Polycarbonate sheets (mixing construction and chemistry)

Polycarbonate (transparent and virtually unbreakable plastic) (polymer containing carbonate

groups) (transparent amorphous thermoplastic)

Lu (2015)
https://www.linkedin.com/pulse/polycarbonate-sheet-wikimake-you-expert-plastic-field-sunny-
sun-6001686744817221632
Classification (solid, hollow, and corrugated - tough and strong to withstand high impact)
Grades (varying degree of light transmission and overall strength)
1. Possess good creep resistance
2. Remain effective within a wide range of temperature limits
3. Have good dimensional stability
4. Exhibit good electrical and thermal insulation
5. Maintain self-extinguishing properties.
6. Good heat resistance with higher melting point

Polycarbonate Properties
Flynt (2019)
https://3dinsider.com/polycarbonate/
Global demand of polycarbonate materials exceeds 4 million tons per years
Properties
Tensile strength (8500 psi)
SG (1.19)
Melting temp (288-316 degrees celsius)
Flexural strength (93 MPa or 13500 psi)
Poisson's ratio (0.37)
History
ASHRAF. M.R. (2014)
https://textileinsight.blogspot.com/2014/09/history-of-polycarbonate-polymers.html
1898 - discovery of polycarbonate by Alfred Einhorn (German chemist) at the University of
Munich
The study and research on the material was abandoned for 30 years
Research has continued through
1953 - rediscovery of polycarbonate by Dr. Hermann Schnell (Germany) and General Electric
scientist Daniel W. Fox (USA)
Schnell (first rediscovered the material at Bayer's R&D laboratories when the company was
finding ways to improve its technology) (Makrolon linear polycarbonate) (commercial
production of Bayer company started last 1958) (U.S. patent last Oct. 16, 1953)
Fox (discovered the material while working on wire-coating material) (Lexan branched
polycarbonate) (commercial production of GE company started last 1960) (GE Plastics Division)
Brown to clear polycarbonate (1970)

http://www.h-i-p.co.za/history-of-polycarbonate-at-bayer.html
1953 - Dr. Hermann Schnell rediscovers polycarbonate at the Bayer laboratories
1955 - Schnell and his team planned a commercial production of linear polycarbonate under the
name Makrolon
1958 - Makrolon polycarbonate was popular in Germany for its insulating effect for electric
applications such as for telephone housings
1959 - use of polycarbonate in electrically-insulating films
1960 use of material for bubble lights in emergency vehicles
1963 - use of material on kitchenware and camping utensils due to its strength and impact
resistance
1964 - wider range of uses and applications of polycarbonate
1970 - first flame-retardant polycarbonate is manufacture with potassium
perflourobutansulfonate technology (C4-salt)
1971 - brown to clear polycarbonate material
1972 - introduction to new technology called Bayblend
1976 - Marketing of polycarbonate blends (Makrolon + other plastics). Use for healthcare
equipment
1982 - Production of music CDs made from Makrolon by Polygram
1986 - due to its features and properties having high light transmission, good weather stability,
and high impact strength, polycarbonate sheets have gained popularity in the construction
industry especially for roofing applications such as that found in the Bay Arena
1988 - introduction of flame-retardant polycarbonate materials (Bayblend) (used for electrical
applications)
2020 - Bayer company strives to improve the quality and performance of polycarbonate
materials and products through laboratory solutions

Manufacture

- Extrusion Process (granular material to a uniform plastic material)

The polycarbonate sheets are produced by an extrusion process, a process that takes place at high
temperatures in which polycarbonate in granular form is transformed into a plastic state (molten)
and then passed into a matrix which gives it its shape. On cooling the material keeps the shape
set in the final product phase of the process.
For sheets that will be exposed to the sun, a further process is necessary which is called “co-
extrusion”, during which an extra external layer is applied directly to the sheet, which provides
UV protection, in a way that means it already becomes part of the sheet during the production
phase.

Flynt (2019)
https://3dinsider.com/polycarbonate/
Reacting bisphenol A (BPA) and Phosgene. Bisphenol from condensation of phenol with
acetone.
Sheet metal techniques could be utilized to produce polycarbonate sheets
Grades (treatments applied to polycarbonate materials for serving different applications and
functions): reinforced, flame retardant, film, crack-resistant, branched and more.
Methods: Extrusion, Injection Molding, Structural Foam Molding, Blow Molding, Vacuum
Forming

