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Introduction

Polycarbonate (PC) sheet, also known as polycarbonate board, lexan sheet, or PC panel, is a high-performance amorphous thermoplastic material manufactured by extrusion or compression molding of polycarbonate resin. It is widely recognized as “transparent plastic king” and “unbreakable glass” due to its unique combination of ultra-high impact resistance, high light transmission, lightweight, excellent weatherability, flame retardancy, sound insulation, and easy processability.

In modern architecture, construction, agriculture, advertising, transportation, machinery, and aerospace industries, polycarbonate sheets have gradually replaced traditional glass, acrylic, PVC, and other materials, becoming the preferred choice for safety glazing, daylighting roofing, noise barriers, greenhouse panels, machine guards, and protective enclosures.

This comprehensive guide will systematically elaborate on all core properties of polycarbonate sheets (physical, mechanical, optical, thermal, chemical, electrical, weathering, safety), compare differences between solid PC sheets, multi-wall hollow PC sheets, corrugated PC sheets, and colored PC sheets, analyze advantages & limitations, summarize typical applications, provide installation & maintenance guidelines, and answer frequently asked questions. At the end, we will also introduce our one-stop polycarbonate sheet customization & processing service to support your project from prototype to mass production.

1. Basic Overview of Polycarbonate Sheet

1.1 What Is Polycarbonate Sheet?

Polycarbonate sheet is a rigid, transparent or semi-transparent thermoplastic plate made of bisphenol A polycarbonate resin (PC resin) through high-temperature extrusion, calendering, or pressing. Its molecular structure contains carbonate groups, endowing it with high toughness, high temperature resistance, and excellent dimensional stability.

Common commercial names:

• Solid PC sheet / Solid Polycarbonate Sheet
• Multi-wall hollow PC sheet / Multi-wall Polycarbonate Sheet
• Corrugated PC sheet / Corrugated Polycarbonate Sheet
• UV-protected PC sheet / UV-Coated Polycarbonate Sheet

1.2 Main Types & Structural Characteristics

1.2.1 Solid Polycarbonate Sheet (Solid PC Sheet)

• Structure: Single-layer solid plate, homogeneous interior
• Thickness: 1.5 mm–20 mm
• Features: Highest impact resistance, best optical clarity, smooth surface, high rigidity
• Typical uses: Safety glazing, machine guards, explosion-proof shields, display windows, protective covers

1.2.2 Multi-wall Hollow Polycarbonate Sheet (Multi-wall PC Sheet)

• Structure: 2–7 layers of parallel walls connected by vertical ribs, forming hollow air chambers
• Thickness: 4 mm–35 mm (2W, 3W, 4W, 5W structures)
• Features: Lightweight, excellent thermal insulation, good sound insulation, flexible bending
• Typical uses: Greenhouse roofing, skylights, carports, canopies, walkway covers, building facades

1.2.3 Corrugated Polycarbonate Sheet (Corrugated PC Sheet)

• Structure: Continuous wavy or trapezoidal corrugation
• Thickness: 0.8 mm–3 mm
• Features: High structural strength, good drainage, easy installation on slopes
• Typical uses: Industrial roofing, agricultural sheds, temporary buildings, wall cladding

1.2.4 Colored & Special-Function PC Sheets

• Colors: Clear, transparent blue, green, bronze, gray, white, opal, black, custom colors
• Special functions: UV-coated, anti-static, fire-retardant, anti-fog, scratch-resistant, sound-absorbing

2. Core Physical Properties of Polycarbonate Sheet

2.1 Density & Weight (Lightweight Advantage)

• Density: 1.20–1.22 g/cm³
• Weight vs. glass: ~50% of glass weight (same thickness)
• Weight vs. acrylic: ~10% heavier than PMMA but 30× higher impact strength
• Practical benefit: Reduces structural load, saves support materials, lowers transportation & installation costs

2.2 Optical Properties (High Transparency & UV Protection)

2.2.1 Light Transmission

• Clear solid PC sheet: 88–92% light transmission (similar to float glass 90–92%)
• Clear multi-wall PC sheet: 75–85% (depends on layers & thickness)
• Colored PC sheet: 10–70% (adjustable by color & pigment concentration)

