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POLYCARBONATE SHEETING
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©2004 Sheffield Plastics. The material contained in
this course was researched, assembled, and
produced by Sheffield Plastics and remains their
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should be directed to the instructor.
©2004
119 Salisbury Road
Sheffield, MA 01257
Telephone: 877-413-7957
Fax: 413-229-4066
E-mail: [email protected]
Internet: www.sheffieldplastics.com
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Slide 1 of 52
• About the Instructor
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Polycarbonate Sheeting
Polycarbonate Sheeting
Presented By:
Doug Mahler
Sheffield Plastics, Inc
119 Salisbury Road
Sheffield MA 01257
Description:
Learn the advantages of polycarbonate sheet products over
other glazing products. Learn what it is and how it can
improve safety in certain applications.
AIA/CES Info:
Provider No. J624 – Course # AEC006; LUs – 1
MCE Info:
Contact your respective governmental licensing & regulatory
agency.
Expiration date:
February 28, 2005
©2004
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Slide 2 of 52
• About the Sponsor
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Polycarbonate Sheeting
How to use this Online Learning Course
•
Read and review the material contained in this seminar.
•
To view this presentation, use the previous/next keys on each slide or the up and
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•
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Slide 3 of 52
• About the Sponsor
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Polycarbonate Sheeting
Learning Objectives
At the end of this seminar, participants will have a better understanding of:
•
What is polycarbonate sheeting
•
The advantages of polycarbonate sheet products over other glazing
products
•
How polycarbonate products can be used to improve safety in certain
applications
•
How to specify the appropriate qualities of polycarbonate sheeting in
various applications
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Slide 4 of 52
• About the Sponsor
• About the Instructor
• Seminar Discussion Forum
Polycarbonate Sheeting
Polycarbonate is All Around You
•
•
•
•
•
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©2004
DVD’s
Compact Discs
Water Bottles
Eyewear
Appliances
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Slide 5 of 52
• About the Sponsor
• About the Instructor
• Seminar Discussion Forum
Polycarbonate Sheeting
Polycarbonate Sheeting Extrusion Process
HOT AIR
FOR DRYING
FEED
HOPPER
COOLING &
FINISHING
ROLLS
SOLID
POLYMER
SPEED
REDUCTION
UNIT
EXTRUSION
SCREW
MOLTEN
POLYMER
AIR
COOLING
AREA
ADJUSTABLE
SLOT DIE
TO HAUL
OFF OR
CUT OFF
UNIT
DRIVE
MOTOR
SUPPORT STAND
IDLER
ROLLS
PULL OFF
ROLLS
Basic sheet extrusion diagram. Plastic beads are fed into the hopper and gravitationally
drawn down into the heated screw barrel where the plastic becomes molten and is
pushed forward towards the die. The opening of the die is adjusted to the desired
thickness of sheet being produced and then goes through a series of rolls that polish the
surface of the sheet. The sheet then is air cooled, inspected, masked and packaged.
Human hands never touch the sheet during the extrusion process.
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Slide 6 of 52
• About the Sponsor
• About the Instructor
• Seminar Discussion Forum
Polycarbonate Sheeting
Distinctive High Performance Properties
• Impact resistance
• Excellent clarity
• Flame resistance
• Dimensional stability
• Light weight
• Weathering
• Ease of fabrication
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Slide 7 of 52
• About the Sponsor
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Polycarbonate Sheeting
Impact Resistance
There are several ways to test the impact strength of glazing
materials, including ASTM D3763, instrumented impact resistance
using the Dynatup impact tester.
Polycarbonate is one of the most impact resistant glazing
materials available and at 1/4" thickness resists over 200 foot
pounds of force.
Over
200
7.5
3.5
2.5
¼”
¼”
Laminate
Glass
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©2004
Tempered
Glass
¼”
Acrylic
¼”
PC Sheet
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Slide 8 of 52
• About the Sponsor
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• Seminar Discussion Forum
Polycarbonate Sheeting
Excellent Clarity
Flexibility abounds with UV resistant polycarbonate. Due to
enhanced UV blocking extrusion technology, UV resistant
polycarbonate has become the product of choice backed by
extensive warranties.
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Slide 9 of 52
• About the Sponsor
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• Seminar Discussion Forum
Polycarbonate Sheeting
Inherent Flame Resistance
Polycarbonate material is one of the least
flammable materials. As with any plastic material,
polycarbonate will burn when exposed to open
flame, however, polycarbonate is self
extinguishing.
