Polycarbonate Sheets – The Complete Buying Guide

Whether you are building a conservatory, creating a lean to roof or roofing your garden pergola, polycarbonate sheeting will likely be one of the top roofing options you will consider. As a lightweight and stronger alternative to glass, polycarbonate is a cost-effective glazing solution that is easy to install whilst creating a stunning finish.

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Buying polycarbonate sheeting online or in-store can be overwhelming so in this buying guide we are going to cover everything you need to know when purchasing polycarbonate roof sheets for your project. We are going to cover common questions about choosing polycarbonate for your project, comparing alternatives, installing polycarbonate and more!

Click on the sections below to skip down to the section you are interested in:

Polycarbonate Sheeting Overview

What is polycarbonate sheet?

Polycarbonate Sheeting is popular compared to other lower grades of plastic sheets, such as Pet G and Acrylic, due to its durability and installer-friendly properties. Polycarbonate is a thermoplastic sheet that was first discovered in the mid-s but only really came into more mainstream use in the early s when more modern technologies allowed it to be manufactured with crystal clear clarity! Prior to this polycarbonate was made with a brown tint, or cognac coloured as they called it.

Fast forward to today and polycarbonate sheeting is one of the most popular plastic sheets manufactured and used in millions of applications globally every year.

Where can polycarbonate be used?

Due to Polycarbonate&#;s unique mix of qualities, it is one of the most versatile materials you will find. It can be used in a wide range of applications both at home and commercially, from canopy glazing to carports to cloches! Since the spread of Covid, people will have been used to seeing it being used as cough screens and protection barriers in shops, offices and public areas more regularly, however, polycarbonates most common use is a roofing sheet. Popular places where polycarbonates sheet is used include:

• Lean tos
• Canopies
• Pergolas
• Porch Roofs
• Greenhouses
• Carports
• Verandas
• Cold frames
• Potting sheds
• Orangeries
• Shelters

Polycarbonate sheeting also is used on many other glazing projects such as stadium dugouts, screening, car wash bay screens and a host of more unique uses! This is why it is unbeatable as a glazing sheet option.

What types of polycarbonate sheeting are there?

Broadly speaking there are two main types of polycarbonate sheets which are solid polycarbonate and multiwall polycarbonate. When considering multiwall polycarbonate, it is often split into Twinwall polycarbonate sheets and multiwall polycarbonate sheeting, however, in essence, these are the same, just different quantities of internal walls!

Both types of polycarbonate sheeting as equally as durable and easy to install meaning the choice between them is more about looks, budget and strength.

What is Solid Polycarbonate?

In a nutshell, solid polycarbonate is a plastic sheet that looks like glass but is a stronger and lighter alternative. At up to 200x stronger than standard glass of the same thickness, solid polycarbonate has the &#;glass look&#; but is virtually unbreakable and only weighs half as much as glass.

Solid Polycarbonate sheets come in a range of thicknesses from 2 to 12mm with the 6mm thickness tending to be the most popular and widely used. To suit different applications, solid polycarbonate is manufactured in a range of tints including clear, bronze, opal, black and patterned.

What is Multiwall polycarbonate sheeting?

Multiwall polycarbonate sheets are manufactured from various layers which create a honeycomb type structure. Ever popular, multiwall sheeting is the most common type of polycarbonate sheeting due to its affordable cost and superior thermal insulation. Much like Solid Polycarbonate sheets, multiwall polycarbonate comes in a range of tints including clear, bronze and opal. The most popular thickness of multiwall polycarbonate is 16mm, however, we also manufacture multiwall bigger thicknesses of 25mm and 35mm.

What is Twinwall Polycarbonate?

Twinwall polycarbonate is identical to multiwall polycarbonate but just has two layers rather than multiple layers &#; as the name suggests! Twinwall polycarbonate is available in a range of three thicknesses including 4mm, 6mm and 10mm giving different strength options for different types of roofs.