2.2.2 UV Resistance

• Raw PC resin: Blocks ~50% UV (280–380 nm)
• Double-sided UV-coated PC sheet: Blocks 99.9% harmful UV rays
• Anti-yellowing performance: Maintains clarity for 10–20 years outdoors (no UV coating: yellowing & brittleness in 1–2 years)

2.2.3 Light Diffusion & Glare Reduction

• Opal/white PC sheet: Uniform light diffusion, no harsh glare
• Suitable for: Skylights, office lighting, greenhouse crop protection, advertising light boxes

2.3 Thermal Properties (Wide Temperature Tolerance & Insulation)

2.3.1 Operating Temperature Range

• Continuous service temperature: -45°C to +135°C
• Short-term peak temperature: Up to 150°C
• Glass transition temperature (Tg): 147°C
• Low-temperature resistance: No embrittlement at -40°C (better than PVC/PE)

2.3.2 Thermal Insulation (Energy Saving)

• Thermal conductivity (λ): 0.20–0.22 W/m·K (much lower than glass 0.96 W/m·K)
• Multi-wall hollow structure: Air chambers enhance insulation by 30–50%
• Energy saving effect: Reduces summer heat gain & winter heat loss, lowers HVAC costs

2.3.3 Coefficient of Thermal Expansion (CTE)

• CTE: 65–70 × 10⁻⁶ /°C
• Important: Must reserve expansion gaps during installation (3 mm per meter length)

2.4 Mechanical Properties (Ultra-High Impact Strength & Toughness)

2.4.1 Impact Resistance (Most Outstanding Property)

• Impact strength: 250–300× higher than ordinary glass, 2–20× higher than tempered glass, 30× higher than acrylic (PMMA)
• Izod impact strength: 600–850 J/m (notch: 20–35 kJ/m²)
• Anti-hail & anti-storm: Withstands 25 mm hail at 100 km/h, strong winds up to 120 km/h
• Safety: Virtually unbreakable; even if cracked, no sharp shards (reduces injury risk)

2.4.2 Tensile & Flexural Strength

• Tensile strength: 55–75 MPa
• Tensile modulus: 2.0–2.4 GPa
• Elongation at break: 80–150% (high ductility, not brittle)
• Flexural strength: 90–110 MPa
• Compressive strength: >80 MPa

2.4.3 Hardness & Wear Resistance

• Rockwell hardness: M70
• Surface hardness: Lower than glass; prone to scratching without anti-scratch coating
• Anti-scratch coating: Improves hardness to 3–4H, extends service life

2.5 Chemical Resistance

• Resistant to: Weak acids, neutral oils, alcohols, aliphatic hydrocarbons, water, ozone
• Not resistant to: Strong acids, strong alkalis, aromatic hydrocarbons (benzene, toluene), ketones (acetone), esters, halogenated solvents
• Outdoor stability: Resists rain, dew, and atmospheric corrosion; no rust (unlike metal)

2.6 Electrical Properties (Insulation & Dielectric Strength)

• Volume resistivity: 10¹⁶–10¹⁷ Ω·cm
• Dielectric strength: 20–25 kV/mm
• Excellent insulator: Suitable for electrical enclosures, switch panels, insulation covers

2.7 Sound Insulation Performance

• Sound insulation: 30–35 dB (4 mm solid sheet; better than same-thickness glass)
• Multi-wall hollow sheet: 35–40 dB (air chambers absorb mid-high frequency noise)
• Application: Highway noise barriers, factory partitions, stadium roofs, residential soundproof windows

2.8 Flame Retardancy & Fire Safety

• Flame retardant grade: UL94 V-2 (standard), V-0 (high-grade)
• Limiting oxygen index (LOI): 25–29%
• Combustion characteristics: Self-extinguishing, no dripping, low smoke emission
• Compliance: Meets B1 (GB 8624), Class 1 (EU), FM 4910 standards

