Polycarbonates (PC): characteristics, production methods, processing technology, applications. Cellular Polycarbonate Polycarbonate Material Description

Cellular, or otherwise - structured or cellular polycarbonate got its name because of the special internal structure: its structure can be two, three or four-layer, filled with a certain number of stiffening ribs forming triangles, cruciform or square joints. Examining a leaf in a section, you can see its resemblance to a honeycomb. Due to this structure, the material has excellent strength characteristics and a high coefficient of flexibility, and the air enclosed in the honeycomb provides its heat-saving properties.

Cellular polycarbonate - how it is made

For the manufacture of honeycomb material, polycarbonate is used - a granular colorless plastic mass, characterized by lightness, frost resistance, dielectric properties, and durability. The unique structure of polycarbonate macromolecules is the main reason for its unique properties.

The thermoplasticity of the material allows it to recover during the solidification process after each melting process, i.e. the material can be recycled many times, which is very important from the point of view of environmental friendliness.

The production of the material is carried out by extrusion, i.e. forcing the melted liquid viscous substance through the forming tool. The result is a web having a predetermined cross-sectional shape.

Properties and advantages of honeycomb material

You can immediately notice that polycarbonate compares favorably with any transparent building material - none of them has the same positive qualities in full.

Cellular polycarbonate is different:

Low coefficient of thermal conductivity, providing higher heat-saving qualities of the material than glass, which allows almost half to reduce energy consumption for heating or cooling premises.
The multilayer structure of the material provides good sound absorption, and, accordingly, good sound insulation properties.
The material scatters light rays well, its transparency is 86%, when light passes through it does not cast a shadow.
The material can be used at temperatures from -40 C to +120 C, i.e. it can be used in almost any natural zone, the quality characteristics of the material to a very insignificant extent depend on changes in the environment. It is not susceptible to chemicals.
Polycarbonate is lightweight, about 16 times less than window glass and 6 times less than acrylic sheet of the same thickness, the use of the material allows you to get savings by designing a less powerful foundation and reducing the cost of building support structures. Installation work can be performed without the use of special construction equipment.
The material has a high viscosity, ensuring its impact resistance (200 times higher than that of sheet glass), it is resistant to bending and breaking loads. If damaged by a very strong impact, sharp fragments will not form. The polycarbonate sheeting can withstand the loads of accumulated snow and does not rip from the gusts of wind like plastic sheeting, making it ideal for greenhouse coverings. Good flexibility of the material allows it to be used for the installation of roof structures with complex geometries, including arched and vaulted ones.
Polycarbonate is distinguished by its reluctance to ignite, it does not burn, but under the influence of an open fire it melts to form a cobweb-like fiber, while toxic substances are not released.
The constancy of the technical characteristics of the material is ensured by the protective layer applied to the front side of the sheets, which blocks the ultraviolet part of the solar spectrum.

Cellular polycarbonate - sheet dimensions and field of application depending on thickness

Cellular polycarbonate is produced in a wide range of colors, its basic colors:

warm - red, brown, bronze, orange, yellow, milky,
cold - white, blue, turquoise, green,
you can also find transparent panels.

If we talk about the size of the sheets, then it should be stipulated that polycarbonate is produced in several versions:

monolithic, from 2 to 12 mm thick, with standard sheet dimensions 2.05x3.05 m,
cellular, with a thickness of 4 to 32 mm, with sheet dimensions 2.1x6 m or 2.1 12 m,
profiled, 1.2 mm thick, sheet size 1.26x2.24 m, profile height up to 5 cm.

Depending on the thickness of the sheets, cellular polycarbonate can be used in different ways, it is recommended to use it in the construction:

4 mm - awnings and greenhouses, showcases, exhibition stands,
6 mm - awnings, greenhouses, canopies,
8 mm - greenhouses, roofs, awnings, partitions,
10 mm - continuous glazing of horizontal and vertical surfaces, production of noise barriers, awnings,
16 mm - roofs over large structures,
32 mm - for roofs with increased load requirements.

Based on such a wide range of products, before starting construction, it will be necessary to study the properties and decide which polycarbonate is rational to use in each specific structure.

Basic principles of working with polycarbonate

Since the sheets of material have rather large dimensions during construction, it will be necessary to give them the required dimensions, i.e. cut. There are no special problems with cutting polycarbonate, if the sheet thickness is from 0.4 to 10 mm, then you can use a construction retractable sharp knife. It is not recommended to remove the protective film from the surface - it will provide protection against scratches.

The incision should be made carefully to ensure a precise, straight line. Use a high speed saw to cut thicker material. The teeth of such a saw should be made of reinforced alloys, small, undiluted. You can also use a jigsaw.

During operation, the sheet should be supported in order to exclude its vibration. Chips that will get inside the sheet during cutting must be removed at the end of the work.

To fix the polycarbonate, you will need to drill holes in the sheets. For this, sharp steel drills are used. It is required to mark the place for drilling so that it is located between the internal stiffeners. The distance from the hole to the edge should be about 10 mm.

It is possible to bend cellular polycarbonate only along the lines of the channels, along the length of the sheet. The bending radius can be 175 times the sheet thickness.

Since there are voids inside the sheets, special attention should be paid to the processing of their end part. If the sheets are to be mounted in a vertical or inclined position, then the closing of the ends in the upper part should be done with a self-adhesive aluminum strip, and in the lower part - with a perforated one, which can protect the material from the penetration of dirt inside, but allowing condensation to drain off.

When using polycarbonate in the construction of an arched structure, it will be necessary to close its ends with a perforated film. Materials for sealing should be selected in a shade corresponding to the colors of the panels.

The highest quality aluminum sealants are considered, they are durable and easy to use.
When using non-perforated sealant, drill holes in the smallest diameter for condensate and vapors to escape.
Leaving the ends open is not recommended - this will reduce the transparency of the panels and reduce their service life.
It is not recommended to glue the ends with ordinary tape.
When installing sheets, orientate them in such a way as to ensure the possibility of unimpeded drainage of condensate.
The installation of panels should be planned in such a way that when vertically installed, the stiffeners are located vertically, when constructing a pitched surface - longitudinally, for an arched surface - arcuate.
For outdoor work, use a material with a layer that protects it from ultraviolet radiation.

Fastening polycarbonate

Bearing longitudinal supports for the frame are mounted in steps:

for 6-16 mm sheets - 700 mm,
for 25 m sheets - 1050 mm.

When calculating the distance between the transverse supports, the following are taken into account:

expected wind or snow loads,
the angle of inclination of the structure.

The distance can be from 0.5 to 2 m.

For fastening polycarbonate, self-tapping bolts or thermal washers are used, one of which is a plastic plate with a high rod, the other is a seal, and there is also a snap-on cap in the kit. The thermal washer provides a strong and tight connection without cold bridges and panel compression. To avoid problems caused by thermal expansion, the holes should have a diameter larger than the cross section of the washer leg by a couple of millimeters.

Do not use nails or rivets to fasten the panels! It is not recommended to overtighten the self-tapping screws during installation. Improper fastening of polycarbonate with self-tapping screws can lead to a reduction in its service life.

If one-piece panels are being installed, then they should be inserted into the fold of the profile with the same thickness as these panels have.

They are attached to the longitudinal support using self-tapping screws. Before starting work, it is recommended to keep the sheets of cellular polycarbonate in a dry, warm room, and only then glue their ends with self-adhesive tape - in this case, condensation will not form inside the cellular material. To prevent the possibility of damage to the surface when the profile is snapped in, a wooden mallet is used.