Installation

https://www.youtube.com/watch?v=Z3cM536JduY
Roof Application
1. Construction suitable framework
2. Line up and cut the bars and end bar infills so that they are the same length as the framework
with an additional 50 - 60 mm overhang (with 12-15 mm gaps between sheets on the jointing
rafters)
3. Drill holes in the center of the glazing bar base at approximately 500 mm centers
4. Apply eaves filler to the top of front beam
5. Peel protective films on polycarbonate sheet
6. Ensuring the sheet is free from dust and any other debris, apply vent tape to the gutter end and
ali tape to the wall end (vent tape withstand constant exposure to hot and cold temperatures, and
ali tape highly impermeable to water vapor and gases)
7. Sheet enclosures should be cut to fit between the bars and positioned centrally over the tapes
end
8. Place sheets into position between the aluminum channels
9. Use Hawk top cap which should click firmly into place. For end sheets ass additional end bar
infill
10. Line up the hole of the end cap with the screw port on the PVC top cap and screw into
position
11. Remove protective film on the sheets
12. Drill 16mm diameter holes in the sheets and ass fixing buttons to securely fix the sheets to
the framework beneath
13. Apply 225 mm flash band to wall and top edge of sheeting to seal between roof and host wall

https://www.youtube.com/watch?v=xmXwZ520WnM
Roof Application
1. U profile applied to the gutter end
2. Capping Bars (40 and 60 mm wide) applied on the rafters
3. Aluminum capping bars
4. F Profile applied to end of sheets (screwed into the gable end rafter)
5. Fixing button
6. Wall finishing profile to fix sheet to wall
https://www.youtube.com/watch?v=nheUhggR0oM

Application

Rogers (2015)
https://www.creativemechanisms.com/blog/everything-you-need-to-know-about-polycarbonate-
pc
generally used for applications requiring transparency and high impact resistance
it also serves as a natural UV light filter as it is being applied to eyewear technology

https://www.emcoplastics.com/polycarbonate-sheet/
Electrical, Glazing, Optical, Automotive, Greenhouses, and Law Enforcement

Polylite (n.d.)
https://www.polylite.com.ph/polycarbonate-roofing-sheet-supplier-philippines-project-polylite-
industrial-corporation/#projects
Residential Skylight
Cavite-Laguna Expressway Sound Barrier
Commercial walkways
Greenhouses and gardens
Warehouse roofing
Gymnasiums
Construction industry (roofing and glazing: lightweight, similar transparency, high impact
resistance, and good heat resistance)

polyPIU (n.d.)
https://www.polypiu.it/en/polycarbonate-applications/
Covered walkways
Overhanging roof canopies
Continuous curved canopies
Vertical skylights
Ventilated vertical glazing

Pros and Cons

Flynt (2019)
https://3dinsider.com/polycarbonate/
Pros
(engineered thermoplastic) (transparency, high toughness, and good heat & impact resistance)
(rigid across temperatures ranging from -20 to 140 degrees celsius with a melting point of 150
degrees celcius)
Treated easily without material degradation
Could be heated at high temperatures and cooled without significant material deterioration
(recyclable)
It is pliable at room temperature which makes it viable for prototyping
Cons
Some polycarbonate materials when in contact with water can undergo hydrolysis (release of
BPA) (production of BPA free products)
Low resistance to scratching (must be treated)
Low resistance to chemicals or organic solvents such as concentrated acid, aromatic
hydrocarbons, halogens, and ketones (must be treated)

https://www.emcoplastics.com/polycarbonate-sheet/
Pros
High impact strength and exceptional strength retention at elevated temperatures
High tensile, flexural, and shear strength
High modulus of elasticity
Low deformation under load
Optimal creep and cold flow resistance
Low coefficient of thermal expansion
Excellent electric insulation properties
Easy to fabricate and machine

Cost

WATCH https://www.youtube.com/watch?v=sgSz7DKGGik

Polylite Company
Polycarbonate Twinwall Sheet (P300 - P8500) (wider range of sizes)

https://olympus.com.ph/15-polycarbonate-sheets
South East Asia Olympus Marketing Incorporated
Sunshield Twinwall Plain Polycarbonate Sheets (P2040 - P8400)
Sunlite Twinwall Polycarbonate Sheets (P1830 - P3670)
Sunshield Vintage Circular Corrugates Sheets (P1200 - P2400)
Sunshield Solid Polycarbonate Shield (P2150 - P4850)

Maintenance Requirements
AC Plastics Incorporated (n.d.)
https://www.acplasticsinc.com/informationcenter/r/polycarbonate-sheets-cleaning-care
Do not use improper cleaners and improper cleaning techniques which includes cleaners with
ammonia such as Windex and the use of dry towels which may rub dirt and dust to the surface of
the sheets and scratch them.
1. Remove all dust and dirt
2. Use a soft cloth
3. Use warm water and a gentle dish detergent
4. Treat with UV protective formulas to be able to withstand constant exposure to the UV rays
from the sun