Primarily used for smaller projects, the Twinwall polycarbonate comes in clear mainly but also opal and bronze in the 10mm thickness. It is worth noting that 4mm and 6mm polycarbonate sheets are not recommended for roofing projects but rather as cost-effective plastic sheeting for smaller garden applications like cloches and cold frames.

Polycarbonate Sheeting Pros & Cons

Benefits of Polycarbonate Sheeting

Both solid and multiwall polycarbonate roofing sheets provide a wide range of benefits for installers making them an excellent choice for a variety of roof projects.

• Virtually unbreakable
• Lightweight
• Easy to cut and drill
• Long-lasting clarity - UV Protected
• Insulating
• Fire-resistant
• Sustainable

Virtually unbreakable: A key benefit of polycarbonate sheets is their robustness and impact resistance which means they are virtually unbreakable! Be aware most plastics are not like this as, unlike acrylics and other plastic sheeting, polycarbonate can be hit with a base bat or football and survive! Homeowners can comfortably install polycarbonate, more so solid sheets, without worrying about the fragility to hail or a stray football coming from the garden!

Lightweight: Ease of installation is a key consideration when you are choosing a roofing sheet to use and a big part of that is weight. Heavy options like glass can cause handling challenges, especially when high up on a roof. Solid polycarbonate is around half the weight of glass of the same thickness and multiwall polycarbonate around is 1/10 the weight of glass of the same thickness! For example,

Glazing Type 6mm Glass Axgard 6mm Solid Polycarbonate  Axiome 25mm Multiwall Polycarbonate Approx. Weight Per Square Metre 15 kg 7.2 kg 3 kg

Easy to cut and drill: Another area polycarbonate shines in is how easy it is to cut and drill. Polycarbonate is undoubtedly the easiest plastic sheet to cut and drill. No need for installers to worry if a sheet is needing to be trimmed down as it can be down easily and neatly. Read on to find out how to cut polycarbonate and how to drill polycarbonate in later sections. Clear Amber Shop can also cut to size for you if you are still unsure.

Long-lasting clarity: UV Protected: Proper UV protection is important on clear roofing sheets to ensure long lasting clarity and light transmission. All our polycarbonate sheets, Twinwall, multiwall and solid, are UV protected on one or two sides to give a great roof lifespan! UV protected sheets are not to be confused with UV stable or UV resistant which are seen on some sheets (like PVC) and aren&#;t as effective. You may well have noticed cracked and mouldy bus stops and bike shelters in your area when non-UV protected plastic has been used and the difference is stark!

Insulating: Polycarbonate naturally retains heat very well and so has great thermal insulation qualities. Multiwall polycarbonate in particular provides great levels of thermal insulation, making it ideal for lean to home extension and conservatories. In general, the bigger thicker gauge multiwall sheets offer higher insulation levels.

Sustainable: Polycarbonate has a great lifespan and the plastic roof panels are fully recyclable once finished!

Fire-resistant: Polycarbonate is fire resistant and unlike acrylic is self-extinguishing.

How long do polycarbonate panels last?

A well-maintained polycarbonate roof can last between 10 and 20 years! Ensuring your roof will last its full expected lifespan is dependent on using the correct glazing bars and installation methods. It is well worth investing a little more time and money into purchasing the correct fixtures and fixings before starting your project.

Is Polycarbonate UV Protected?

Yes, multiwall and solid polycarbonate comes UV protected as standard. We often get asked: &#;Why is UV protection required on plastic sheets?&#;. UV protection is essential to protect roofing sheets from going brittle or yellowing over time.

All our Solid Polycarbonate Sheeting is UV Protected on both sides to give a high-quality finish. Our Multiwall Polycarbonate is UV protected on the outer side so it should always be installed with that that side out towards the sun.

What are the disadvantages of polycarbonate?

There are honestly very few disadvantages to polycarbonate sheets which is why it is a popular roofing solution for DIYers and trade. The only disadvantage is that it can scratch if not handled carefully. This isn&#;t a deal breaker because solid polycarbonate sheets come with sheet protective film on both sides to help protect it whilst you are installing. Once installed you simply peel the protective film off.