During installation, it should be borne in mind that polycarbonate is not classified as static materials, its dimensions, albeit to a small extent (up to 0.065 mm / m with a temperature change of 1 degree), but change from temperature changes. Therefore, during installation, you should leave the appropriate gaps, but you should not forget about the need to use special fasteners that will prevent the panels from slipping when the temperature drops. It is enough that the free wheeling reserve is 2 mm for each running meter. The above requirements must correspond to the diameters of the holes prepared for fasteners.

Operation and maintenance of polycarbonate surfaces

Before installation, the panels should be stored in a packed form, transported in a horizontal position.
Storage of panels in direct sunlight or rain is not recommended.
Do not walk on polycarbonate sheets.
The panels are cleaned with a soft cloth moistened with a solution of soap or dishwashing detergent.
Do not use detergents that contain ammonia, acids, chlorine, solvents, salts.
Do not use sharp objects to remove dirt - they can scratch the UV protective layer.
The sheets are installed in such a way that the side on which the protective film is applied is outward. On the packaging, you should find the designation of UV protection.

Belongs to the class of synthetic polymers - linear polyester of carbonic acid and diatomic phenols. They are formed from the corresponding phenol and phosgene in the presence of bases or by heating a dialkyl carbonate with a dihydric phenol at 180-300 ° C.

Polycarbonates are a colorless transparent mass with a softening point of 180-300 ° C (depending on the production method) and a molecular weight of 50,000-500,000. They have high heat resistance - up to 153 0С. Heat-resistant grades (PC-HT), which are copolymers, can withstand temperatures up to 160-205 ° C. Possesses high rigidity combined with very high impact resistance, including at high and low temperatures. Withstands cyclic temperature drops from -253 to +100 0С. Basic grades have a high coefficient of friction. Recommended for precise details. Has high dimensional stability, low water absorption. Non-toxic. Sterilized. Has excellent dielectric properties. Allows soldering contacts. Possesses good optical properties. Sensitive to residual stresses. Parts with high residual stresses are easily cracked when exposed to gasoline and oils. Requires good drying before processing.

Polycarbonate has high chemical resistance to most non-inert substances, which makes it possible to use it in aggressive environments without changing its chemical composition and properties. Such substances include mineral acids, even in high concentrations, salts, saturated hydrocarbons and alcohols, including methanol. But it should also be borne in mind that a number of chemical compounds have a destructive effect on the PC material (there are not many polymers that can withstand contact with them). These substances are alkalis, amines, aldehydes, ketones and chlorinated hydrocarbons (methylene chloride is used for gluing polycarbonate). The material is partially soluble in aromatic hydrocarbons and esters.

Despite the apparent resistance of polycarbonate to such chemical compounds, at elevated temperatures and in the stressed state of the sheet material (bending, for example), they will act as cracking agents. This phenomenon will lead to a violation of the optical properties of polycarbonate. Moreover, the maximum crack formation will be observed in the places of the greatest bending stresses.

Another distinctive feature of polycarbonate is its high permeability to gases and vapors. When barrier properties are required (for example, when laminating and using decorative vinyl films of medium and large thickness from 100 to 200 microns), it is necessary to first apply a special coating to the polycarbonate surface.

It has no analogues in terms of mechanical properties among the currently used polymeric materials. It combines properties such as high temperature resistance, unique impact resistance and high transparency. Its properties depend little on temperature changes, and the critical temperatures at which this material becomes brittle are outside the range of possible negative operating temperatures.

Characteristics of the brand assortment
(minimum and maximum values for industrial brands)

Indicators (at 23 0С)	Polycarbonate (PC)	PC + 40% fiberglass	PC heat-resistant PC-NT
Density, g / cm3
Heat resistance according to Vicat (50 0С / h, 50 N), 0С
Tensile yield point (50mm / min), MPa
Tensile strength (50mm / min), MPa
Tensile modulus (1mm / min), MPa
Tensile elongation (50mm / min),%
Charpy impact strength (notched sample), kJ / m2
Ball indentation hardness (358 N, 30 s), MPa
Specific surface electrical resistance, Ohm
Water absorption (24 h, humidity 50%),%
Light transmission coefficient for transparent brands (3 mm),%

An outstanding property of PC film is its dimensional stability, it is completely unsuitable as a shrink film; heating the film to 150 ° C (i.e. above the softening point) for 10 minutes. shrinks only 2%. PC is easily welded by both pulsed and ultrasonic methods, as well as by conventional hot electrode welding. The film is easy to form into articles, and large draw ratios with good shape reproduction are possible. A good print can be obtained by different methods (silkscreen, flexography, engraving).

Industrial methods of obtaining

The main industrial methods for producing polycarbonates are:

phosgenation of bisphenols in an organic solvent in the presence of tertiary organic bases that bind hydrochloric acid - a by-product of the reaction (polycondensation method in solution);

phosgenation of bisphenols dissolved in an aqueous alkali solution at the interface in the presence of catalytic amounts of tertiary amines (interfacial polycondensation method);

Polycarbonate in construction is a great alternative to glass. It has a very high light transmittance due to its 90% transparency and is also very lightweight. In addition, polycarbonate is several hundred times stronger than glass - a hammer and bullets are not afraid of it. It is he who is preferred by gardeners in the construction of greenhouses, then no hail or hurricane can spoil it.

In addition to the installation of greenhouses, polycarbonate material is used for the construction of shop windows, billboards, in the glazing of buildings, balconies and loggias, in the arrangement of office partitions, as fences in playgrounds or swimming pools and in other transparent structures. This material is aesthetic and pleasant, therefore it is also used as a decoration.

Learn more about the characteristics and benefits of polycarbonate

Polycarbonate is a transparent polymer plastic that is stored in granular form until it is recycled. The composition of this substance includes: diatomic phenol, water, carbonic acid, solvents and dyes. At high temperatures, it does not lose its properties, is capable of self-healing, and therefore is environmentally friendly.

Important: do not open the original packaging until the polycarbonate sheets are used, so that condensation does not get in, and you also cannot tear off the protective film - dust or insects can get in, this will negatively affect the appearance of the sheet.

Two types of polycarbonate are produced - cellular and monolith. They are the same in quality. The only difference is that the structure of cellular polycarbonate is cellular (inside it is hollow, there are only partitions between the cells), and the monolith is solid without empty cells inside.

Specifications:

As already mentioned, this material is most loved when installing greenhouses - it has excellent thermal insulation.

Flame retardant and non-toxic, has self-extinguishing properties.

Unrealistically shockproof - used in the construction of fences against vandalism.

Resistant to temperature extremes. Not vulnerable in difficult weather conditions.

Important: although the material does not lose its properties when exposed to high temperatures, it can increase in size up to 4mm - this must be taken into account during installation and storage.

Due to the fact that the material is very flexible, it is convenient to make arches and other structures from it, which need to be given an original geometric shape. For this, a honeycomb sheet is more often used.

Does not transmit ultraviolet light. The material itself is destroyed under the influence of UV, but the manufacturers took this nuance into account and add a special protective agent to its composition.

In order not to doubt which type of polycarbonate to choose - cellular or monolithic, remember that the only difference is that the cellular one has less weight than the monolith, and also the cellular one has slightly higher sound insulation, thanks to the voids in the honeycomb.

Polycarbonate itself is a very light material; you can work with it without using special power equipment. Another important advantage is that the material is safe both in installation and in everyday life. If the glass is accidentally hit, it will break and may injure someone - with polycarbonate, such cases are completely excluded.

Description of polycarbonate greenhouse installation

Building a greenhouse with your own hands from polycarbonate is much easier than from glass. In addition, the plasticity of the material allows you to give the greenhouse a more interesting shape.

Polycarbonate is not fragile, unlike glass.

Easily cut with metal scissors (you can use a saw or a knife).

