Which polycarbonate is best for building a roof and shed
Considering the design of various polycarbonate sheets, you will notice that they have a different structure. Usually a sheet consists of one or more layers, which are interconnected by a kind of stiffening ribs. The difference in designs is primarily due to the variety of purposes.
Sheet polycarbonate
Sheet polycarbonate also has a second more common name - monolithic. This type of material has only one continuous layer without stiffening ribs inside. It differs primarily in the thickness of the sheet, and can also have a wide variety of colors. Most often, sheets of monolithic polycarbonate with a thickness of 6 to 12 mm are found, but for some purposes a thickness of 20 mm is used.
Cast polycarbonate canopy
This material has a high level of strength, is easily transported, assembled and disassembled if necessary. It can be used both independently and in conjunction with metal frames.
Corrugated polycarbonate
Wavy polycarbonate, like the previous type of this material, has an integral, monolithic structure, but its surface is wavy. This design is also explained, first of all, by its purpose. Such polycarbonate sheets are used for roofing work, the wavy surface allows rainwater to collect in grooves and flow into drainage systems.
Corrugated polycarbonate canopy
Using corrugated polycarbonate for roofing is a fairly simple process and does not require special skills, almost anyone can handle it.
Cellular polycarbonate
Cellular polycarbonate in its structure differs from monolithic, it consists of two layers, which are interconnected by stiffening ribs. This design is lightweight, yet robust and flexible. It is cellular or cellular polycarbonate that is most often used.
Cellular polycarbonate canopy
It is extremely easy to work with this material; in almost any case, you can cope with the simplest tools.
Which polycarbonate is best for building a roof and shed
As mentioned above, polycarbonate is actively used for the construction of a wide variety of structures; a roof or canopy is most often found among others. As a rule, before the start of construction, an approximate design plan is drawn up, also at this stage the choice of materials takes place.
Cellular polycarbonate canopy project
First of all, you should decide on the thickness of the polycarbonate sheet, this important indicator will affect not only the strength of the entire structure, but also its service life.
You should also take into account the climatic conditions and loads that will fall on the roof or shed at different times of the year.
Zoning of the territory of the Russian Federation according to the calculated value of the weight of the snow cover
Particular attention is paid to the quality of the material. Poor quality polycarbonate is not the best choice for long-term construction, it may be worth re-prioritizing and saving on something else
When choosing the type of polycarbonate, you should also take into account the purpose of the structure, and the conditions of its operation. For awnings, the use of monolithic sheets is not recommended. They are more suitable for vertical use. But cellular polycarbonate or corrugated is perfect for the construction of roofs and sheds.
Cellular polycarbonate roof
Quality issues: what to expect in a couple of years?
Initially, monolithic polycarbonate conquered the world market by the fact that it deservedly took first place in strength among all existing transparent materials. It is not for nothing that they are glazed with attics and balconies, billboards, sheathed greenhouse structures and even covered the entrance to metro stations.
But, unfortunately, the idea of using monolithic polycarbonate in private construction is often abandoned when they see cracked and muddy material, which is only 2-5 years old, at stops or balcony peaks.
In fact, low-quality Chinese polycarbonate is almost always used on street buildings and government buildings, which is much cheaper than the original one.
After all, if we talk about strength, then as an advertising step, monolithic high-strength polycarbonate was used even for an advertising installation with money, breaking which you could immediately take the entire amount for yourself. And even the most resourceful were not helped by hammers or a strong kick! So what happens then? The answer is simple: such a polycrabonate is simply destroyed under the sun, like any plastic without protection.
By all rules, such protection must be provided in the form of a thin film co-extruded onto the sheet. But some retailers prove that they have UV protection right in the bulk of the polycarbonate. What raises some doubts - is this technology too expensive?
Indeed, such a polycrabonate exists, and the volume of such a stabilizer in granules can reach up to 30%! But such material is expensive, and certainly this is not the case when you purchase budget polycarbonate for your veranda at a discount.