3. Key Advantages of Polycarbonate Sheet

1. Unbreakable Safety: 250× stronger than glass; no sharp fragments
2. High Light Transmission: 88–92% clarity, UV-blocking 99.9%
3. Lightweight & Cost-Effective: 50% lighter than glass, reduces structural costs
4. Extreme Weather Resistance: -45°C to +135°C, anti-hail, anti-wind, anti-aging
5. Energy-Saving Insulation: Low thermal conductivity, hollow structure saves energy
6. Excellent Soundproofing: 30–40 dB noise reduction
7. Easy Processing & Installation: Cold bendable, cuttable, drillable, customizable
8. Long Service Life: 10–20 years outdoors (UV-coated)
9. Eco-Friendly: 100% recyclable, non-toxic, no harmful emissions
10. Diverse Customization: Size, thickness, color, function, printing available

4. Limitations & Solutions of Polycarbonate Sheet

4.1 Surface Scratching

• Limitation: Lower surface hardness than glass; easy to scratch by sand or hard objects
• Çözüm: Anti-scratch coating (3–4H), protective film during construction, soft cloth cleaning

4.2 Thermal Expansion & Contraction

• Limitation: Large CTE; may warp or crack if no expansion gap
• Solution: Reserve 3 mm/m expansion gap, use flexible EPDM gaskets, avoid over-tightening screws

4.3 Chemical Sensitivity

• Limitation: Attacked by strong acids, alkalis, and organic solvents
• Solution: Avoid contact with acetone, benzene, ammonia; clean with neutral detergent

4.4 Higher Cost Than PVC/PE

• Limitation: Raw material cost higher than PVC/PE
• Solution: Longer service life (2–3× PVC), lower maintenance cost, overall cost-effective

5. Polycarbonate Sheet vs. Other Materials (Comparison Table)

Mülkiyet	Polikarbonat	Cam	Akrilik (PMMA)	PVC
Impact Strength	★★★★★ (250× glass)	★☆☆☆☆	★★☆☆☆ (30× lower)	★★☆☆☆
Işık İletimi	88–92%	90–92%	91–93%	70–85%
Weight (vs. glass)	50%	100%	45%	40%
Hava Koşullarına Dayanıklılık	★★★★★ (10–20y)	★★★★★	★★★☆☆ (3–5y)	★★☆☆☆ (2–3y)
Isı Yalıtımı	★★★★☆	★☆☆☆☆	★★★☆☆	★★★★☆
Flame Retardancy	V-0/V-2	Incombustible	V-2	V-0 (additive)
Processability	★★★★★	★☆☆☆☆	★★★★☆	★★★★☆
Maliyet	Orta-Yüksek	Medium	Medium	Düşük

 

6. Typical Applications of Polycarbonate Sheet

6.1 Construction & Architecture

• Skylights & roof glazing
• Carports, canopies, walkway covers
• Building facades & curtain walls
• Balcony enclosures & sunrooms
• Noise barriers (highway, railway, factory)
• Safety glazing (schools, hospitals, stadiums)

6.2 Agriculture & Greenhouse

• Greenhouse roofing & side panels
• Livestock shed lighting
• Aquaculture covers
• Plant nursery shading

6.3 Advertising & Decoration

• Light boxes & signboards
• Display stands & showcases
• Interior partitions & ceiling panels
• Decorative wall cladding

6.4 Industrial & Machinery

• Machine guards & safety shields
• Explosion-proof covers & observation windows
• Electrical enclosures & insulation panels
• Conveyor belt covers

6.5 Transportation

• Bus/train windows & partitions
• Boat/windshield panels
• Cargo container lighting covers

6.6 Security & Protection

• Anti-riot shields & bulletproof panels (special grade)
• Bank/shop security windows
• Prison isolation panels

7. Specifications & Customization Options

7.1 Standard Sizes

• Width: 1220 mm, 1560 mm, 1820 mm, 2100 mm (max 2500 mm)
• Length: 2440 mm, 3000 mm, 6000 mm (custom length up to 30 m)
• Kalınlık:
  • Solid: 1.5, 2, 3, 4, 5, 6, 8, 10, 12, 15, 20 mm
  • Multi-wall: 4, 6, 8, 10, 12, 16, 20, 25, 32, 35 mm

7.2 Customization

• Boyut: Cut-to-size, irregular shapes, CNC routing
• Renk: Clear, blue, green, bronze, gray, white, black, custom Pantone
• Function: UV coating, anti-scratch, anti-fog, anti-static, flame retardant, sound-absorbing
• Baskı: Silk screen printing, UV digital printing, logo/brand customization
• Processing: Bending, drilling, tapping, bonding, polishing