Flexibility - you can make a roof in the form of an arch. This will help to avoid joining, which cannot be said about the installation of a glass greenhouse.

Important: despite the fact that polycarbonate is flexible enough, you need to observe the measure. Do not exceed the bending radius indicated on the package, this will lead to a violation of the special coating from ultraviolet radiation.

Greenhouse foundation and frame

The first step is to fill in the foundation of the greenhouse. If the greenhouse will be located on soft ground, then the strapping should be made, and then the concrete foundation should be poured. You can use brick or stone. Such a foundation will last for many years.

The frame for the greenhouse can be wooden, profiled or metal. It is better to use metal, because the profiled is not very strong and can bend under pressure, and the wooden one needs to be painted - it shrinks. The ideal option would be a metal corner or square reinforcement.

Sheathing of the greenhouse frame with polycarbonate sheets

The first step is to rip off the factory film from the sheets. It is better to do this before sheathing, then it will be very inconvenient, and you will have to tinker.

Sheets are attached to the outer side of the frame, with an overlap, using thermal washers and self-tapping screws.

Try to keep the UV protected side outside.

It is possible to bend cellular polycarbonate only in the direction of the stiffeners.

It is not necessary to tighten the fasteners too much - the sheet should hold tight, but be able to move freely so that there is room to expand when heated.

There is nothing difficult in doing the installation of the greenhouse yourself. You can, of course, purchase a ready-made frame, sheathed with polycarbonate, which is then only installed on the foundation, but this will cost a little more. In addition, you can not guess with the size, which will entail unnecessary spending, although it's up to you - both options have their pros and cons. In the first option, you waste your time and effort, but save money, in the second - on the contrary.

Polycarbonate life

If you take proper care of polycarbonate and observe all precautions during installation, then it can last several decades longer than indicated by the manufacturer.

Polycarbonate care

Polycarbonate is easy to clean. To do this, you can use any dishwashing detergent, if you do not have a special one, and a cotton cloth.

Important: the detergent should not contain ammonia, it destroys the material, and use ethyl alcohol for greasy stains! Do not rub it with a brush or scraper, only with a cotton cloth! Otherwise, damage the coating that protects against ultraviolet radiation.

In conclusion, a few words about the color of polycarbonate

The main purpose of colored polycarbonate is to add beauty and originality to the appearance of the building. But some experts argue that for the construction of a greenhouse, color is important not only in aesthetic terms. It is believed that green is not suitable for greenhouses, because it inhibits plant growth, red or orange, on the contrary, promotes. In any case, if you decide to use this material in construction, then you will have a place to show your imagination.

Polycarbonate care

Using the example of a greenhouse, upon the arrival of spring, polycarbonate must be cleaned of dirt that accumulates over the winter. Due to dirt, the material loses its transparency, and from this it heats up more, which leads to deformation of the sheet. Keep the building clean.

Polycarbonate easy to clean. To do this, you can use any dishwashing detergent, if you do not have a special one, and a cotton cloth.

Important : the detergent must not contain ammonia, it destroys material, and for greasy stains use ethyl alcohol! Do not rub it with a brush or scraper, only with a cotton cloth! Otherwise, damage the coating that protects against ultraviolet radiation.

In conclusion, a few words about the color of polycarbonate

Polycarbonate has a wide range of colors, especially honeycomb. The cast does not have such a great variety of colors, because it is used less often than honeycomb, but still there is a choice.

Polycarbonate - what is it: material, description, specifications

Polycarbonate in construction is a great alternative to glass. It has a very high light transmittance due to its 90% transparency and is also very lightweight.

Polycarbonate: what is it and what can it be used for?

For a long time, silicate glass has been a traditional material for creating translucent structures (windows, greenhouses, greenhouses, decorative elements). It has a high degree of translucency, however, the fragility and technical characteristics of the glass severely limited the possibilities of use. The opposite of this expensive but unreliable material is polycarbonate. This term unites a whole group of transparent synthetic thermoplastics, which have high strength, high load-bearing capacity, and plasticity. This article will explain what polycarbonate is and how it is used for construction.

Composition and production process

All types of polycarbonate belong to the group of thermoplastic synthetic polymers. This material was not specifically developed by scientists, it was discovered in the course of research on pain relievers when chemists noticed a strong, transparent byproduct of the reaction. The secret of the strength of this compound lies in the special structure of the molecule, which is obtained in the following ways:

By the method of transesterification of diphenyl carbonate under vacuum conditions with the introduction of complex bases into the composition of the substance under the influence of a stepwise increased temperature. This method is good in that a solvent is not used in production, however, it will not work to obtain a good quality material in this way, since a small amount of catalyst remains in the composition in any case.
By the method of phosgenation of A-bisphenol in a solution with the presence of pyridine, no more than a temperature of exactly 25 degrees. The positive side of this method is that the production takes place at a low temperature in the liquid phase. However, the high cost of pyridine makes this method economically disadvantageous for the manufacturer.
By the method of interfacial polycondensation of A-bisphenol with phosgene in organic and alkaline solvents. The described reaction is low temperature, which is good for production. However, to wash the polymer, a lot of water is spent, which is discharged into water bodies, polluting the environment.

Interesting! Having excellent technical characteristics, low cost, high load-bearing capacity and translucency that is not inferior to silicate glass, some types of polycarbonate have been used reluctantly for a long time. Since exposure to ultraviolet radiation led to clouding of the material. The introduction of an ultraviolet absorber into the composition of the substance brought polycarbonate to a new level, making it the most rational solution for creating translucent structures and anti-vandal glazing.

The term "polycarbonate" includes a large group of synthetic linear polymers that are derivatives of phenol and carbonic acid. The molecular structure of the granules of this material is an inert, translucent, stable granule. Different production conditions (high pressure, temperature, environment) impart different technical characteristics to the substance, making it possible to create polycarbonate with different properties. Currently, 2 main types of this building material are produced:

Monolithic. This material resembles silicate glass in appearance, it is transparent, has a smooth, smooth surface. Sometimes monolithic polycarbonate is called "impact-resistant glass", as it has high mechanical strength, impact resistance, flexibility and at the same time lightness. The performance characteristics and different thicknesses of monolithic polycarbonate make it possible to use this unique material for decorative glazing, curved decorative elements, anti-vandal structures of the urban environment (stops, signs, road signs, billboards). However, it costs several times more than its cellular counterpart.

Important! Manufacturers produce transparent, translucent and matte polycarbonate, which can be colorless or colored. A colorless transparent material with a transparency of 84-92% is used for the construction of greenhouses and greenhouses. And translucent and matte colored are suitable for decorative glazing of commercial and administrative buildings.

Dimensions and properties

Different types of polycarbonate plastic have different operational and technical characteristics, including impact resistance, load-bearing capacity, thermal insulation qualities and transparency. Material properties also depend on the structure and thickness of the sheet. When choosing polycarbonate, the following parameters should be considered:

The width of cellular polycarbonate plastic is 210 cm, and that of monolithic plastic is 2.05 m.
Manufacturers produce cellular polycarbonate plastic in the form of sheets up to 12 m long, which is convenient for installing greenhouses and greenhouses. Monolithic polycarbonate is produced with a length of up to 6 m.
Cellular polycarbonate is produced with a sheet thickness of 4 mm, 6 mm, 8 mm, 10 mm, 16 mm, 20 mm, 25 mm, it depends on the shape of the cells and the number of layers in the composition of the material. The thickness of the monolithic type polycarbonate is 6 mm, 8 mm, 10 mm or 16 mm.
Monolithic polycarbonate weighs more than its cellular counterpart, 1 square meter of such a coating is 4.8 kg, however, this is still 2 times less than the weight of glass of the same area. Cellular polycarbonate weighs 0.8 kg / m2.
The heat resistance of both types of material is 145 degrees, despite this, it belongs to the class of self-extinguishing.
The impact resistance of monolithic polycarbonate is more than 400 J, which is tens of times more than impact-resistant glass. A sheet of cellular polycarbonate has an impact resistance of more than 27 J.