In fact, there is a bit of truth here: manufacturers introduce a little UV stabilizing substance into the granules of polycarbonate raw materials. It will allow you to preserve the sheets during long storage. But the concentration of this substance is quite low, and therefore it cannot be enough for full protection.
Yes, indeed, back in the 70s, they first encountered the need to protect polycarbonate from ultraviolet radiation. And then the stabilizer was added to the granules, but later almost all manufacturers abandoned this method due to the high cost and unreliability in favor of extrusion. And those copies in which they still add up to 30% protection directly to the granules are produced for special tasks, and they serve up to 25 years!
And when there is no protective layer in ordinary polycarbonate, things are bad. The rays, acting on polymers in the ultraviolet spectrum, develop reactions of destruction of macromolecules. In simple terms, the polymers themselves become brittle and degrade over time. That is why, in the process of manufacturing a monolithic sheet, a light stabilizer is applied to it with a thin layer (only 35-60 microns).
This layer is sufficient for the durability of the coating. But the thickness of this almost invisible layer is not visible to the eye. And therefore, the seller will have to believe about the number of microns.
And, if you were deceived, get ready for the fact that a sheet without UV protection can remain intact only for a year, and with protection, less than the norm - only 5 years. These are exactly the sheets that, after the first hail, are covered with small holes (they like to share their photos on social networks).
And it should be like this: for cellular polycarbonate, protection from UV rays goes only on one side, and for monolithic polycarbonate, on both. This layer is thin, only 50-80 microns, but still manages to give the sheet additional hardness:
You probably have a question here: why cover both sides of the sheet with a UV protective film? After all, the sun cannot shine from inside the terrace or gazebo in any way. It is rather curious how the manufacturer explains this: two films on both sides of the sheet are needed so that these sides do not accidentally get mixed up.
Indeed, in this case, polycarbonate will not live long at all, and then the buyer will go to make claims to the seller.Among dealers, this technique is tacitly called "fooling around".
The second reason: waste-free installation. The presence of a protective film on both sides of the sheet is necessary so that the sheet can be bent or turned over with the side that is needed in any part of a complex structure.
In addition, there are still situations when the sun really shines on the seamy side - in the case of the installation of advertising structures, fences and transparent buildings on the street. So the film on both sides completely protects the entire mass of the sheet. By the way, some brands of cellular polycarbonate also have double-sided UV protection.
Advantages and disadvantages in comparison with PVC profiles
Transparent plastic PVC corrugated board is a direct competitor of profiled polycarbonate. Especially after the appearance on the market of the biaxially structured French profiled sheet Ondex. It is with him that we will compare the properties of the Borrex polycarbonate profile. Let's start with the benefits.
Profiled Borex is a more impact-resistant material. Hail, even large, falling of small branches during a hurricane wind, hitting a tennis or soccer ball - all this will not damage the roof made of polycarbonate profile. However, the difference is not very big - even the budget series is tested for strength with a "hail" of hundreds of wooden balls with a diameter of 20 mm, which at the moment of impact reach a speed of 80 km / h.
The more important advantage of Borex is thermal stability. Its operating temperature range is from −50 ° С to +75 ° С with the possibility of long-term heating up to +100 ° С and short-term heating up to +135 ° С
PVC profiled sheet Ondex can be used at temperatures from -20 ° C to +60 ° C, while in the zone of negative temperatures the impact resistance of the material decreases very sharply, and the lower the temperature, the more fragile the PVC sheet becomes.
Finally, the main advantage of Borrex polycarbonate sheeting is its price. It costs at least 75% less than Ondex sheets of the same thickness.
Example
Take Borrex profiled polycarbonate - you can buy the thinnest 0.8 mm sheet even from an intermediary for 700-750 rubles. With dimensions of 2000 × 1050 mm, 330-360 rubles per 1 m² comes out. Ondex Ecolux price starts from 550 rubles per 1 m².
