Help Me Choose - Polycarbonate or Corrugated Roofing Sheets

28 January 2025 | Regan

Comparison – Polycarbonate Roofing Sheets or Corrugated PVC Roofing Sheets – Which Should I choose?

It can be difficult to choose what sheets to use for you roofing project especially when there are so many choices online! Historically corrugated PVC sheets were used as a cost-effective solution for roofing a patio, carport or outdoor area. Whilst corrugated PVC is still a great material to use for your roofing project, polycarbonate roofing sheets are now seen as the go-to product for canopy roofing, but both have their benefits.

In this brief guide we will walk you through the benefits of both roofing materials and try to help you to decide which is best for your roof by offering a comparison between both materials.

Cost

First up is cost! Always a major factor for choosing any building materials. So, what is the most cost-effective way to roof my canopy or carport?

Twinwall polycarbonate roofing sheets are generally more expensive than their PVC counterpart. Whilst there is not a massive difference in price of the sheets when compared to corrugated PVC you must factor in the cost of the glazing bars and accessories that are required to complete your project. In general, polycarbonate will be more expensive than corrugated roofing sheets; however, it is worth considering the lifespan of both products before making your choice.

Corrugated PVC Roof Sheets are more budget friendly than polycarbonate so the initial outlay will be less. This makes them a popular choice for use in jobs where lifespan is not the determining factor, such as temporary roofing applications or for repairs to existing roofs. We always recommend choosing the thickest PVC sheet possible for your budget to maximise its lifespan.

Lifespan

Of course, lifespan is key when choosing your material – you must ask yourself how long you want your material to last. Which sheet will last the longest? Spoiler alert! In this respect there is one clear winner!

Polycarbonate sheets are supplied with a 10-year warranty, which covers discolouration, premature ageing and strength. However, most modern polycarbonate sheets should outlive this warranty by some margin. Polycarbonate sheets have been known to last up to 20 years with little or no signs of defect other than sheets being a little weathered. Polycarbonate sheets supplied by Varico Ltd are UV protected on one side meaning that they are resistant to the harmful effects of UV light protecting the sheets for many years. Polycarbonate is also excellent at performing in the harshest of conditions. Sheets can withstand high temperatures as well as temperatures well below freezing with little to no effect to the material. This makes them the perfect choice long term installations in the UK such as carports, canopies and pergolas.

Corrugated PVC Roofing Sheets by comparison tend to have a more limited life cycle than polycarbonate sheets. Whilst PVC sheets are very good at resisting weather, they are more susceptible to premature weathering than polycarbonate which over the years can lead to brittleness and cracking. Corrugated sheets are thinner than polycarbonate meaning they tend to flex more in windy conditions which adds to this issue. We tend to see corrugated sheets lasting between 5 – 10 years before a replacement is recommended.

Light Transmission

This can be a large factor in choosing your roofing material as many people want to keep dry but retain as much daylight as possible. Which sheets perform the best in this area?

Polycarbonate Roof Panels provide an excellent light transmission. 10mm clear polycarbonate sheets have a light transmission figure of around 75-80% which is very good for a double layer sheet. For reference clear glass is about 85-90%. As a multi-layered sheet there is a little clarity distortion due to the flutes of the sheets, but generally clear sheets are a popular choice for customers wishing to maximise the light penetration into darker areas. This is particularly useful if you have a window underneath you roof. Clear sheets are also an excellent choice for greenhouses and growing areas. Due to the multi-layered design sheets provide an excellent thermal efficiency when compared to glass meaning greenhouses benefit not only from the light transmission but the insulation value too. Sheets are also available in bronze and opal tints which are great at diffusing the light – especially useful for south facing gardens.

Corrugated Roofing Sheets also offer a very good light transmission. This is helped by the sheet being a single skin construction meaning light passes through the sheet much easier than a twinwall sheet. Generally corrugated PVC sheets have a light transmission figure of between 75-85% dependant upon the thickness of sheet you choose. However, it is worth remembering that due to the way in which corrugated sheets weather this figure will likely decrease with time due to discoloration and surface wear.

Conclusion

Fundamentally there is no bad choice for your roof whether you use polycarbonate or corrugated sheets both will do an excellent job of providing shelter from the elements. From our years of experience, we would suggest the following as a general guide:

If you want a long lasting, lightweight roofing solution with a 10-year warranty and if you budget allows polycarbonate roofing sheets should be the product of choice for your roof.
If you are looking for a more budget friendly low-cost solution that does not need to be in place for years and years or if you are sheets on an existing roof, corrugated PVC sheets should be selected.

The good news is that the friendly, helpful team here at Varico are on hand to help you choose between polycarbonate or PVC. So, if you can’t decide what to go for, or are just looking for a little advice, just pick up the phone or drop us an email and we’ll help you decide what is best for you. Our team is used to working with customers from all over the country, from the exposed areas of the Orkney Isles to the tranquil surroundings of the New Forest, we’ve seen it all so please do not hesitate to get in touch.

Tel: 01922 455338

Email: support@varicoltd.com