Note! Cellular and monolithic polycarbonate have different light transmittance coefficients. The light transmission coefficient of monolithic polycarbonate plastic is 91%, for comparison, for glass this figure is 87-89%. Cellular polycarbonate has a transparency of 80-88%.

Advantages

The performance and technical characteristics of polycarbonate plastic make it possible to use this material in many areas of construction. The light weight, impact resistance and transparency of polycarbonate and the low production cost made it possible to compete with silicate glass. The indisputable advantages of this material are:

A light weight. Monolithic plastic is 2 times lighter than glass, and cellular plastic is 6 times, which allows you to create lightweight structures that are not weighted down by unnecessary supporting elements.
Strength. High load-bearing capacity makes polycarbonate resistant to intense snow, wind or weight loads.
Transparency. The monolithic appearance of the material transmits even more light than silicate glass, and cellular polycarbonate plastic transmits up to 88% of the visible spectrum.
Insulating qualities. Polycarbonate, especially honeycomb, is an excellent material for sound and noise insulation.
Security. When polycarbonate breaks, it does not generate sharp fragments that cause injury.

Please note! All types of this material do not require serious maintenance, they can be washed with water with the addition of soap or dishwashing detergent. In no case should ammonia be used for purification, which destroys its structure.

What is polycarbonate

What is polycarbonate? Types, technical and operational characteristics of the material. Standard sizes of honeycomb and monolithic polycarbonate plastic

What is cellular polycarbonate

Polycarbonate, what is it, cellular polycarbonate dimensions, application, methods of cutting, fastening

Cellular polycarbonate - how it is made

For the manufacture of cellular material, polycarbonate is used - a granular colorless plastic mass, characterized by lightness, frost resistance, dielectric properties, and durability. The unique structure of polycarbonate macromolecules is the main reason for its unique properties.

Properties and advantages of honeycomb material

You can immediately notice that polycarbonate compares favorably with any transparent building material - none of them has the same positive qualities in full.

Cellular polycarbonate is different:

Low coefficient of thermal conductivity, providing higher heat-saving qualities of the material than glass, which allows almost half to reduce energy consumption for heating or cooling premises.
The multilayer structure of the material provides good sound absorption, and, accordingly, good sound insulation properties.
The material scatters light rays well, its transparency is 86%, when light passes through it does not cast a shadow.
The material can be used at temperatures from -40 C to +120 C, i.e. it can be used in almost any natural zone, the quality characteristics of the material to a very insignificant extent depend on changes in the environment. It is not susceptible to chemicals.
Polycarbonate is lightweight, about 16 times less than window glass and 6 times less than acrylic sheet of the same thickness, the use of the material allows you to get savings by designing a less powerful foundation and reducing the cost of building support structures. Installation work can be performed without the use of special construction equipment.
The material has a high viscosity, ensuring its impact resistance (200 times higher than that of sheet glass), it is resistant to bending and breaking loads. If damaged by a very strong impact, sharp fragments will not form. The polycarbonate sheeting can withstand the loads of accumulated snow and does not rip from the gusts of wind like plastic sheeting, making it ideal for greenhouse coverings. Good flexibility of the material allows it to be used for the installation of roof structures with complex geometries, including arched and vaulted ones.
Polycarbonate is distinguished by its reluctance to ignite, it does not burn, but under the influence of an open fire it melts to form a cobweb-like fiber, while toxic substances are not released.
The constancy of the technical characteristics of the material is ensured by the protective layer applied to the front side of the sheets, which blocks the ultraviolet part of the solar spectrum.

Cellular polycarbonate - sheet dimensions and field of application depending on thickness

Cellular polycarbonate is produced in a wide range of colors, its basic colors:

warm - red, brown, bronze, orange, yellow, milky,
cold - white, blue, turquoise, green,
you can also find transparent panels.

If we talk about the size of the sheets, then it should be stipulated that polycarbonate is produced in several versions:

monolithic, from 2 to 12 mm thick, with standard sheet dimensions 2.05x3.05 m,
cellular, with a thickness of 4 to 32 mm, with sheet dimensions 2.1x6 m or 2.1 12 m,
profiled, 1.2 mm thick, sheet size 1.26x2.24 m, profile height up to 5 cm.

Depending on the thickness of the sheets, cellular polycarbonate can be used in different ways, it is recommended to use it in the construction:

4 mm - awnings and greenhouses, showcases, exhibition stands,
6 mm - awnings, greenhouses, canopies,
8 mm - greenhouses, roofs, awnings, partitions,
10 mm - continuous glazing of horizontal and vertical surfaces, production of noise barriers, awnings,
16 mm - roofs over large structures,
32 mm - for roofs with increased load requirements.

Based on such a wide range of products, before starting construction, it will be necessary to study the properties and decide which polycarbonate is rational to use in each specific structure.

Basic principles of working with polycarbonate

During operation, the sheet should be supported in order to exclude its vibration. Chips that will get inside the sheet during cutting must be removed at the end of the work.

It is possible to bend cellular polycarbonate only along the lines of the channels, along the length of the sheet. The bending radius can be 175 times the sheet thickness.

When using polycarbonate in the construction of an arched structure, it will be necessary to close its ends with a perforated film. Materials for sealing should be selected in a shade corresponding to the colors of the panels.

The highest quality aluminum sealants are considered, they are durable and easy to use.
When using non-perforated sealant, drill holes in the smallest diameter for condensate and vapors to escape.
Leaving the ends open is not recommended - this will reduce the transparency of the panels and reduce their service life.
It is not recommended to glue the ends with ordinary tape.
When installing sheets, orientate them in such a way as to ensure the possibility of unimpeded drainage of condensate.
The installation of panels should be planned in such a way that when vertically installed, the stiffeners are located vertically, when constructing a pitched surface - longitudinally, for an arched surface - arcuate.
For outdoor work, use a material with a layer that protects it from ultraviolet radiation.

Fastening polycarbonate

Bearing longitudinal supports for the frame are mounted in steps:

for 6-16 mm sheets - 700 mm,
for 25 m sheets - 1050 mm.

When calculating the distance between the transverse supports, the following are taken into account:

expected wind or snow loads,
the angle of inclination of the structure.

The distance can be from 0.5 to 2 m.

Do not use nails or rivets to fasten the panels! It is not recommended to overtighten the self-tapping screws during installation. Improper fastening of polycarbonate with self-tapping screws can lead to a reduction in its service life.

If one-piece panels are being installed, then they should be inserted into the fold of the profile with the same thickness as these panels have.

Operation and maintenance of polycarbonate surfaces

Before installation, the panels should be stored in a packed form, transported in a horizontal position.
Storage of panels in direct sunlight or rain is not recommended.
Do not walk on polycarbonate sheets.
The panels are cleaned with a soft cloth moistened with a solution of soap or dishwashing detergent.
Do not use detergents that contain ammonia, acids, chlorine, solvents, salts.
Do not use sharp objects to remove dirt - they can scratch the UV protective layer.
The sheets are installed in such a way that the side on which the protective film is applied is outward. On the packaging, you should find the designation of UV protection.

Polycarbonate, what is it, cellular polycarbonate dimensions, application, methods of cutting, fastening

What is cellular polycarbonate Polycarbonate, what is it, cellular polycarbonate dimensions, application, methods of cutting, fastening Cellular, or otherwise - structured

Cellular Polycarbonate Specifications

Polymeric materials are widely used in the construction of buildings and structures for various purposes. Cellular polycarbonate is a two- or three-layer panel with longitudinal stiffeners located between them. The cellular structure provides high mechanical strength of the sheet with a relatively low specific gravity. To understand and understand all the technical characteristics of cellular polycarbonate, we will consider its properties and parameters in more detail.