Of course, there are other advantages, but they are insignificant and depend on which sheet thickness you compare. So, as a rule, a polycarbonate profile has a slightly better indicator of sound insulation and resistance to heat transfer, but the difference is so small that it makes no sense to take it into account.
Advantages:
- more shockproof,
- costs less
- wider operating temperature range,
- less brittleness at low temperatures.
Borrex profiled polycarbonate also has many drawbacks. Let's dwell on the main ones.
Ondex sheets are stiffer. Therefore, under a static load, which occurs, for example, from a snow cap on the roof, they sag less. To compensate for the lack of rigidity, polycarbonate corrugated board is made thicker, and, therefore, heavier.
Profiled PVC Ondex has more possible colors (20 shades) and shapes (over 50 trapezoidal and wavy profiles). In practice, this means that you can choose a profile that will accurately fit the selected wall or roof grade of corrugated board.
Polycarbonate is highly electrified, which causes dust and dirt to be attracted to its surface. Plus, it's not that sleek. As a result, Ondex sheets retain their transparency longer, it is easier to clean them of dirt and need to be done less often.
Under the influence of open fire, Ondex opens like a flower, and immediately stops burning when heating is stopped. Polycarbonate melts and flows downward, igniting other materials such as wooden rafters.
Disadvantages:
- less rigidity,
- less fireproof,
- more weight,
- fewer flowers,
- radically fewer possible profiles,
- electrification,
- rougher surface.
In short, profiled Borex polycarbonate is a material for the northern regions, as well as in the case of a limited budget. Ondex sheets are a solution for southern and central regions. They are ideal for translucent inserts in corrugated roofs and walls, and are also optimal if ease of cleaning and variety of colors are more important than material cost.
Advantages of polycarbonate profiled sheet
Polycarbonate corrugated board is an impact-resistant material that is almost impossible to break. Its specific impact strength is 163 kJ / m², which is 108 times that of silicate glass. The material will not be seriously damaged by hail or hitting with a tennis ball. Roofing profiled polycarbonate can only be pierced by a massive icicle that has fallen from a great height, but this can hardly be called a typical case.
Profiled polycarbonate withstands static load no worse than shock. The squeezed "waves" make it rigid - the sheet does not deform even under a weight of 350 kg / m², if it is evenly distributed over the entire area. Thanks to this, the material can be used for roofing buildings in northern regions with a large snow load. But the slope of the slopes should be quite large so that a thick snow cap does not grow on the roof.
Polycarbonate or corrugated board: which is better?
If you do not know what material to choose for the roof: polycarbonate or metal profile, then, first of all, decide on the task. Do you want to illuminate the room with sunlight? Then choose a polycarbonate sheet. In all other cases, a steel profiled sheet is better suited - it is stronger, more durable, cheaper.
Polycarbonate corrugated board is a fireproof material. It does not spread flame, is hardly flammable, practically does not form smoke when burning. Simply put, it is extremely difficult to set it on fire, and it immediately dies out, it is worth removing the heating source.
The polycarbonate profiled sheet is transparent. It transmits up to 90% of the sun's rays - a record figure for building materials. Only glass shows itself better, but due to its fragility, its use is very limited.
Polycarbonate sheet is lightweight - from 1.17 kg / m² to 2.9 kg / m², depending on the thickness. Therefore, a gazebo or a canopy made of profiled monolithic polycarbonate does not need an expensive strip foundation. If the soil is not swampy, the foundation can be made from shallow recessed concrete posts.
Corrugated polycarbonate is protected from ultraviolet radiation by a polymer layer with a high concentration of a substance that can effectively reflect UV rays. Some manufacturers use titanium dioxide as a UV filter. Such a coating not only protects the material itself from yellowing and cloudiness, but also prevents UV radiation from penetrating into the room. Therefore, under a canopy made of profiled polycarbonate, you can enjoy sunbathing and pleasant warmth without the risk of getting burned.
