The Ultimate Guide to Polycarbonate Sheets

Polycarbonate is a widely used material that can probably be found in many of the everyday objects and buildings you see. If you're planning your next DIY project, looking to roof your shed or working with materials in a professional setting, polycarbonate is a great choice to consider.

In this article we will explore the different types of polycarbonate, its impressive qualities and many benefits.

What is Polycarbonate?

So, what is polycarbonate? Polycarbonate (PC) is a material you may not have heard of before, but it is one of the most popular engineering plastics globally. It is a strong, lightweight and transparent thermoplastic that is used in various industries. With an impact strength 250 times greater than glass, polycarbonate is also heat-resistant and maintains its shape well.

While it is known for its high impact resistance, it is actually very easy to mould. Which is why its versatility and durability make it preferred over materials like acrylic and glass.

Polycarbonate was first discovered around 1900 by Alfred Einhorn, a German chemist and became commercially available in the 1950s. Initially, it had a brown tint, but by 1970 it was made crystal clear. This made it suitable for countless applications.

How is Polycarbonate Made?

Polycarbonate is made through a chemical reaction of bis-phenol A (BPA) and carbonyl chloride (phosgene). Here is the process in simple steps:

First, BPA is produced in acidic conditions by the condensation of phenol with acetone.
This BPA is then reacted with carbonyl chloride in an interfacial polymerisation process to create long chains of polycarbonate molecules.
This product can then be manufactured into sheets or other forms through extrusion or moulding.
At this stage, additives may be used to introduce properties such as UV resistance and impact strength.
After processing is complete, the polycarbonate sheets are cooled, cut to size and can be further shaped or finished as needed.

This manufacturing process is how polycarbonate is made. The beauty of polycarbonate lies in its versatility. It can be produced in various colours and thicknesses depending on its intended function.

Types of Polycarbonate:

Generally speaking there are two main types of polycarbonate sheets:

Multiwall Polycarbonate:

Is the most common type, often used in roofing for conservatories and lean-tos.
It has excellent thermal and sound insulation, making it energy efficient.
Its lightweight structure makes it easy to handle and install.
Comes with built-in UV protection to prevent damage from sunlight.

Solid Polycarbonate:

Allows up to 90% light transmission, making it ideal for applications where clarity is important.
Despite being lightweight, it offers incredible strength and is significantly more durable than glass.
It also provides excellent impact resistance, making it suitable to use for safety glazing and windows.

Polycarbonate Uses

As of today, polycarbonate is used in numerous industries and in many everyday products.

Glazing and roofing: Because of its strength and its ability to have UV protection, polycarbonate sheets are a great option for glazing and roofing. It is a popular alternative to glass for roofing, glazing and sound walls. It can diffuse light, resist impact and control temperature. Perfect for canopies, greenhouses, sheds and conservatories.

Safety Equipment: Polycarbonate is an essential for safety applications, such as bulletproof glass, safety helmets and face shields. Its impact resistance and durability also make it ideal for protective gear and security installations.

Technology: Polycarbonate is commonly used in the production of CDs, DVDs, mobile phones and other electronic devices.

What are the Benefits of Polycarbonate?

Polycarbonate benefits include:

Transparency

Because of its transparency polycarbonate has a ‘glass look’, which provides excellent light transmission.

Impact Resistance

It has a high impact resistance and is virtually unbreakable. This is why polycarbonate is used in safety applications.

Heat Resistance

Polycarbonate can withstand high temperatures without melting or changing shape. This is suitable for items exposed to raised temperatures, like microwave-safe cookware.

Lightweight

A great benefit of polycarbonate is that it is significantly lighter than standard glass. Which is useful in industries like aerospace and automotive to reduce excess weight.

UV Resistance

This material offers good resistance to ultraviolet (UV) radiation. Making it ideal for greenhouse panels and protective covers for outdoor equipment.

For more details on the benefits of polycarbonate, check out our article on The Advantages of Multiwall Polycarbonate Sheets.

Is Polycarbonate Recyclable?

So, is polycarbonate recyclable? Yes, that’s another great thing about polycarbonate is that it is fully recyclable, so it is a sustainable option.

The recycling process begins by sorting the material and then shredding it into small pieces. After shredding, the pieces are washed and granulated, making it ready for manufacturers to use again.

Polycarbonate is known for its long life and strength, which helps recycling facilities get good results.

How to Clean Polycarbonate?

Believe it or not but there is a correct way to clean polycarbonate sheets. Despite their low maintenance they do need to be cleaned from time to time. Especially if you use polycarbonate sheets for roofing, they can become dirty. Some cleaning tips include:

There is no need to use any harsh chemicals to clean your polycarbonate sheets, simply use a mild soap and lukewarm water with a cloth.
Avoid using brushes or anything that could scratch the surface. A microfibre cloth is all you need.
When it comes to cleaning roofing, refrain from using a power wash due to its high pressure. You can rinse them with a garden hose instead.

Polycarbonate Cost

Polycarbonate is a relatively affordable material and is a cheaper alternative to glass.The cost of polycarbonate sheets can vary based on a number of factors. This depends on the type of polycarbonate you are after, the amount and the thickness. Standard thicknesses usually range from 2mm and prices will increase with thickness.

Polycarbonate at Sheet Plastics

At Sheet Plastics we offer a wide range of polycarbonate sheets that can be cut to size. If you are looking for roofing or glazing, you can trust our strong and lightweight sheets to deliver exceptional results.

We stock premium multiwall and structured polycarbonate sheets that are durable and long-lasting. With options that cater to your needs, including UV protection and impact resistance. Choose polycarbonate as a practical alternative to glass and other materials.

Our sheets start at just 6p depending on your requirements. Our standard size starts from 50 mm x 50 mm in width with thicknesses from 2 mm to 12 mm.

Browse our selection of polycarbonate sheets and don't hesitate to contact us if you have any questions.