What is cellular polycarbonate

In cross-section, the sheet resembles a honeycomb of a rectangular or triangular shape, hence the name of the material itself. The raw material for it is granular polycarbonate, which is formed as a result of condensation of carbonic acid polyesters and dihydroxyl compounds. The polymer belongs to the group of thermosetting plastics and has a number of unique properties.

Industrial production of cellular polycarbonate is carried out using the technology of extrusion from granular raw materials. The production is carried out in accordance with the technical specifications TU-2256-001-54141872-2006. This document is also used as a guide for the certification of material in our country.

The main parameters and linear dimensions of the panels must strictly comply with the requirements of the standards.

The structure of cellular polycarbonate in cross-section can be of two types:

Its sheets are produced with the following structure:

2H- Two-layer with rectangular cells.

3X- three-layer structure with a combination of rectangular cells with additional inclined partitions.

3H- three-layer sheets with a rectangular honeycomb structure, produced with a thickness of 6, 8, 10 mm.

5W- five-layer sheets with a rectangular honeycomb structure, as a rule, have a thickness of 16 - 20 mm.

5X- five-layer sheets, consisting of both straight and inclined ribs, are produced with a thickness of 25 mm.

Temperature conditions for using cellular polycarbonate

Cellular polycarbonate is extremely resistant to adverse environmental conditions. Temperature modes of operation directly depend on the brand of this material, the quality of raw materials and compliance with the production technology. For the vast majority of panel types, this figure ranges from -40 ° C to + 130 ° C.

Some types of polycarbonate are able to withstand extremely low temperatures down to - 100 ° C without destroying the material structure. When the material is heated or cooled, its linear dimensions change. The coefficient of linear thermal expansion for this material is 0.0065 mm / m- ° C, determined in accordance with DIN 53752. The maximum allowable expansion of cellular polycarbonate should not exceed 3 mm per 1 m, both in length and width of the sheet. As you can see, polycarbonate has significant thermal expansion, which is why it is necessary to leave appropriate gaps during installation.

Change in the linear dimensions of cellular polycarbonate depending on the ambient temperature.

Chemical resistance of the material

The panels used for decoration are exposed to a wide variety of destructive factors. Cellular polycarbonate is highly resistant to most chemical inert substances and compounds.

1. Cement mixtures and concrete.

2. Plasticized PVC.

3. Aerosols are insecticidal.

4. Strong detergents.

5. Sealants based on ammonia, alkalis and acetic acid.

6. Halogen and aromatic solvents.

7. Methyl alcohol solutions.

Polycarbonate has a high chemical resistance to the following compounds:

1. Concentrated mineral acids.

2. Saline solutions with neutral and acidic reaction.

3. Most types of reducing and oxidizing agents.

4. Alcoholic solutions, excluding methanol.

When installing the sheets, silicone sealants and specially designed EPDM-type sealing elements and analogs should be used.

Mechanical strength of cellular polycarbonate

The panels, thanks to their honeycomb structure, are capable of withstanding significant loads. At the same time, the surface of the sheet is subject to abrasion during prolonged contact with fine particles such as sand. Scratches may occur when rough materials of sufficient hardness are in contact.

Indicators of the mechanical strength of polycarbonate largely depend on the brand and structure of the material.

During the tests, the panels showed the following results:

Testing of cellular polycarbonate for strength indicators is carried out in accordance with the ISO 9001: 9002 standard. The manufacturer guarantees the preservation of operational characteristics for at least five years, provided that the sheets are correctly installed and special fasteners are used.

Sheet thickness and specific gravity

The production technology makes it possible to manufacture cellular polycarbonate of various standard sizes. Currently, the industry produces panels with a thickness of 4, 6, 8, 10, 16, 20 and 25 mm with different internal panel structures. The density of polycarbonate is 1.2 kg / m 3, determined according to the measurement method specified in the DIN 53479 standard.

UV resistance of cellular polycarbonate

The characteristics of cellular polycarbonate are capable of providing reliable protection against harsh UV radiation. To achieve this effect, an interlayer of a special stabilizing coating is applied to the sheet surface by coextrusion during the production process. This technology is guaranteed to provide a minimum service life of the material for 10 years.

At the same time, peeling of the protective coating during operation does not occur due to the fusion of the polymer with the base. When installing the sheet, you should carefully examine the marking and orient it correctly. The UV protection cover must face outward. The light transmission of the panel depends on its color and for unpainted sheets this figure ranges from 83% to 90%. Transparent colored panels transmit no more than 65%, while polycarbonate perfectly diffuses the light transmitted through them.

Thermal insulating properties of cellular polycarbonate

Cellular polycarbonate has very good thermal insulation characteristics. Moreover, the heat resistance of this material is achieved not only due to the fact that it contains air, but also because the material itself has a greater thermal resistance than glass or PMMA of the same thickness. The heat transfer coefficient, which characterizes the thermal insulation properties of a material, depends on the thickness and structure of the sheet. It ranges from 4.1 W / (m² · K) (for 4 mm) to 1.4 W / (m² · K) (for 32 mm). Cellular polycarbonate is the most suitable material where transparency and high thermal insulation must be combined. That is why this material has become so popular in the production of greenhouses.

Industrial greenhouse made of polycarbonate.

Fire performance

Cellular polycarbonate is resistant to high temperature effects. This material belongs to category B1, which is characterized by the European classification as self-extinguishing and hardly flammable. When burning, polycarbonate does not emit gases that are toxic and hazardous to humans and animals.

Under the influence of high temperature and open flame, the structure is destroyed and through holes are formed. The material is significantly reduced in area and moved away from the heating source. The appearance of holes ensures that combustion products and excess heat are removed from the fire.

Lifetime

Manufacturers of cellular polycarbonate guarantee the preservation of the basic technical characteristics of the material for a service life of up to 10 years, subject to the rules of installation and maintenance. The outer surface of the sheet has a special coating that provides UV protection. Damage to it significantly reduces the service life of the panel and leads to its premature destruction.

Noise isolation

The honeycomb structure of polycarbonate contributes to the low acoustic penetration of the material. The panels have a pronounced soundproofing property, which directly depend on the type of sheet and its internal structure. Multilayer cellular polycarbonate with a thickness of 16 mm or more ensures the attenuation of sound waves within 10-21 dB.

Resistant to moisture

This sheet material does not transmit or absorb moisture, which makes it indispensable for roofing work. The main difficulty in the interaction of cellular polycarbonate with water is its penetration into the panel. Removing it without dismantling the structures is almost impossible.

Long-term presence of moisture in the combs can cause its flowering and gradual destruction.

In order to exclude such a development of events, only special fasteners with sealing elements should be used in the installation process. Polycarbonate edges are covered with special tape. The easiest way to clean the honeycomb is to blow it with compressed air from a cylinder or compressor.

To protect the edge from moisture, the following is used: 1. - a special adhesive tape, 2. - a special profile, which is put on over the glued tape.

Panel colors

Cellular polycarbonate is marketed in transparent and colored versions.

Manufacturers offer the consumer panels of the following colors:

There is also a completely opaque version of the silver-colored panels. The light transmission of cellular polycarbonate depends on its thickness and its internal structure. For transparent material, the light transmittance ranges from 86% for 4 mm sheet, up to 82% for 16 mm material. The coloring of the material is carried out in an array, which contributes to the retention of color throughout the entire service life.