Unlike PVC profiled sheeting, including Ondex, polycarbonate profiled sheeting can be used in a wide temperature range: from -50 ° C to 100 ° C. In addition, it can withstand short-term heating up to 125–135 ° С, depending on the brand.
Corrugated polycarbonate sheet, especially with a small wave height, bends well. Here are some examples of the radius to which the profiled polycarbonate can be applied, depending on the depth of the profile:
- 18 mm - 4–4.5 m and more;
- 35 mm - 13 m and more;
- 40 mm - 17 m and more.
be careful
To calculate the minimum radius, you cannot use the formula for a solid material: R = 150 h, where h - sheet thickness in millimeters. This formula gives a large error even for sheets with very small wave heights. Due to the corrugation, the minimum radius depends much more on the depth of the profile than on the thickness of the plastic.
Polycarbonate profiled sheet is resistant to acids, fats and salt solutions.It can be used to make roofs and walls of buildings in the immediate vicinity of salt water bodies and chemical plants. And to remove stubborn dirt and writing, you can use isopropyl alcohol without risk of damaging the material.
Finally, the profiles of the polycarbonate profiled sheet coincide with the shape of the popular brands of corrugated board and euro slate. In particular, many companies produce polycarbonate profiled sheet MP 20x1100 - some brands call a similar profile Greca or Greca 76. This allows you to lay C20 corrugated board together with transparent plastic without any difficulties.
Advantages:
- shock resistance,
- rigidity,
- withstands a lot of weight,
- Fire safety,
- ease,
- transparency,
- UV protection,
- flexibility,
- chemical resistance,
- temperature resistance,
- profile compatibility with corrugated board and euro slate.
Major Brands of Corrugated Polycarbonate
Basically in Russia, polycarbonate corrugated board of four brands is sold: Russian Borrex and Plastilux, Israeli Palram SUNTUF and Plazit Polygal CURROGAL (GRECA). There are also British polycarbonate sheets Marlon and products of Chinese manufacturers, but rarely.
Polycarbonate profiled sheet Borrex is produced by the Yug-Oil-Plast company with the main plant in Karachay-Cherkessia. Sheets are made from German or Japanese raw materials on Italian lines, so the material is of relatively high quality. But the price of Borrex polycarbonate profiled sheet is the lowest, except for the products of Chinese brands: 400 rubles per 1 m² with a thickness of 0.8 mm. However, such savings will have to pay with versatility - Borrex sheets can only have two profile shapes: wave and trapezoid, both 13 mm high.
Borrex profiled polycarbonate
Details about the material: technical characteristics, comparison with PVC corrugated board, table of permissible loads, possible colors and prices. Read, compare, choose.
Company Plastilux produces profiled polycarbonate under four trademarks at once: ROYALPLAST, POLYNEX, SUNNEX and GREENHOUSE-nano. These grades belong to different segments - from premium to ultra-budget - and differ in sheet thickness, density and thickness of the UV protective layer, as well as expected service life. At the same time, the shape of the profile is the same for all sheets - the company produces only profiled polycarbonate MP-20. Unlike Borrex, Russian raw materials are used for sheet extrusion, and the material costs about the same - from 415 rubles per 1 m².
Palram SUNTUF - Israeli-made corrugated polycarbonate. Strong, durable material with a 10-year guarantee against haze, yellowing and damage to the sheet, subject to the rules of installation and operation. There are five types of this material, including UV protection sheets on both sides and a specialized type for greenhouses with anti-condensation coating. Unlike Russian polycarbonate corrugated board, Palram SUNTUF has more than 20 possible profile shapes, including Greca 76 and MP-20, but it also costs almost twice as much - from 765 rubles per 1 m².