Does polycarbonate crack?

No! Polycarbonate is a very robust plastic so is virtually unbreakable. The Solid type of polycarbonate is often used in high impact scenarios such as vandal-proof shelters, riot shields and prisons etc. There is no need to worry about your roof panels shattering when installing polycarbonate on your roof!

Can you bend polycarbonate sheets?

Yes, polycarbonate sheeting can be bent and installed on a curved roof. It is quite easy to install with curved glazing bars on a wide range of radii. Common curved installations include bike shelters, barrel roof lanterns and greenhouses. As a rule of thumb, the thinner gauge sheets bend more easily.

Choosing Polycarbonate Sheeting

Polycarbonate Versus Glass

Glass is still a popular glazing choice for many projects due to its high clarity and clean modern style. However, if you are looking to achieve the clean &#;glass look&#; on your glazing then there are actually glazing sheet options two options: solid polycarbonate or glass. Solid polycarbonate sheeting is increasingly becoming a more popular alternative to glass panels due to its similar style but wider range of benefits.

 Polycarbonate

Glass

High clarity High clarity Virtually unbreakable - 200x stronger Fragile Light - 50% less or more Heavy Easy to Cut and Drill Difficult to cut and drive Low to medium cost High cost Wide range of sizes  Limited sizes on standard delivery Vulnerable to scratches (if badly handled!) Scratch Resistance Degree of flexibility Rigid

Weighing up the pros and cons of glass versus solid polycarbonate roofing sheets, it is clear to conclude that for domestic projects solid polycarbonate is the better choice. Reduced installation challenges and ease of handling make polycarbonate a no-brainer for home and garden projects like pergola lean-tos, verandas and oak gazebos.

Even on commercial projects, solid glazing sheets have become a viable alternative to the inconveniences and costs of installing glass sheets.

Multiwall polycarbonate versus Solid Polycarbonate

Deciding between multiwall and solid polycarbonate sheets is easy as they have distinct pros and cons. Generally, solid polycarbonate glazing is considered a more premium option for a quality finish and multiwall is a more economical option for those on tighter budgets. Both are an installer&#;s dream, being easy to install, cut and handle.

Solid Polycarbonate

Twinwall and Multiwall Polycarbonate

££

£

High Clarity (glass look)

Medium Clarity

Limited thermal insulation

Great thermal insulation (especially thicker gauges)

5 tint options

3 tint options

Medium Weight

Lightweight

 

For exterior options, if you are looking for a first-class finish that will elevate your home then solid polycarbonate offers unbeatable value.

What are the differences between Twinwall and Multiwall?

Twinwall and Multiwall polycarbonate sheets are the same types of sheet, however, as the name suggests have varying quantities of internal walls. The reason sheets are made with internal walls is to enhance their strength and insulation factor.

Twinwall Polycarbonate Sheeting is extruding with two external layers and internal connectors. On the other hand, multiwall polycarbonate sheets have two external layers and then multiple internal layers, ranging from 3 layers total upwards.

The thicker the sheet the more walls they tend to have. 4mm, 6mm and 10mm thickness are considered to be Twinwall and 16mm, 25mm and 35mm are Multiwall. Thicker gauge sheets have better thermal insulation (lower U Value) Also thicker multiwall sheets tend to have greater sound reduction compared to the thin 6mm and 10mm, although this is less of a factor.

What thicknesses are polycarbonate sheets made in?

We manufacture Twinwall and Multiwall polycarbonate sheeting in a range of thicknesses including 4mm, 6mm, 10mm, 16mm, 25mm, and 35mm. Solid Polycarbonate is available in a wider range of thicknesses including 2mm, 3mm, 4mm, 5mm, 6mm, 8mm, 10mm and 12mm. There is plenty of choice no matter the application!

What is the best thickness of polycarbonate roofing?