Purpose and scope of material

Cellular polycarbonate is mainly used in construction for the construction of roofs and enclosing structures.

This material, due to its exceptional properties, is increasingly used for the manufacture of the following elements:

1. Arched structures

2. Awnings over the entrance doors

3. Public transport stops

4. Carports

5. Soundproof screens along railway tracks and high-speed highways

In private households, such panels are used for glazing verandas, attics, gazebos or summer kitchens. Another area of application of the panels is in the production of agricultural greenhouses, which are distinguished by their durability.

The complexity of installing cellular polycarbonate

Installation of cellular polycarbonate is carried out by attaching it to a frame made of steel or aluminum profiles. Bending of sheets across stiffeners is allowed; this property is widely used in the manufacture of canopies and roofs. The minimum radius of curvature of the panel depends on its thickness in an inverse relationship. Cellular polycarbonate 25 mm thick cannot be bent.

When performing installation, a number of rules must be followed:

1. Cutting panels up to 10 mm thick is carried out with a sharpened knife, a saw with fine teeth

2. Drilling is carried out with a drill; the minimum distance from the edge is at least 40 mm.

3. The panels are fixed to the frame with self-tapping screws with sealing washers.

4. Individual sheets are joined together using special connecting elements

Cellular polycarbonate - specifications in detail

Cellular polycarbonate is becoming more widespread in our country, this is facilitated by the excellent technical characteristics of cellular polycarbonate, which we will describe in detail.

Polycarbonate is a modern material that perfectly replaces glass, while being in no way inferior to it in many properties.

Polycarbonate is a polymer that, due to its characteristics, is defined as a synthetic, low-combustible material. If we compare this material with acrylic and glass, it turns out that polycarbonate is much more durable (100 times more than glass and 10 times more durable than acrylic). The temperature range of application is also wide, in which the properties of the material remain unchanged - from -40 ° C to + 120 ° C.

It is made from special raw materials - polycarbonate granules. Slabs of this or that type of polycarbonate are melted by special processing. Polycarbonate is used quite widely due to its properties in construction, aircraft construction, medicine, production of household appliances and electronics, where it is necessary to create a lightweight but durable case.

There are two types of polycarbonate:

monolithic;
cellular.

Monolithic polycarbonate is a single plate, similar in appearance to glass. However, polycarbonate is 100 times stronger than glass, 2 times lighter and transmits more light (up to 90%).

The panel thickness can be 0.75-40 mm. Multilayer monolithic polycarbonate is often found. The color scheme and texture of the layers can be different. In addition, different layers are often given different properties: for example, one is durable, the second does not transmit light, and the third has a matte surface. Monolithic polycarbonate with two layers that do not transmit ultraviolet light has become widespread.

In the construction industry, horizontal structures are erected from. In this case, it is not necessary that they have a strict rectangular shape - it can also be a rounded overlap.

Rounded monolithic polycarbonate

The roundness of the shape is achieved by using hot forming technology. For the technology, special domes with a radius of 4-5 m with a rectangular floor are used. To control the thickness of the monolithic polycarbonate being produced, powerful lights are used, which are drawn along the entire inner area of the dome.

The dome with the raw material is immersed in the furnace, where the temperature is gradually built up and air circulates. The sheet heated to a certain temperature is stamped. The impact resistance of stamped polycarbonate is very high due to the fact that during the stamping process the parts are reinforced with special ribs. The need to insert metal stiffeners is eliminated, thereby keeping the structure lightweight.

Another option is a wave-shaped profiled polycarbonate

Cellular polycarbonate

Structurally, these are two (or more) layers of plates, between which longitudinal bridges are drawn - stiffeners.

Cellular polycarbonate is also called cellular or structured. However, the name "cellular polycarbonate" is firmly established in the construction industry. Cellular polycarbonate is used to create roofs, awnings, ventilation lamps on the roofs of industrial buildings and premises.

Important! Cellular polycarbonate is produced by forcing granules heated to a molten state through a forming part, which determines the shape and dimensions of the future sheet.

The advantages of cellular polycarbonate, which determine its scope, include the following:

light weight (1 m2 of sheet weighs from 1500 to 3500 g, which is 6 times less than glass);
low thermal conductivity;
high performance of sound insulation (2 times higher than that of glass);
high impact resistance;
high bearing capacity;
high light transmittance (up to 85% - also more than that of glass);
flexibility;
resistance to many aggressive chemicals, etc.

Important! Polycarbonate has a negative property that should be taken into account even in the process of designing a construction site - when exposed to high temperatures, the material begins to increase in volume, due to which horizontal ceilings with a large area or load-bearing structures may suffer.

Also, polycarbonate, like glass, does not tolerate mechanical stress. For the successful installation of floors, it is customary either not to remove the protective film, or to process the surface with special compounds.

Cellular polycarbonate prices

cellular polycarbonate

Cellular polycarbonate in agriculture

Cellular polycarbonate is widely used in the agricultural sector. Impact resistance, the ability of the material to scatter direct sunlight, long wear life and thermal insulation properties are highly valued here. In addition, cellular polycarbonate transmits only part of the ultraviolet rays, which are quite enough for the normal life of plants. Due to these properties, cellular polycarbonate is actively used for the construction of greenhouses and greenhouses, not only on an industrial scale, but also for private purposes.

For the construction of greenhouses and greenhouses, sheets of cellular polycarbonate with a thickness of 8 mm are usually used. It is this thickness that is considered the golden mean - the combination of cost and technical characteristics is the most successful. Many manufacturers specially produce 8 mm cellular polycarbonate with a coating that does not allow water to linger on the inner surface, which improves the light transmittance of the finished greenhouse.

Table. Main characteristics of 4 mm thick cellular polycarbonate of popular brands.

Specifications	Unit measurements	SafPlast Novattro	Bayer Makrolon	"Polygal"	PlastiLux Sunnex
Distance between ribs	mm	6	6	5,8	5,7
Specific gravity	kg / m2	0,75	0,8	0,65	0,79
Light transmission	%	84-87	81	82	86
Minimum bending radius	mm	700	750	800	700
Heat transfer resistance	m2 ° C / in	5,8	4,6	2,56	3,9

Monolithic and cellular polycarbonate - what is common?

Both types of polycarbonate have common properties, including:

excellent light transmission;
ease;
shock resistance;
low thermal conductivity.

Both types are often used to build transparent ceilings of the most complex shapes in both private and commercial construction. Most often, polycarbonate floors can be found in the design of passages, gyms, museums, workshops and shopping centers.

According to the standard, polycarbonate sheets of different thicknesses are produced - 4 mm, 6 mm, 8 mm, 10 mm, 16 mm, 20 mm and 25 mm. On the domestic market, sometimes sheets with a thickness of 32 are found. One sheet, as a rule, has dimensions of 2100 * 6000 mm or 2100 * 12000 mm.

For construction, polycarbonate of 8-10 mm is usually used, and when heat saving is needed - over 20 mm thick.

Polycarbonate in private construction

Polycarbonate has recently become available to the general public and immediately gained popularity. Its relative cheapness and excellent properties found a consumer response, and the material began to be used in all spheres of life, including in private construction.

Recently, the construction of polycarbonate fences has gained wide popularity. The ability to create fences of an unusual shape, good noise insulation and ease of installation have made polycarbonate one of the most favorite materials among designers and architects.

An important role in general acceptance is played by the fact that polycarbonate can be light-transmitting and matte, of different colors and shapes. There is plenty of room for imagination and the ability to create a custom design.

Polycarbonate is easy to clean, making it easy to maintain the fence. To care for a polycarbonate fence, water and a cotton cloth are enough. As an additional means of washing, you can use any product that does not contain ammonia. Soundproofing properties are also a big plus for such a fence.