Profiled polycarbonate SUNTUF Palram
Find out all the most important about the material before making a purchase decision: types, colors, profile drawings, characteristics and price comparisons. Polycarbonate corrugated sheet Plazit Polygal CURROGAL (GRECA) is very similar in characteristics to SUNTUF
This is due to the general conditions for both companies: they were founded at about the same time in Israel, and their products had to meet the same requirements. But these are, nevertheless, different materials. Polygal profiled sheet has fewer varieties, only one profile shape, but more color palette. In addition, in addition to the UV filter, you can choose to apply one of several selective coatings that allow only the desired spectrum of sunlight to pass through. Material costs from 640 rubles per 1 m², taking an intermediate place between SUNTUF and Russian brands
Polycarbonate corrugated sheet Plazit Polygal CURROGAL (GRECA) characteristics are very similar to SUNTUF. This is due to the general conditions for both companies: they were founded at about the same time in Israel, and their products had to meet the same requirements. But these are, nevertheless, different materials.Polygal profiled sheet has fewer varieties, only one profile shape, but more color palette. In addition, in addition to the UV filter, you can choose to apply one of several selective coatings that allow only the desired spectrum of sunlight to pass through. Material costs from 640 rubles per 1 m², taking an intermediate place between SUNTUF and Russian brands.
Monolithic polycrabonate in modern construction
The most in demand today is monolithic polycarbonate for glazing and as a roof covering. The thickness of the sheet itself can be very different, which will directly affect their strength.
So, for domestic manufacturers, it varies from 2 to 12 mm, and from 1 to 20 mm for European ones. And, depending on the thickness and strength of the panels, they are allowed to be used in one area or another:
Especially beautiful made of monolithic polycarbonate verandas and summer cafes are obtained. Indeed, in the end, the extension remains as transparent and light as with glass (at first glance it is even difficult to distinguish it), but at the same time it is much more shock-resistant.
The same ball of children playing in the yard is able to crush the most beautiful structures. Moreover, it is unsafe for tea-makers on the veranda!
So why not put this durable material instead of glass, and also play with color (bronze or simply darkened perfectly harmonizes with wooden or log walls). At the same time, it is not necessary to darken the entire roof and walls - it is enough to close only the part that faces south from the sun:
It will be interesting for you to know that monolithic polycarbonate appeared already in the middle of the twentieth century, and was patented by a German physicist. And today the global production of polycarbonate exceeds 100 thousand tons, which is impressive!
This material has unique characteristics: transparency like glass, lightness and almost extreme impact resistance. At the same time, monolithic polycarbonate is 10 times stronger than plexiglass and 180 times stronger than usual. Thanks to these properties, such polycarbonate is successfully used today in the construction of anti-vandal structures.
Of course, due to the absence of internal honeycomb, the heat preservation ability of monolithic polycarbonate is much worse than that of cellular polycarbonate. But the radius of deflection is larger, which makes it possible to make beautiful structures from it:
Advantages and disadvantages of "plastic glass"
Let's list the main points of difference between monolithic polycarbonate from cell and otherssimilar materials:
- Transparency. Monolithic polycarbonate, unlike cellular, looks richer. And, at the same time, it loses in this aspect: the honeycomb allows you to gently scatter the light, and the monolithic sheet transmits all direct sunlight (therefore, it is not very suitable for building a greenhouse, since the plants get burned).
- Noise isolation. Polycarbonate is also renowned for its high sound absorption properties. You often see it as a fencing of residential buildings from a noisy highway, airport and industries.
- Fire safety. Another nice bonus: hard-flammable monolithic polycarbonate, moreover, from the group of self-extinguishing polymers.
- Durability. Monolith stands (as builders often call it for convenience) and to chemical compounds. It can withstand temperatures from -40 to + 120C.
- Stability. Even in extreme conditions, monolithic polycarbonate does not change its structure and does not deform, and therefore shows its best side both in hot and frosty climates. Although usually building materials behave very differently in different conditions.
- Anti-vandal properties. Monolithic polycarbonate is so strong that it is even used for shockproof windshields and personal protective equipment.