The best thickness of polycarbonate sheet for your roof entirely depends on the type of roof you are constructing. However, as a guide, our 6mm Axgard Solid Polycarbonate sheets and 16mm Multiwall Polycarbonate sheets tend to be the most popular thicknesses of each type. 

In the next section, we give a few common application types for each thickness as an approximate guide.

What thickness of polycarbonate should I use?

When choosing a polycarbonate sheet thickness there are two main factors to bear in mind; strength and insulation. Quite simply, the thicker the sheet the greater the strength and higher the thermal insulation. It is worth noting that thermal insulation is more of a consideration when using multiwall type sheets. Here are some common uses for each thickness:

Solid Polycarbonate

2 mm &#; Wall protection, Secondary glazing

3 and 4mm &#; Screens, Bike shelters, curved dugouts, shed windows

5 and 6mm &#; Oak Pergolas, canopies, lean tos, gazebo glazing

8,10 and 12mm &#; lean tos, verandas

Multiwall Polycarbonate

4mm &#; cloches and temporary glazing (not suitable for roofing applications)

6mm - cold frames and greenhouses (not suitable for roofing applications)

10mm &#; potting sheets, pergolas

16mm &#; lean to, gazeboes, canopies, carports

25mm &#; lean to extension, garden buildings

35mm &#; conservatory roofs, orangeries, extensions

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At the end of the day when choosing the best sheet thickness for your project it is always dependent on your project&#;s factors, such as the location, wind loading, exposure, structure etc, so you are always best to make a judgement based on your project!

Which colour polycarbonate sheet is best?

When choosing what colour polycarbonate is best for you roof the three points to considering are the light transmission, heat rejection and visual appearance.

Light transmission simply means how much light is let through by the sheets. Clear sheeting has the greatest light transmission (and clarity) which is why it tends to be most popular. Then Bronze has less and opal the least light transmission.

Bronze and opal sheets are opposites with bronze reducing sun glare and creating shader and opal sheets providing some heat rejection and a clean white glow. Check the overview tables below for a complete comparison.

To learn more about the solid Axgard Glazing Sheet tint options compared to glass please read our &#;Glass or Plastic Sheets &#; Which is Best?&#; Blog.

Where to buy polycarbonate sheeting

Installers often search for polycarbonate sheets near me however, with the fast paced improvement of ecommerce your best option for ordering polycarbonate sheeting is online. With the widest range of sizes and rapid delivery direct to your door Clear Amber Shop makes ordering your roofing sheets hassle free.

To order, simply choose from our range of Multiwall or Solid sheets, add the required glazing bars for your project and then place via our checkout. With a nationwide delivery network your order will be with you in a couple of days from placing the order!

Have an unanswered question about polycarbonate sheets?

Simply jump on our Live Chat or via   where our Teams will provide you with all the advice and support you require for your project.

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Our Teams are here to support help you with every step of your project!

The method of joining polycarbonate roofing sheets is often misunderstood by DIYers, when they want to cover a structure they have created, due to the number of factors involved. However, joining your polycarbonate sheet correctly is the most important point in ensuring a long-lasting installation as it is integral to the strength and durability of the roof.

There are many aspects to consider when deciding which polycarbonate joiners to use but here are the top 6 points you should consider before joining your roofing sheets. Click to jump a question to  

This article will help make each of these key points clearer and hopefully help you get the best out of your roof structure!

Before jumping into the main factors, it will be helpful to clarify as we often get asked; what is a glazing bar? A glazing bar is simply a strip designed to join polycarbonate sheets and secure them down to your roof rafters or self support the sheets over a span between two beams or structures. Glazing bars are most commonly manufactured from aluminium or PVC, with aluminium being the stronger option.

Other common names for glazing bars you may hear in the trade are polycarbonate sheet joining strips, h sections or h sections and roof sheet caps &#; which are all just other names for a glazing bar!

Which type of glazing bar to use?