Polycarbonate garage buildings

Two designers - Tapio Spelman and Christian Grau - wondered how to create an unusual and practical premium car garage so that it looks modern, while the car is visible and safe at the same time. The solution came almost immediately: they developed a garage with transparent polycarbonate walls with the addition of liquid crystals that can hide the car from prying eyes. When this project is implemented, the result is a beautiful building that perfectly fulfills its functions and pleases the eye.

Greenhouses, greenhouses and winter gardens made of polycarbonate

The fashion for the use of film for the device of the greenhouse is gradually disappearing. Compared to polycarbonate, the film is unprofitable and impractical - even if its integrity is not violated, then in 2-3 years they will inevitably self-destruct under the influence of sunlight. In addition, the film must be removed for the winter season and reinstalled in the spring, which poses additional problems. All of the above, in tandem with unaesthetic qualities, make this material completely uncomfortable and problematic.

Much easier and easier to arrange. Many firms supply ready-made structures with a galvanized frame, which only need to be assembled.

Advantages of a polycarbonate greenhouse:

long service life of floors (up to 25 years);
long service life of the galvanized frame (up to 25 years);
no need to put a foundation - the frame adheres perfectly to any surface;
mobility of the structure - the greenhouse or greenhouse can be moved to another place;
ease of assembly / disassembly;
prolongation of the harvest time due to the optimal climate;
the ability to equip a winter garden;
the assembled greenhouse takes up little space;
the greenhouse set includes all the necessary fasteners that securely fixes the structure in the assembled state.

Unlike greenhouses made of other materials, polycarbonate structures provide an even distribution of light rays to all plants. For example, if the greenhouse is covered with glass, the ultraviolet rays, without reflecting, fall only on the tops of the plants, while the lower part remains in the shade. In such conditions, plants often fall ill and die.

Polycarbonate provides an optimal microclimate for efficient plant growth. In addition, the galvanized iron, from which the frame is made, is distinguished by its durability and the fact that it has no material value in the eyes of criminals.

Important! For lovers of aesthetics and landscape design, polycarbonate will become a real gift - the ability of cellular polycarbonate to take the most complex forms allows you to build structures of any kind.

A polycarbonate greenhouse keeps heat much better. If you have a heated greenhouse or winter garden, then you can save about 30% of the fuel used in a year.

This might be helpful

Below are some useful information and applications for polycarbonate.

In industrial and private construction, polymer products began to be used in the 70s of the last century. Half a century of practice has proven and actually confirmed the numerous advantages of using synthetic products. However, not everyone is still familiar with its compelling priorities.

Moreover, there are people who have no idea at all what polycarbonate is, what technical characteristics and technological advantages it attracts builders, how a completely new, but not yet known material, works in structures and structures.

To get full answers to your questions, it is worth understanding the specifics of the polymer product and the peculiarities of its production.

The popularity and demand for polycarbonate in construction is justified by a number of priority qualities inherent only to polymer materials. Its extraordinary lightness is combined with a fairly high strength and resistance to a number of external influences.

Polymer sheet material actively displaces fragile and heavy silicate glass. It is used much more actively and readily in the glazing of building structures.

Using polycarbonate, they equip terraces and greenhouses, build awnings, canopies over the entrance groups and roofs of arbors. Serves as a roof covering, a light-conducting element of panoramic windows, wall cladding.

Polycarbonate, unlike glass, can hold a pretty impressive load without cracking and deformation. It is suitable for covering large spans, does not create risky situations arising from the destruction of large-scale panoramic glazing.

The material of synthetic origin does not require an extremely careful attitude during transportation, delivery to the place of work and installation work. Easy to process, does not create complications in cutting. While working with it, there are practically no waste and spoiled pieces that are not suitable for further use.

According to structural indicators, polycarbonate sheet is divided into two subspecies, these are:

Monolithic. Material with a monolithic structure and equal characteristics throughout its thickness. When cut, the sheet looks like the glass we are used to, but it is 200 times more durable. It bends, however, to the limits set by the manufacturer.
Cellular. Material with characteristic "honeycomb", if you look at its cut. In fact, these are two thin sheets, between which there are distance longitudinal partitions. It is they who form the honeycomb structure, and also serve as stiffeners.

Both varieties are suitable for the formation of rounded surfaces, which is completely impossible with glass. But those who want to implement an interesting idea should take into account the bending radius, which is necessarily indicated by the manufacturer of the material in the technical documentation.

Both types of materials are obtained as a result of polycondensation of two chemical components: the acid chloride of definilopropane and carbonic acid. As a result, a viscous plastic mass is created, from which a monolithic or cellular polycarbonate is formed.

In order to get a full understanding of both varieties, let's figure out the specifics of their production and application features.

Monolithic polycarbonate sheets

The raw material for the production of monolithic thermoplastic polymer is supplied in granular format. Manufacturing is carried out using extrusion technology: the granules are loaded into an extruder, where it is mixed and melted.

The softened uniform mass is pressed through the die of the extruder - a flat-slot device, at the exit from which a polymer plate of equal thickness is obtained at all points. The thickness of the polycarbonate plate varies from 1.5 mm to 15.0 mm. Simultaneously with the thickness of the slab, the required dimensions are given.

Monolithic polymer boards are produced in an extensive range, they differ:

By light-conducting qualities. They are transparent, transmitting up to 90% of the luminous flux, and opaque, practically not conducting light.
By relief. They are flat and wavy. Polymeric transparent and non-conductive slate is one of the varieties of monolithic polycarbonate.
By color. In the abundance of trade items offered to customers, there are materials of various colors.

Among the positive qualities of monolithic polycarbonate is zero moisture absorption. It does not absorb atmospheric water and household fumes at all, therefore it does not lose weight and does not create conditions for the resettlement of fungal colonies.

The monolithic version is not afraid of low and high temperatures, it works perfectly in a wide range. In hot weather, like all polymers, it is prone to linear expansion, which must be taken into account when designing and carrying out installation work.

Honeycomb Polycarbonate Panels

The production of a honeycomb polymer material differs from the production of a monolithic colleague only in the shape of the die. When pushed through it, a multilayer material with long longitudinal channels of small cross-section is created.

There is air in the channels formed by the die, due to which the insulating qualities of the polymer product are significantly increased, at the same time the weight is significantly reduced.

Items from the cellular assortment differ:

By the total thickness of the panel. At the disposal of architects and designers is now honeycomb material with a thickness of 4.0 mm to 30.0 mm. Naturally, the thicker the sheet, the worse it bends and less suitable for the formation of rounded planes.
By color and light-transmitting qualities. Due to the peculiarities of the structure, cellular polycarbonate cannot transmit more than 82% of the light rays. The colorful range is not inferior to the monolithic nomenclature.
By the number of layers and the shape of the honeycomb. There can be from 1 to 7 layers in a honeycomb panel. Stiffening ribs, which are at the same time distance elements and walls of air channels, can be located strictly perpendicular to the upper and lower surfaces of the sheet or be at an angle to them.

The channels created by the bridging ribs can be safely attributed to both the pluses of the material and its minuses. Despite the complete inability of polycarbonate itself to absorb water, they, on the contrary, can "suck" moisture from nearby soils and plants, and easily let in household vapors.

In order to prevent water from penetrating into the channels, which, by the way, significantly reduces the priority insulating qualities of cellular polycarbonate, when performing installation work, they should be covered with flexible profiles - linear mounting parts. They are used both for edge protection and for joining adjacent sheets into one structure.

Optimization of quality characteristics

Polycarbonate panels are an excellent building material, but still they are not without drawbacks. It transmits ultraviolet light of groups A and B. To minus we attribute sensitivity to sunlight, the tendency to unevenly scatter rays and the ability to maintain combustion.

