete or ambiguous drawings and documents can lead to misinterpretation on site, creating a cascade of errors from fabrication to installation.

·       Lack of clarity on jointing, interfaces, and fixings.

·       Missing information on tolerances and sequencing.

How to Avoid:

·       Produce comprehensive, detailed drawings and specifications.

·       Review documents with all relevant stakeholders for completeness and clarity.

·       Use 3D models to visualise complex junctions and interfaces.

7. Rushed or Poor-Quality Installation

Mistake: Even the best-designed systems can fail if installed incorrectly. Common issues include misaligned mullions, poorly sealed joints, or skipped steps due to tight schedules.

·       Inadequate training or supervision of site operatives.

·       Failure to adhere to manufacturer’s instructions.

How to Avoid:

·       Vet and train installation teams thoroughly and provide clear method statements

·       Implement robust quality assurance and inspection regimes.

·       Allow realistic timeframes for each stage of installation.

8. Insufficient Maintenance Planning

Mistake: Once installed, facades and curtain walls require ongoing maintenance for optimal performance. Neglect can lead to stained glass, corroded frames, or failed seals.

·       Lack of access provisions for cleaning and inspection.

·       No scheduled maintenance programme.

How to Avoid:

·       Design facades with accessible features and safety in mind.

·       Develop detailed maintenance/replacement strategies.

·       Educate building owners and facility managers on upkeep requirements.

Additional Tips for Success

·       Mock-Ups and Prototyping: Develop and test full-scale mock-ups to identify and resolve issues before mass production.

·       Regular Site Inspections: Conduct frequent on-site checks to ensure alignment with design intent and documentation.

·       Post-Completion Reviews: After project handover, monitor facade performance and address issues promptly.

·       Continuous Learning: Stay informed about emerging technologies, materials, and regulations in facade engineering.

Conclusion

Facades and curtain walls are more than architectural statements—they are complex, performance-driven systems that demand careful planning, precise execution, and ongoing stewardship.

A façade can represent over 40% of a new build cost

By recognising and proactively addressing the common mistakes outlined in this article, architects, engineers, contractors, and building owners can ensure stunning, resilient, and lasting exteriors.

Embrace best practices, foster collaboration, and never underestimate the value of attention to detail. In doing so, you’ll not only avoid costly errors but also elevate the built environment for generations to come.