There are two types of glazing bar systems available for joining polycarbonate sheets:

• Self Supported Glazing Bars
• Rafter Supported Glazing Bars

The most common application we find is that installers have already created a structure out of wood or similar material so there is a base that can be worked off. When there is a structure in place, you should use rafter supported glazing bars. Timber rafter glazing bars are available as Aluminium rafter Glazing Bars or PVC snap down glazing bars. Aluminium Glazing bars are stronger and high quality so often used for conservatory roofing whereas PVC glazing bars are budget and used for garden and DIY projects.

Where there is no structure in place, you will need to use a Self-Supporting glazing bar system which can span unsupported from two beams. A heavy duty self support glazing bar provides the structure for your polycarbonate roofing sheets to sit on, removing the need for supporting rafters.

As self supporting bars for polycarbonate, like 16mm Twinwall polycarbonate sheets, are manufactured from aluminium it can seem a more expensive option compared to a wooden structure but with the way the price of timber has increased over recent months it may actually prove as cost effective!

Whatever the type of structure you have in place, the joins need to support the full length of your roofing sheets.

Which type of joiner is best - Plastic or Aluminium Glazing Bar?

Aluminium Rafter Glazing Bars are typically most popular for medium to large projects at home and commercial projects where roof lifespan and quality are key factors. Popular applications for aluminium joiners include pergolas, gazebos and conservatories where their slim clean style stands out. More reasons to use aluminium bars are:

• Colour Options - The main benefit of aluminium sheet joiners versus PVC sheet joiners, beyond durability, is that aluminium glazing bars are available in white or brown and also can be coated in any colour!
• Long lifespan - The expected lifespan of the aluminium glazing bars is 20 years plus which means you have a durable, long-lasting option. No one wants to spend money on a project that is going to have to be re-done in just a few years.
• Ease of installation - Aluminium glazing are easy to install with any thickness of Solid or multiwall polycarbonate sheets

PVC Snap Down glazing bars are used where structures are maybe smaller and where budget is a key factor. Because plastic is a readily available material in today&#;s world and not as durable the cost of a PVC glazing bar is less than an aluminium glazing bar. One benefit of PVC sheet joiners is that they come in one colour &#; white &#; which makes for easy decision making!

As with the Aluminium bar systems, the PVC glazing bars are very easy to install and have an expected lifespan of 10 years which means it is a viable option to consider. PVC glazing bars will be more susceptible to weathering just because of the material they are manufactured from.

Are you joining Multiwall polycarbonate or Solid Polycarbonate?

There`s no huge difference in the method of joining solid polycarbonate sheets versus twinwall or multiwall polycarbonate sheet; both can be easily secured and installed. However, there are a couple of key points of difference that you need to think about:

Multiwall or Twinwall Polycarbonate Sheeting gives you more glazing bar options as you can use budget PVC Glazing bars which are snap fix so perfect for those with only a little DIY experience. The snap fix glazing bars are designed to snap to a certain thickness, for example 16mm or 25mm, so can be used exclusively with the multiwall polycarbonate sheeting.

This isn&#;t to say that the Aluminium Glazing Bar System can&#;t be used with your polycarbonate roofing sheets! In fact, aluminium glazing tends to be more popular in medium to large domestic projects and commercial projects due to its high quality and longer lifespan. With the aluminium glazing bars, you can get them in any RAL colour you like so where you have bronze or opal polycarbonate you can have matching aluminium rafter bars &#; or you can go to another colour completely!

Both glazing bar ranges have all the items you will need from Top wall Flashing, Wall Glazing Bars, to Joining/Glazing Bars and Drip trim.

Solid Polycarbonate Sheeting can only be installed with compatible aluminium glazing bars because this type of sheet, being a solid sheet, is heavier compared to multiwall polycarbonate therefore a heavier duty joining bar is required. As the weight is higher per square metre you will need a heavier-duty glazing bar and that is where popular ranges like the Alukap-XR and Alukap-SS step in. Unlike PVC Glazing bars these systems can work with any thickness of polycarbonate sheeting, including the most popular 6mm thickness.