Consider the methods by which manufacturers of polymer sheets are struggling with negative properties. So we will understand what to look for when choosing polycarbonate for private construction.

UV protection application

It is not in vain that the ability to transmit the ultraviolet component of solar radiation, which is harmful to, for example, plants in a greenhouse, is recognized as a significant disadvantage of plates made of polycarbonate. It is far from being useful for those who have a rest under a canopy, and for those who swim in a pool with a polymer pavilion.

In addition, UV negatively affects the polycarbonate sheet itself, which turns yellow, becomes cloudy, and eventually collapses. In order to protect the material and the space equipped with it, the outer side is supplied with a layer that plays the role of a reliable barrier from destructive rays.

Previously, the protective layer was made with a varnish coating, the disadvantage of which was the unevenness of the application, the ability to crack and quickly grow cloudy. It can still be found on counterfeit products, since the manufacturers of such products have neither the equipment nor the compositions to perform the correct UV protection.

High-quality polycarbonate is not covered with a protective shell, it is, as it were, melted into its top layer. This method is called co-extrusion. As a result of the mixing of the two substances at the molecular level, a shield is created that is impenetrable to ultraviolet radiation.

The thickness of the layer created by fusion is only a couple of tens of microns. In fact, it is the same polycarbonate, but enriched with a UV stabilizer. During operation, the layer does not crack, does not crumble or crumble, but faithfully serves the owners exactly as much, as much as the polycarbonate panel is used.

Note that the presence of a stabilizer is not determined visually, its presence is confirmed only by technical documentation from a manufacturer that values its own reputation. In order to be able to determine this substance in polycarbonate, an optical additive is also introduced in the process of its fusion.

You can consider an optical additive under an ordinary ultraviolet lamp, but you will never see the stabilizer itself. Therefore, it is better to buy material in responsible stores that purchase polycarbonate from trusted suppliers. Only in this case it will be practically impossible to "run into" counterfeit products.

Also remember that UV stabilizer is not applied to the entire thickness of the sheet. Such concentration is simply irrational, and the price of the product would rise hundreds of times. Therefore, the assurances of the seller or the manufacturer of the material that the stabilizing substance has been applied at full capacity can with good reason be regarded as a deception and a desire to sell a fake.

The side where the stabilizer is fused is indicated on the material as “top”. It is necessary to install polycarbonate sheets only so that it creates an outer surface and is the first to meet the sun's rays. Only in this case, protection from ultraviolet radiation will completely fulfill the duties assigned to it.

Light scattering additive

The ability to diffuse light is a very useful property in the greenhouse industry. Therefore, you should pay attention to it if polycarbonate sheets are bought for the construction of a greenhouse.

Light scattering provides a more complete coverage of the illuminated area by redirecting the sun's rays, and guarantees uniform light delivery to all plants in a closed object. In addition, the scattered rays inside the greenhouse are additionally reflected from various surfaces, which further enhances the light flow.

The property of uniformly distributing the sun's rays in monolithic sheets is much higher than that of honeycomb panels. And since the cellular version is mainly used in the arrangement of greenhouses, it is necessary to inquire about the percentage of light scattering from the seller or find information about it in the product passport.

You need to remember that:

In a cellular transparent material, this property usually does not exceed 70-82%.
For opaque color modifications it varies from 25 to 42%.

Polycarbonate begins to refract and scatter light after the introduction of LD - microscopic particles that form the specified effect into the diffuser.

This additive is introduced during the production of transparent panels, due to which the light transmission of monolithic sheets is increased by up to 90% (data for a material with a thickness of 1.5 mm). It is added in the manufacture of white polycarbonate, the light transmittance of which ultimately varies in the range from 50 to 70%.

Injection of an anti-combustion inhibitor

Like all polymer compounds, polycarbonate without the use of specific additives will keep the fire going. After the introduction of inhibitors, this quality is noticeably reduced. Monolithic sheets and honeycomb panels resist fire for a long time and do not emit toxic toxins during combustion.

Standard monolithic polycarbonate belongs to G2 group in terms of ignition parameters, cellular to G1. Those. monolithic sheets are moderately flammable, and honeycomb panels are slightly flammable.

At the request of customers, monolithic sheets can also be manufactured in accordance with the requirements of the G1 group. In this case, the buyer must obtain a certificate for a product with the appropriate characteristics. In terms of flammability, ability to spread fire and toxicity, there may also be variations.

Elimination of the phenomenon of indoor rain

Cellular polycarbonate is very popular in the construction of greenhouses, verandas, covered pavilions for pools, greenhouses, terraces. The use of polymer panels practically excludes air movement or significantly reduces its speed. The situation is aggravated by the specific fasteners used in construction, which ensure tightness.

Despite the presence of ventilation components in structures made of polycarbonate, it is almost impossible to completely exclude condensation from occurring. Natural vapors and condensation accumulate on the inner surface, reducing light transmission.

Condensation and vaporous water have a negative effect on plants and promote rotting in sealed greenhouses. A negative effect is exerted on wooden parts of structures, on the surface of which a destructive fungus settles. Indoor pools create an unhealthy atmosphere.

How to remove fogging? Yes by applying an anti-fog coating, which has received the technical term Antifog (anti-fog). After its application on the inner surface of polycarbonate structures, evaporation and condensation are not retained due to a change in tension on the surface of the drops.

The multicomponent composition creates conditions for the uniform distribution of water over the polymer surface. Water interacts with it, and not with neighboring similar molecules. Vapors and condensation eventually do not turn into large droplets that pose a threat to plants and people if they fall out, but evaporate quickly.

Consideration of thermal expansion

In order for the structure constructed with the use of polycarbonate not to deform, it must be borne in mind that as a result of thermal exposure, sheets and panels can increase in size.

Polycarbonate building material is designed for normal operation in the temperature range from -40 ° C to + 130 ° C. Naturally, with positive values, the polymer will change in a linear direction.

Consideration of thermal expansion is mandatory at the stage of project development, and information about the linear size of thermal expansion is extremely important for the designer.

Average values of thermal expansion for polymer panels are:

2.5 mm for each running meter for transparent, milky material for and products close to milky light colors;
4.5 mm for dark colored material: blue, gray, bronze samples.

In addition to the designers, the thermal expansion capacity must be taken into account by the installers, since fasteners must be installed in a special way. In order for the sheets and panels to have the ability to move, holes for self-tapping screws are drilled larger than the diameter of their trunk, and hardware with large caps and expansion joints is also used.

Honeycomb panels and monolithic polymer sheets are laid so that a gap remains between them. Then, when expanding, the polymer elements will have a reserve, thanks to which they will not "push" each other, resting on the edges. This gap closes a flexible profile in constructions.

If thermal expansion is taken into account in the design and assembly of structures, the structures will easily serve longer than the period guaranteed by the manufacturer. Arranged with polycarbonate sheets and panels, components will not crack and collapse from tension and excess stress.

Independent home builders should also remember about the tendency of polymer sheets and panels to expand under thermal exposure, both direct and indirect, that is, occurring under conditions of increasing degrees in the surrounding space.

Video number 1 will help you to visually familiarize yourself with the types of polycarbonate and understand what is the difference:

Video # 2 will present tips for choosing polycarbonate honeycomb panels for building a greenhouse:

Video No. 3 will briefly acquaint with the standard sizes and scope of cellular polycarbonate:

The information we offer does not just acquaint interested visitors with the popular building material and the specifics of its application.

We tried to explain to you how to choose a product worthy of your attention that will last a guaranteed period and, for sure, much longer. Taking into account the criteria and advice given in the description is necessary to achieve a positive result, both in the acquisition and in the construction.