Technical and Installation Guide - Solid Polycarbonate

TECHNICAL AND INSTALLATION ADVICE
FLAT SOLID POLYCARBONATE SHEET

All the information in this Technical and Installation advice guide is
provided for guidance only and is given in good faith, but without
warranty or guarantee of any kind, whether implied or expressed.
It must be understood that The Polycarbonate Store has no control

over how the information in this document is perceived and
interpreted and therefore cannot be held responsible for any resulting
fabrication or product failure, howsoever caused.
Statutory regulations regarding health and safety of operative’s

personnel should be strictly adhered to. The Polycarbonate Store
cannot be held responsible for any failure to comply with them. This
statement does not affect your statutory rights.
The Polycarbonate Store policy is to continually improve products,

therefore methods, materials and changes of specification may be
made from time to time without prior notice.
This guide is given in good faith and changes may be made without
prior notice
TECHNICAL INFORMATION
OVERVIEW
Widest range of clear flat polycarbonate roof panels,

glazing and sign & display solutions
Flat solid polycarbonate sheets are an excellent alternative to glass for a

wide range of applications as they are 200 times stronger and weigh less
than half. The Polycarbonate Store offers flat polycarbonate sheets for these
applications.
PROPERTIES
Ÿ High impact strength

Ÿ Glass like transparency
Ÿ Wide range of product variations
Ÿ Excellent range of sizes and
thicknesses
Ÿ Wide temperature service range
Ÿ Dimensionally stable
Ÿ Easy to fabricate
Ÿ Excellent electrical properties
APPLICATIONS
Ÿ Anti-vandal glazing
Ÿ Rooflights
Ÿ Walkways
Ÿ Security glazing
Ÿ Barrel vaults
Ÿ Balustrades
Ÿ Transportation
Ÿ Street furniture
Ÿ Machine guards
Ÿ Low level glazing in public places
Ÿ Replacement windows
TECHNICAL INFORMATION
Weight
The specific gravity of Polycarbonate sheets is 1.2, which
is about half that of glass.
The following table compares the weight of
Acoustic Properties
Polycarbonate sheets have excellent sound insulation
properties as indicated in the table below. The ability to
absorb sound waves, together with its impact resistance,
has made Polycarbonate widely used for clear acoustic
barriers.
GENERAL INFORMATION
How To Cut Polycarbonate

Polycarbonate sheets come in all different sizes and a thickness. So
when it comes to your individual projects you'll often need to cut them
down to size. Below is a step-by-step guide to help you re-size your
sheets effectively.
What you will need:
Ÿ Either a fine-toothed handsaw or jigsaw

Ÿ Clamps
Ÿ Tape Measure
Ÿ Straight Edge
Ÿ Safety Goggles and gloves
Ÿ Pencil
Method:
1. Measure out the size of polycarbonate sheet you require and using the
straight edge, mark out the lines to be cut.
2. Place the sheet on a stable surface and clamp down. We recommend
to use a timber block to cushion the impact of the clamp.
3. Begin cutting. Polycarbonate is a material that is very easy to cut so
you won't need to worry about splintering or cracking- just let the blade
do all the work.
4. When you've finished, firmly tap the sheet to remove any excess
debris.
5. Peel back the protective film.
GENERAL INFORMATION
Drilling Holes In Polycarbonate

Standard wood working drill bits are suitable for drilling holes in
polycarbonate sheet. Be sure to use another piece of material (scrap
wood or acrylic is perfect) underneath the panel to act as a backstop.
This will ensure the drilling will not blowout the panel as the drill exits
the material.
Do not under any circumstances use a centre punch on a polycarbonate

panel, it’s very likely to cause damage. It’s a good idea to start by drilling
a small pilot hole to help locate the drill.
Be patient and drill at a steady speed and pause regularly to remove any
swarf collecting around the drill, not doing so is likely to cause over
heating and in turn will damage the hole.
When approaching the other side of the panel, continue to drill through
it and into the backstop to ensure the exit hole does not splinter.
Cleaning Polycarbonate
Start by blowing and brushing any loose dirt and dust from the
polycarbonate sheet.
With a mild solution of lukewarm water and a drop of standard washing

up liquid use a soft cloth to wipe clean any stubborn dirt and grime.
Gently rinse with clean water before dabbing dry with a mircofibre cloth
to ensure water spots do not develop.
Polishing scratches
Specialist polish can be used to polish out fine scratches from
polycarbonate sheet, however T-cut car polish achieves great results too.
INSTALLATION ADVICE
REPLACEMENT GREENHOUSE WINDOWS
Replacement Solid Polycarbonate