If you are sheeting over a curved roof structure both types of polycarbonate sheets can be used, however, you will need to use a rafter support aluminium glazing bar system that is suitable to be curved to a radius. Alukap-XR Curved Glazing Bars are commonly used on roof lanterns, bike shelters, dug out shelters, curved roof lights and station canopies!

Alternative ways to join polycarbonate sheets

Can you screw Roofing Sheets down?

No, it is not recommended to screw polycarbonate sheets down to secure them. This is because the screws only secure that particular point of the sheet and not down the join the whole length of the plastic sheet, therefore, meaning your roof is less secure and can be damaged easily in storms.

Also, another risk when screwing roofing sheets down is if the roofing sheets aren&#;t fitted correctly with screws they can easily warp under expansion and contraction which can cause waterproofing problems further down the line!

In general, polycarbonate fixing buttons are used on cross purlins on wider sheets as a secondary fixing to reduce the risk of wind uplift. For every application it is always recommended to use a joining bar as the primary fixing method.

Can you join polycarbonate sheets with glue?

No, although gluing polycarbonate sheets may sound like a simple way to install it is not recommended as will have little strength against wind uplift or snow loading.

The best thing to create a long-lasting roof is to install the sheets using glazing bars. If you are using glue to seal around the side or ends of your polycarbonate roofing sheets then use a compatible LMN silicone sealant (Low Modulus Neutral Cure). 

How to secure the edge or gable of a polycarbonate roof?

Generally, there are two ways a roof will finish on the side &#; either it&#;s up against another structure such as a wall or it will be open sided.

It&#;s important to finish this area correctly to protect against potential wind uplift, for waterproofing (if it&#;s against a wall) and also to help create a neat finish on the outside edge where it is visible. This is an area that has previously been hard to complete due to there either being only Lead Flashing, which works to a degree, or there were complicated, fiddly trims which were a nightmare to fit.

Thankfully, we have created innovative products to combat these and also ease installation!

For an open structure such as a Pergola, you would use a Gable bar for the sides of your roof. This easy to install innovation is manufactured in both PVC, Aluminium rafter supported and Aluminium self-supporting. What these Gable Bars achieve is an extremely simple way to finish the edge of the roof whilst securing the roofing sheet, keeping the waterproof properties, and keeping the style consistent across your roof.

Where the structure is up against the wall you should use a wall glazing bar to seal the side effectively and ensure the majority of water drains down off your roof rather than down the side of the wall. Traditionally this would have been a difficult, potentially ugly area to complete but now, with the Side Wall Bar, this is easy-to-finish with the same glazing bar style. Again the wall bar is available in PVC, Aluminium rafter supported and Aluminium self-supporting.

In conclusion &#; what is the best way to join the Polycarbonate Sheets?

The best way to join polycarbonate roofing sheets is with a glazing bar. Glazing bars primary come in PVC or aluminium options and are designed to make installation easy. Never think just using enough screws in the roof is a substitute as even with a large number of fixings a roof can easily uplift if not secured down with glazing bars as the primary fixing method.

In summary, joining your roofing sheets is one of the most important areas in creating a durable structure. They complete the roof, help create the look you want but most importantly are key to creating the durable structure you need. Available in either long-lasting Aluminium, or Plastic these glazing bars, or joining bars, are what you need to join your polycarbonate roofing sheets.

They are designed to be the main fixing point in the roof compared to screws which unfortunately don&#;t meet the requirement as they are a secondary fixing method.

Want to learn more about installing polycarbonate sheets?

To help make it easier for you, we have a range of How2 Install Videos available and on the Clear Amber YouTube Channel that are simple to follow and cover many essential installation stages. Also on the Product Pages, there are Technical Guides and Installation Guides with all the details if you prefer non-video style instructions!

Our Teams are also happy to assist on our Live Chat or you can   where we will provide you with all the advice and support you require for your polycarbonate project.

If you want to learn more, please visit our website Polycarbonate Solid Sheet.