- Environmental friendliness. And finally, products made of monolithic polycarbonate are not only durable, but also recyclable if necessary. And this is a plus for everyone who is not indifferent to the future of our planet.
Here is a more detailed video review of the qualities of this material:
Although we immediately note that the issue of absolute transparency of monolithic polycarbonate is quite controversial. Unfortunately, after a few seasons, small scratches will still appear on it.
When this happens with a cell phone, it is not so noticeable. It mainly depends on how you looked after the material itself. If it is wrong to clean off the snow from such a roof, then the coating is scratched. As a result, the appearance of such polycarbonate from a neighbor can discourage the desire to acquire it for yourself, and this is wrong:
Cutting and forming polycarbonate panels at home
Let's start with the fact that monolithic polycarbonate is produced with the parameters of 3.05x2.05 m. If the overhang of the roof is chosen unsuccessfully, then you will have to either make a transverse joint, or order the required size from the factory through dealers. Of course, no one willingly undertakes to make a pair of such sheets. Then you have to cope on your own.
Although we advise you to initially order a whole sheet, and not glue or solder two separate ones. After all, such a roof will have a transverse joint problem, which cannot be solved except with an overlap.
By the way, factories always produce only solid sheets, without welding or gluing. Indeed, in a production environment, it is too difficult to maintain the accuracy of such complex technological processes.
Plus thermal deformation of the sheet then destroys any seam. Therefore, monolithic polycarbonate is welded and glued only in industrial conditions, but not for construction, but for completely different purposes. The standard width of polycarbonate sheets is 2050mm and the length is 3050mm. As a special order, the length of the sheet in the factory is increased to 12 meters, but no more.
Tinkering with sheets of monolithic is a pleasure! And for the manufacture of unusual stylish shapes, this material lends itself well to molding. With a milling machine, you can make beautiful curved shapes for a wide variety of tasks. For this, cutters for metal with a large clearance angle and an acute cutting angle are used.
The milling cutter must be one-blade high-speed steel:
A hand-held electric milling cutter is especially convenient in this regard. In this case, the material is simply fixed on the desktop. A guide rail is used to cut a straight piece of sheet, and a prefabricated plywood template is used to walk along the outline. It is enough to put it on a sheet and circle it with a milling cutter. At the same time, put a roller on the cutter, which will work with the workpiece without deforming it.
Use clamps to securely hold sheets for drilling or cutting. Just between the sheet itself and the clamp, place felt or polymer spacers to protect the material. Use gloves and goggles while working. Polycarbonate, of course, is not glass, but it can still form fragments.
In the process, constantly brush away the shavings, which can scratch the sheet. Do not use high speed steel cutting tools - the edges may be melted. You can also cut off the desired piece of a monolithic sheet using an ordinary clerical knife and metal scissors:
Cutting monolithic polycarbonate is also allowed with a jigsaw, a circular saw and a grinder with a diamond disc. Fortunately, monolithic polycarbonate does not require end profiles or tapes, as does honeycomb, or problems with dirt inside the honeycomb.
Scope of corrugated polycarbonate
The PC has found application in various fields. It is used both for the construction of an entire object and for an insert alternative to conventional glazing.
- Roof. You can lay a roof from PC over the adjoining terrace, gazebo in the garden; various types of canopies (over the porch or balcony) and awnings are made from it. Also, inserts into a regular roof in the form of light windows can be made from PC;
- Construction of agricultural buildings.Wavy polycarbonate is widely used in agriculture. Sheds, woodsheds, premises for keeping birds and livestock are built from it. Separately, it should be said about greenhouses, for the construction of which this type of thermoplastic is an ideal material due to its light transmission, as well as thermal insulation and anti-condensation properties. Greenhouses made of profiled polycarbonate are characterized by increased productivity;
- Commercial construction. PK is used for the construction of summer cafes and outdoor sheds;
- Buildings on a private territory. Pergolas, terraces and verandas are built from PC.