Known for their durability, light weight and ease of handling, polycarbonate sheets are an essential material for the DIY roof builder and tradesman alike. Whether you are planning a new roofing project or looking to update an older structure, polycarbonate is ideal for the job.
Polycarbonate Sheet 101
In this beginners guide we will take a look at the different types of polycarbonate sheets, their composition, production, structure and more!
What is a Polycarbonate Sheet?
Polycarbonate is a high-performance thermoplastic material, derived from polymerized carbonates. It is lightweight, strong, and can transmit light, making it a popular roofing material for a wide range of projects. Polycarbonate sheets are made from these polymers and extruded into versatile sheets that can be used for a wide range of projects that offer a range of optical clarity and insulation. For interesting information on the history of polycarbonate sheet, or more technical aspects like chemical resistance, visit the British Plastics Federation website.
Composition and Production of Polycarbonate Sheets
Polycarbonate sheets are primarily made from Bisphenol A (BPA) and phosgene. The production process synthesizes these chemicals into polymer chains. These are then extruded (forced through a mold) into flat solid transparent sheets, multiwall structured ones or wave like corrugated ones. Our blog ‘what is polycarbonate and how is it made’ looks more deeply at this.
The material is often modified with UV stabilizers to make it suitable for outdoor use. Structured sheets have a co-extruded UV layer for protection from the sun.
Types of Polycarbonate Sheet
Here are three types of polycarbonate sheet, each designed for specific applications:
Multiwall Polycarbonate Sheets: These polycarbonate sheets feature multiple walls or layers of polycarbonate separated by air channels known as flutes. They are ideal for conservatories, canopy roofs, carport roofs and greenhouse glazing. These sheets offer an excellent more thermally efficient alternative to glass. The levels of thermal insulation increase as the sheets get thicker and has more layers of flutes and walls. 35mm polycarbonate sheet is highly efficient and a fabulous choice for conservatories.
Solid Polycarbonate Sheets: Known for their excellent optical clarity, these sheets are commonly used as a visual alternative to glass in canopy roofs, skylights and in displays.
Corrugated Polycarbonate Sheets: These sheets have a wavelike structure that provides added strength and makes them very easy to fit by overlapping them. They are suitable for a wide range of roofing and cladding applications.
Structures and thicknesses
Polycarbonate sheets have different structures and thicknesses depending on their type.
Multiwall Polycarbonate Sheets: These polycarbonate sheets are made up of walls and cavities which form air channels known as flutes. These flutes provide thermal insulation which increases as the sheet gets thicker and there are more layers. Multiwall polycarbonates sheets are ideal for conservatories, canopy roofs, carport roofs and greenhouse glazing. The thinner sheets start with two walls and one row of cavities and are known as twinwall. 16mm polycarbonate has three walls and two rows of cavities and is known as triple wall. 25mm has a 'X' structure with seven walls. 35mm also has seven walls with six rows of cavities. They are much lighter in weight in relation to their thickness due to the hollow cavities within them.
Solid Polycarbonate Sheets: Solid polycarbonate is most commonly available in 2mm to 12mm thicknesses. Their solid structure makes them much heavier than multi-wall sheets.
Corrugated Polycarbonate Sheets: Corrugated polycarbonate comes in a wide range of thicknesses from 0.8mm to as much as 3mm. The corrugated or ‘rippled’ structure of these sheets give them additional strength than if they were flat.
What colour do the polycarbonate sheets come in?
Depending on the type of polycarbonate sheet, there are many choices available to suit your project.
Multi-wall polycarbonate is available in a wide range of colours dependant upon the thickness of the sheet. New options becoming available the thicker the sheets get. The thickest sheets in the range even have dual-tint options for added performance. They are as follows:
Clear: Offers maximum light transmission and is available for all sheet thicknesses.
Opal: Has a white appearance with reduced light transmission while providing a softer, more diffused light. This is available from 10mm polycarbonate and thicker.
Bronze Tint: Provides a brownish shaded effect and reduced glare. Ideal for brown roof bars and canopies. This tint is also available from 10mm polycarbonate upwards.
Dual tints: Bronze Opal and Heat guard Opal sheets offer added benefits. Specifically developed for conservatories, these polycarbonate sheets offer excellent thermal insulation qualities. These dual tint sheets are available in 25mm dual-tinted polycarbonate, 32mm dual-tinted polycarbonate and 35mm dual-tint polycarbonate sheet.
Solid Polycarbonate has clear as the most popular choice due to its glass-like appearance. There are other colours available including opal, bronze and even black.
Corrugated polycarbonate sheets are most commonly available in clear, translucent or bronze but other options are available dependant on the manufacturer and range.
Benefits of Polycarbonate Roofing
Polycarbonate roofing is very popular for both residential and commercial projects. With the right glazing bars and accessories a polycarbonate roof is economical and easy to install making it the best choice for the professional and DIY person alike. Here are some key benefits:
Durability: Polycarbonate sheets are virtually unbreakable, able to withstand extreme weather conditions, impact, and heavy loads.
UV Protection: Many polycarbonate sheets come with a UV-resistant coating, protecting them from discoloration and ensuring a longer lifespan.
Lightweight: Polycarbonate sheets weigh far less than glass, making them easier to handle and install.
Thermal Insulation: Multiwall polycarbonate sheets provide insulation, reducing heat transfer and keeping indoor spaces cooler in summer and warmer in winter.
Fire Resistance: Polycarbonate has a high ignition temperature and is self-extinguishing. This makes it a safer choice in fire-prone areas.
Ease of Installation
Polycarbonate sheets are easy to fit, even for the DIYer. The sheets can be cut to size on site and have purpose made accessories to make installation even easier. As a light weight option, the sheets are easier to handle.
To sum up
Polycarbonate sheets are versatile and practical and are suited for lots of applications. They are durable, strong and light weight making them easy to fit and maintain. Whether you need a solid, multiwall, or corrugated sheet, polycarbonate offers a range of options in thicknesses, colours, and structures, allowing you to choose the right solution for your project.