What Are Polycarbonate Sheets and Why Are They Popular for Roofing?
What Are Polycarbonate Sheets and Why Are They Popular for Roofing?
What are polycarbonate sheets?
They are high-performance, transparent panels made from a thermoplastic polymer called polycarbonate resin. They are well-known for their exceptional strength and durability. And these sheets tend to be a safer and more versatile alternative to traditional glass or acrylic in a wide range of settings.
So, from skylights and greenhouses to industrial protective barriers, polycarbonate sheeting give you impressive impact resistance and thermal stability. These are the key reasons they’re so popular in the UK for roofing applications.
Composition: How Polycarbonate Sheets Are Made
Polycarbonate sheets come from a thermoplastic polymer made by combining bisphenol A (BPA) and phosgene under high temperatures.
The result is a lightweight yet incredibly durable plastic capable of maintaining clarity and structural integrity under extreme conditions. Unlike standard plastics, polycarbonate is practically shatterproof and retains its shape even when exposed to high-impact forces.
Why Are Polycarbonate Sheets Popular?
Polycarbonate sheeting is widely recognised for its outstanding strength, transparency and lightweight construction.
Many industries, from construction and agriculture to manufacturing rely on it because:
- It’s safer and lighter than glass, yet allows comparable light transmission.
- It resists UV damage, making it suitable for outdoor installations like roofing, skylights and greenhouses.
- It’s easy to cut, drill and mould, which speeds up both your DIY and professional projects.
The Key Properties of Polycarbonate Sheets
High impact resistance
With up to 250 times the strength of glass, polycarbonate can withstand heavy blows and extreme weather, reducing the risk of cracks or shattering.
Transparency
Polycarbonate lets in up to 90% of available light, similar to glass. This makes it ideal for any project that requires natural light, such as greenhouses or roof panels.
Thermal resistance
They are able to tolerate both hot and cold conditions, polycarbonate remains structurally sound in varied climates and temperatures.
UV protection
Many sheets come with a protective coating that prevents yellowing and degradation caused by prolonged exposure to sunlight.
Fire resistance
Polycarbonate is self-extinguishing, adding an extra layer of safety in fire-prone or high-heat environments.
Durability & Strength
It’s polycarbonate’s resilience that makes it the go-to option for safety-critical applications. Unlike glass or acrylic, it can endure impacts without shattering. Its natural flexibility also helps absorb shocks and retain shape, meaning it stays intact even in challenging conditions. This toughness means fewer replacements and longer service life overall.
Lightweight and Flexible
Despite its impressive strength, polycarbonate is around half the weight of glass. This makes transportation, handling and installation way more cost-effective and less labour-intensive. Polycarbonate can also be curved or shaped without breaking, enabling more creative designs. So, if you’re wondering what is polycarbonate used for? This can include domed skylights, arched roofing, or even custom canopies.
UV Resistance & Transparency
Excellent clarity and high light transmission rates is what makes polycarbonate a favourite for greenhouses, skylights and other applications that require natural light. Thanks to its UV-protective coating, it maintains transparency over time, safeguarding interiors (plants, furniture, etc.) from harmful UV rays.
Types of Polycarbonate Sheets
Solid Polycarbonate Sheets
These resemble glass in appearance but are far more robust. Often used for protective barriers, skylights and machinery guards.
Twin/Double Wall Polycarbonate Sheets
Two parallel layers separated by air channels, boosting insulation. They are commonly used for greenhouse walls and energy efficient roofing.
Multiwall Polycarbonate Sheets
Multiple layered walls for added insulation and structural support, suitable for large-scale roofing projects or industrial cladding.
Corrugated Polycarbonate Sheets
A wave-like structure that increases load-bearing capacity. Often chosen for agricultural or industrial roofing due to its strength and water run-off benefits.
The Advantages of Polycarbonate Sheets
High impact resistance: Provides strong protection for security windows, machine guards and skylights.
Weather & UV resistance: Prolongs lifespan in outdoor environments without fading or yellowing.
Versatile application: Works in construction, agriculture, automotive and so much more.
Lightweight material: Minimises shipping costs and eases installation.
Long-term durability: Stands up to harsh weather, reducing maintenance needs over time.
Are There Any Downsides?
Susceptibility to scratching
While impact-resistant, polycarbonate can scratch more easily than glass. Scratch-resistant coatings are available but may raise costs.
Higher cost compared to other plastics
Polycarbonate typically costs more than acrylic or PVC. However, its longevity and toughness often justify the initial investment.
Where Are Polycarbonate Sheets Commonly Used?
Construction (Skylights, Roof Panels): They provide natural light with strong protection and insulation.
Greenhouses & Agriculture: Allows sunlight in while shielding plants from harmful UV rays.
Safety & Security (Protective Barriers): Ideal for things like riot shields, machine guards and bullet-resistant windows.
Industrial & Commercial Projects: It functions well for roofing, cladding and covers in harsh environments.
Polycarbonate Sheets vs. Other Materials
Polycarbonate vs. Acrylic: Polycarbonate is stronger and more impact-resistant; acrylic is cheaper and more scratch-resistant.
Polycarbonate vs. Glass: Polycarbonate is lighter and safer; glass offers a slightly clearer finish and is more scratch-resistant.
Polycarbonate vs. PVC: Polycarbonate is more durable and heat-resistant; PVC is more affordable and suited for low-impact or temporary uses.
By now, it should be clear what polycarbonate sheets are and why they’re favoured for roofing, greenhouses and other demanding applications. Whether you’re focused on durability, light transmission, or straightforward installation, polycarbonate sheeting delivers modern construction and beyond.
If you have more questions about what polycarbonate is or what polycarbonate is used for, Varico Ltd is here to guide you toward the best solution for your project.
FAQ’s
Can Polycarbonate Sheets Be Cut to Size?
Yes, polycarbonate sheets can be easily cut to size using tools such as circular saws or jigsaws. Proper techniques should be followed to prevent cracking or rough edges.
Are Polycarbonate Sheets Heat Resistant?
Yes, polycarbonate sheets have excellent thermal resistance and can withstand high temperatures without melting or deforming, making them suitable for both hot and cold environments.
How Long Do Polycarbonate Sheets Last?
With proper installation and maintenance, polycarbonate sheets can last for 10 to 20 years or more, particularly if they are treated with UV protection.
Are They Eco-Friendly?
Polycarbonate can be recycled, making it a more sustainable choice than some other plastics. However, the production process involves petrochemicals, so its overall environmental impact depends on proper disposal and recycling efforts.