This means that when the flame is removed the
polycarbonate will not continue to burn where
other materials will continue to flame and
combust presenting an increased fire risk.
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Slide 10 of 52
• About the Sponsor
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• Seminar Discussion Forum
Polycarbonate Sheeting
Dimensional Stability
• Maintains properties
over a broad
temperature range
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Slide 11 of 52
• About the Sponsor
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• Seminar Discussion Forum
Polycarbonate Sheeting
Lightweight Qualities of Polycarbonate vs Glass
Polycarbonate of equivalent thickness is approximately half the weight of glass.
Thickness
Polycarbonate
lbs./ft.²
Glass
lbs./ft.²
0.080”
0.50
1.02
0.093”
0.58
1.20
0.125”
0.78
1.60
0.187”
1.17
2.40
0.25”
1.56
3.20
0.375”
2.34
4.80
0.500”
3.12
6.40
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Slide 12 of 52
• About the Sponsor
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Polycarbonate Sheeting
Energy Efficient
Unlike glass as the thickness of polycarbonate increases
your insulation (U values) values increase proportionately.
Summer heat gain decreases and winter heat loss
decreases.
Summer
Heat Gain
U Value
Thickness
PC
Glass
PC%
PC
Glass
PC%
1/8”
0.98
1.04
7
1.06
1.16
10
3/16”
0.94
1.04
10
1.02
1.15
13
1 /4”
0.90
1.04
14
0.97
1.14
17
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©2004
Winter
Heat Loss
U Value
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Slide 13 of 52
• About the Sponsor
• About the Instructor
• Seminar Discussion Forum
Polycarbonate Sheeting
Product Grades
• General purpose
• UV enhanced
• Abrasion resistant / UV enhanced
• Polycarbonate security laminates
• Architectural grade multiwall
polycarbonate sheet
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Slide 14 of 52
• About the Sponsor
• About the Instructor
• Seminar Discussion Forum
Polycarbonate Sheeting
General Purpose Polycarbonate Sheeting – Summary
Characteristics & Advantages
Market Areas
Impact resistance
Light weight
Won’t support ignition
UV stabilized
Energy Efficient
Fabricate with standard tools
Machine guards
Plant maintenance / repair
Industrial glazing
Freight doors
Hockey rinks
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Slide 15 of 52
• About the Sponsor
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Polycarbonate Sheeting
UV Enhanced Polycarbonate Sheet
Coextruded layer in highly
UV-stabilized polycarbonate
Standard polycarbonate
General Purpose polycarbonate sheet is UV
stabilized, however, does not offer UV
protection and will discolor over time in
external environments.
To prolong polycarbonates superior
performance characteristics in an outdoor
application, a layer of highly UV stabilized
polycarbonate is co-extruded onto the
surface of the exposed face.
Coextruded
layer
containing
UV absorber
Plastic Sheet
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Slide 16 of 52
• About the Sponsor
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• Seminar Discussion Forum
Polycarbonate Sheeting
UV Enhanced Polycarbonate Sheet
Real Time Outdoor Testing
Accelerated Weathering
– UV exposure
– Moisture
– Temperature variation
Although most standard polycarbonate sheet is UV
stabilized, to protect against physical property loss from
UV exposure, there are polycarbonate products that offer
enhanced UV protection to resist against discoloration
from UV exposure. In addition to real time weathering in
extreme environments such as Arizona desert and south
Florida, accelerated testing is performed using a variety of
machines to simulate long term UV exposure in shorter
time frames.
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Slide 17 of 52
• About the Sponsor
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• Seminar Discussion Forum
Polycarbonate Sheeting
UV Enhanced Polycarbonate Sheet – Yellowness Index
The yellowing of UV protected polycarbonate sheet will not be apparent to the
naked eye until 8% yellowing occurs, far past 5 years. 10-year warranties are
available.
10%
Visible Yellowness at 8 or Greater
9%
8%
7%
6%
5%
4%
UV PC
3%
2%
1%
0%
1
2
3
4
5
Years
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Slide 18 of 52
• About the Sponsor
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Polycarbonate Sheeting
Missile Impact Tests
Test Method
Missile
Value
Large Missile
2” x 4”
Pass/No Penetration
Small Missile
Steel Ball / Gravel
Pass/No Penetration
Dade County, Florida. Actual large
missile impact test being performed.
Note: Test engineer is sitting behind
a polycarbonate wall.
