A Guide To Polycarbonate Roofing Sheets | Varico

A Guide to Polycarbonate Roofing Sheets

You’ve probably seen these durable products many times before – but how much do you know about polycarbonate sheets, and how can you be sure they are the best fit for your next roofing project?

Let’s take a closer look at their pros, cons and characteristics here.

What are polycarbonate roofing sheets, and what are they used for?

Polycarbonate roofing sheets are a type of roofing material made from a durable and versatile thermoplastic that is naturally transparent.

Known for their exceptional strength and resistance to extreme temperatures, polycarbonate sheets are a solid alternative to acrylic materials and have become an increasingly popular choice for both residential and commercial roofing projects. They’re a particularly good bet for the latter because they can be easily worked and thermoformed, meaning they can be manipulated to suit any design and cut and fixed as needs be without losing their toughness.

How is each sheet produced?

A polycarbonate roofing sheet will undergo a series of carefully controlled processes while it’s being manufactured.

The polycarbonate resin (the raw material) is usually supplied in the form of small pellets or granules and will need to be checked for any impurities before they it’s fed into an extruder. This machine will combine heat and pressure to melt the resin into a thick liquid. Sometimes, extra additives are introduced at this stage – or example, if the roofing sheet needs to be specifically fire-resistant, then flame retardants will be added into the mix.

Once it has been blended and melted, the polycarbonate resin will be pushed through a die, which moulds it into the right format – in this case, a thin, continuous sheet with the correct thickness and width for its intended use.

From here, the sheet will be passed through a range of cooling rollers. It will be cooled gradually to make sure it maintains its shape. Surface treatments can then be applied; many manufacturers choose to add a UV-resistant coating to ensure the product retains its clarity and continues to perform well over time. The sheet will be subjected to a final inspection before it’s approved and shipped to its intended destination.

What are the typical characteristics of polycarbonate sheets?

• As mentioned earlier, polycarbonate sheets are highly durable and impact-resistant, making them suitable for areas that are prone to harsh weather, like hailstorms and heavy snowfall. They can withstand a significant amount of force without cracking or breaking – which is every engineer’s dream!
   
• Despite their strength, polycarbonate sheets are lightweight. This makes them easier to handle and install compared to traditional roofing materials like glass or metal, reducing labour costs and installation times for a quicker and more cost-efficient project overall.
   
• Polycarbonate roofing sheets can transmit up to 90% of light, making them an excellent choice for applications requiring natural light, such as skylights, greenhouses, and commercial atriums. They allow engineers to emulate the effects of glass panels with a material that’s virtually impossible to destroy.
   
• Many polycarbonate sheets come with a UV-resistant coating, protecting them from the damaging effects of prolonged sun exposure. This feature extends the lifespan of the sheets and protects the interiors of buildings from harmful UV rays, too.
   
• Polycarbonate sheets provide good thermal insulation, which helps to maintain a stable indoor temperature and reduce energy costs. This makes them particularly beneficial for commercial buildings where engineers are encouraged to enhance the sustainability of the build, and energy efficiency is a priority.

Polycarbonate sheets are perfect for creating:

Skylights, atriums, and conservatory roofs. The high transparency of polycarbonate sheets makes them ideal for these kinds of structures in commercial buildings. They allow natural light to flood into the interior space, reducing the need for artificial lighting and creating a more pleasant working environment for everyone.

Greenhouses and nurseries. Their ability to transmit light while providing thermal insulation creates an optimal environment for plant growth.

Canopies and awnings – specifically in restaurants, hotels and shopping centres. Polycarbonate sheets will provide shelter from the elements while allowing natural light to penetrate, enhancing the area’s aesthetic appeal.

Walkways and covered pathways – for example, in larger commercial offices or complexes. These products provide protection from sun, rain and all manner of weather conditions while maintaining an open and airy feel.

Roof structures in warehouses, factories and other industrial settings. They often play an instrumental role in creating a safe, stable environment inside the building, which is crucial to the business’s operations. Polycarbonate sheets are also a great option for machine guards and other security components.

Are there any downsides to these products?

Due to their exceptional strength and durability, polycarbonate sheets can be more expensive than other materials. They are prone to scratching, which can affect their appearance over time – and if they are not treated with a UV-resistant coating, they can become discoloured after too much exposure to the sun.

Practically, polycarbonate sheets are prone to expanding and contracting as temperatures change. To combat this, we often recommend creating oversized holes for screws or investing in specific types of fasteners. They also have a limited load-bearing capacity, so if your roof needs to cope with excessive weight, then metal might be a better choice.

Generally, however, polycarbonate sheets are a fantastic all-round option for most standard roofing structures. For more information on these products or to find out if they are the best fit for your needs, contact Varico Ltd now!