8. Installation & Maintenance Guidelines

8.1 Storage & Handling

• Store indoors, flat on pallets, ≥10 cm off ground
• Avoid direct sunlight, rain, and heavy stacking (≤1 m height)
• Wear gloves when handling to prevent fingerprints/stains

8.2 Cutting & Drilling

• Cutting: Circular saw with carbide-tipped blade (fine teeth), jigsaw, laser cutter
• Drilling: Twist drill (HSS), hole diameter 1–2 mm larger than screw (for expansion)
• Edge distance: ≥5 cm from sheet edge

8.3 Installation Steps

1. Prepare supporting frame (aluminum, steel, wood)
2. Reserve expansion gap: 3 mm per meter length
3. Kullanım EPDM rubber gaskets (≥5 mm thickness) between sheet and frame
4. Fasten with PC-specific self-tapping screws + neoprene washers
5. Screw spacing: 35–50 cm, avoid over-tightening
6. Seal edges with neutral silicone sealant (avoid acidic sealant)

8.4 Daily Maintenance

• ile temizleyin neutral detergent + soft cloth/sponge, rinse with water
• Avoid abrasive cleaners, steel wool, or high-pressure washing
• Remove scratches: Polish with fine polishing compound
• Inspect fasteners & seals annually, replace damaged parts

9. Our Polycarbonate Sheet Customization & Processing Service

Biz bir professional polycarbonate sheet manufacturer & processor with 15+ years of experience, providing one-stop solutions from raw material to finished product for global clients.

9.1 Our Core Products

✅ Solid PC sheets (1.5–20 mm)

✅ Multi-wall hollow PC sheets (4–35 mm, 2–7 layers)

✅ Corrugated PC sheets (0.8–3 mm)

✅ UV-protected, anti-scratch, flame-retardant PC sheets

✅ Custom colored & printed PC sheets

9.2 Custom Processing Services

✅ CNC cutting, routing, drilling, tapping

✅ Cold bending, hot bending, thermoforming

✅ Silk screen printing, UV digital printing, logo engraving

✅ Edge polishing, bonding, assembly

✅ OEM/ODM service (custom size, color, function, packaging)

9.3 Why Choose Us?

• Factory Direct: ISO 9001 certified, strict quality control, competitive price
• High Quality: 100% virgin PC resin, double-sided UV coating, 15–20 year warranty
• Full Customization: Any size, thickness, color, function, processing available
• Global Delivery: Fast shipping, safe packaging, door-to-door service
• Professional Support: 24/7 technical consultation, free samples, CAD design assistance

9.4 Our Commitment

We are committed to providing high-quality polycarbonate sheets & reliable processing services to help you complete projects with safety, durability, and cost-effectiveness. Whether you need small prototype samples or large-scale mass production, we will tailor the best solution for you.

10. Frequently Asked Questions (FAQs)

Q1: How long does polycarbonate sheet last outdoors?

A: 10–20 years with double-sided UV coating; 1–2 years without UV coating (yellowing/brittleness).

Q2: Can polycarbonate sheet be bent?

A: Yes. Cold bend for thin sheets (≤6 mm, bend radius ≥200 mm); hot bend for thick sheets (≥8 mm, 120–140°C).

Q3: Is polycarbonate sheet safe for food contact?

A: Food-grade PC sheets comply with FDA 21 CFR 177.1580, safe for food containers & kitchenware.

Q4: How to clean polycarbonate sheet without scratching?

A: Use neutral detergent + soft cloth/sponge, rinse with water; avoid abrasives & high pressure.

Q5: Can polycarbonate sheet be recycled?

A: Yes, 100% recyclable. Waste PC sheets can be reprocessed into new products.

Sonuç

Polycarbonate sheet is a versatile, high-performance engineering plastic with outstanding impact resistance, light transmission, weatherability, insulation, and processability. It has become an irreplaceable material in construction, agriculture, industry, advertising, and security fields.

By understanding its core properties, advantages, limitations, and application scenarios, you can select the most suitable polycarbonate sheet type and specification for your project. Our professional customization & processing service will provide you with high-quality products and reliable technical support to ensure your project’s success.

If you have any questions or need a free quote & sample, please get in touch with us today!