Greenhouse/ Shed Windows
1.Measure the dimensions of the window frame to make sure you get the
perfect fit
2.Gather together your equipment - a putty knife or old butter knife,

heavy duty work gloves, tape measure, razor blade, some glazing points,
window putty or adhesive silicone sealant, plus your polycarbonate
replacement panes
3.It makes sense to protect your eyes with goggles, just in case, and
cover the floor beneath your working area with newspaper
4.Remove the broken glass and sweep up all the broken bits – that's why
you need thick work gloves. If there's old glass stuck in the frame take
great care, gently hooking out the biggest shards first. and the small ones
last. If it's stuck fast, you can often get a pane out by gaffer-taping over
the outside of it, making sure all the shards are taped, then using a
hammer to gently dislodge the pane. Goggles and gloves are a must at
this stage
5.Loosen all the old putty using a putty or butter knife, making sure you
get it all off to leave a clean surface. You can shave off any awkward
scraps using a razor blade or craft scalpel
INSTALLATION ADVICE
REPLACEMENT GREENHOUSE WINDOWS
6.Remove the old glazing points and make sure you have a smooth, even
and clean surface to fix the new pane to, otherwise you'll compromise its
structural integrity
7.Evenly apply putty or adhesive silicone sealant all around the edge of
the frame, creating a uniform look
8.Gently press the new pane into the putty or sealant, using glazing
points to make it sit squarely in the frame - 2 -3 glazing points on each
side of the frame is good, more if the pane is a big one
9.Apply a final layer of putty or sealant evenly along the entire frame and
give the outer edge a neat 45-degree angle, using the face of your knife
blade. This helps protect the junction and frame itself from condensation
and rain
10. Remove any debris then let the putty or sealant dry fully.
INSTALLATION ADVICE
SECONDARY GLAZING
Secondary Glazing
Polycarbonate secondary glazing is the most simplest, affordable and
successful way to draught-proof a Sash window.
This provides a cheap and easy option for draught-proofing leaky

windows, and one that also looks attractive.
The polycarbonate sheets can be stored under a bed during the

summer, and attached to the window frames with magnetic strips
during the winter. The magnetic strips (usually provided in dark
brown/black) can be gloss painted to match the window frames to
blend in with your window frames when not in use.
Sizing up the polycarbonate
The polycarbonate will need to seal the window completely, so needs

to be stuck to a flat surface around the edges of all moving parts. This
is obviously easier for some windows than for others. If there is not
currently a flat surround to the window, you may be able to work
around this by adding a baton, or fitting a small additional frame
around the edge.
Leave the protective coating on the polycarbonate for as long as

possible to prevent scratching.
INSTALLATION ADVICE
SECONDARY GLAZING
Fixing in place
Fixing the magnetic strips onto the windows/frames is very straight

forward, but needs care to ensure that there is an exact fit. The best
approach is to stick the strip to the polycarbonate first, place the
corresponding magnetic strip on top, and stick to whole thing to the
window frame so you know that the sections will match up exactly.
When sticking in place, take care to ensure the magnetic strip is

aligned exactly to the edge of the polycarbonate, so it follows a
straight line. The glue is very strong and difficult to remove once stuck
on, expose just a small section of tape at a time, and press firmly into
place before moving on.
The easiest thing to get the polycarbonate sheets on and off is a plastic
suction cup – when applied by a corner of the window it is strong
enough to lift this off, so you can peel the remainder back.
INSTALLATION ADVICE
SECONDARY GLAZING
Fabrication
The Polycarbonate Store has a team of fabrication specialists with

years of experience turning customers designs into real masterpieces.
We can fabricate many types of plastics from Acrylic, Polycarbonate,

PETG, Aluminium Composite and many more.
We work with many types of projects from a single display stand to a

full production run of leaflet holders.
To request a free quotation, simply send your requirements/ drawing

to sales@thepolycarbonatestore.co.uk.

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TECHNICAL AND INSTALLATION ADVICE

FLAT SOLID POLYCARBONATE SHEET

It must be understood that The Polycarbonate Store has no control

Statutory regulations regarding health and safety of operative’s

The Polycarbonate Store policy is to continually improve products,

Widest range of clear ﬂat polycarbonate roof panels,

Flat solid polycarbonate sheets are an excellent alternative to glass for a

Ÿ High impact strength

How To Cut Polycarbonate

What you will need:

Ÿ Either a ﬁne-toothed handsaw or jigsaw

Drilling Holes In Polycarbonate

Do not under any circumstances use a centre punch on a polycarbonate

With a mild solution of lukewarm water and a drop of standard washing

Replacement Solid Polycarbonate

2.Gather together your equipment - a putty knife or old butter knife,

This provides a cheap and easy option for draught-prooﬁng leaky

The polycarbonate sheets can be stored under a bed during the

Sizing up the polycarbonate

The polycarbonate will need to seal the window completely, so needs

Leave the protective coating on the polycarbonate for as long as

Fixing the magnetic strips onto the windows/frames is very straight

When sticking in place, take care to ensure the magnetic strip is

The Polycarbonate Store has a team of fabrication specialists with

We can fabricate many types of plastics from Acrylic, Polycarbonate,

We work with many types of projects from a single display stand to a

To request a free quotation, simply send your requirements/ drawing

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