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Slide 19 of 52
• About the Sponsor
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Polycarbonate Sheeting
UV Enhanced Polycarbonate Sheet
What To Specify
•
•
•
•
•
•
•
UV Polycarbonate Cap
Light Transmission
Yellowness Index
Flammability Class
Code Approval
Safety Glazing Standards
Burglar Resistant
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©2004
Integral co-extruded UV layer
≤ ∆ 7 % - 10 years
≤ ∆ YI 10 - 10 years
CC-1 / ASTM D 635
BOCA / UBC / SBCCI / ICC /Dade County
CPSC: 16 CFR 1201, I,II / ANSI Z97.1
UL 972
Next
Slide 20 of 52
• About the Sponsor
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Polycarbonate Sheeting
UV Enhanced Polycarbonate Sheet – Summary
Characteristics & Advantages
Color and surface stability
Long term weatherability
Model building code approval
Cold formable – tight radii
Heat formable
Weathering warranty
Market Areas
Skylights
Sloped / vertical glazing
Barrel vaults
Covered walkways
Hurricane / windstorm / earthquake
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Slide 21 of 52
• About the Sponsor
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Polycarbonate Sheeting
Natural Disaster Mitigation
Polycarbonate and polycarbonate
laminated products offer substantial
protection, far exceeding the
performance of glass in the case of
natural disasters.
Polycarbonate materials are Dade
County approved.
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Slide 22 of 52
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Polycarbonate Sheeting
Hurricane Resistant
Dade County Florida
covered walkway/ barrel
vault. Thermoformed UV
resistant polycarbonate
meets Dade County
approval for this covered
walkway.
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Slide 23 of 52
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• Seminar Discussion Forum
Polycarbonate Sheeting
Design Freedom
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Slide 24 of 52
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Polycarbonate Sheeting
Excellent Light Transmission
Due to the weight savings
vs. glass of equal thickness.
Lightweight, less expensive
framing systems can be used
in many applications.
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Slide 25 of 52
• About the Sponsor
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• Seminar Discussion Forum
Polycarbonate Sheeting
Protection from the Elements
Polycarbonate offers substantial design
freedom vs. other similar materials.
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Slide 26 of 52
• About the Sponsor
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Polycarbonate Sheeting
Brilliant Graphics & Ease of Forming
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Slide 27 of 52
• About the Sponsor
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Polycarbonate Sheeting
Abrasion Resistant Polycarbonate Sheet – Surface
• State-of-the-art
silicone hardcoat
• Nonstick surface
• Dual protection
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Slide 28 of 52
• About the Sponsor
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Polycarbonate Sheeting
Abrasion Resistant Comparison
Test Method:
ASTM D-1044
Uncoated
Polycarbonate:
35.0
Coated
Polycarbonate:
0.8 – 2.0
Glass:
0.5
To protect polycarbonate from UV attack and scratching, a non-stick,
chemical resistant hardcoat is put onto the surface of the sheet. The
hardcoat typically increases uncoated polycarbonates scratch resistance
approximately 8-10 times.
The plastic industries standard method to measure surface hardness is the
Taber Test (ASTM 1044-99). A specimen is placed between two hard
rubber wheels that are embedded with metal flake, a 500 gram load is
placed on the top of the arm and the wheels are rotated 100 revolutions.
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Slide 29 of 52
• About the Sponsor
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Polycarbonate Sheeting
Installation
•
•
•
•
Edge engagement
Gaskets
Sealants
Glazing tapes
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Slide 30 of 52
• About the Sponsor
• About the Instructor
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Polycarbonate Sheeting
Abrasion Resistant Polycarbonate Sheet
• What To Specify
•
•
•
•
•
•
•
•
AR Exterior Coating
Light Transmission
Yellowness Index
Haze
Flammability Class
Code Approval
Safety Glazing Standards
Burglar Resistant
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©2004
Thermal Cure Primer & Topcoat
≤ ∆ 7 % - 7 years
≤ ∆ YI 10 - 7 years
≤ 15%
CC-1 / ASTM D 635
BOCA / UBC / SBCCI / ICC /Dade County
CPSC: 16 CFR 1201, I,II / ANSI Z97.1
UL 972
Next
Slide 31 of 52
• About the Sponsor
• About the Instructor
• Seminar Discussion Forum
Polycarbonate Sheeting
Abrasion Resistant Polycarbonate Sheet - Summary
Characteristics & Advantages
911 Building, San Francisco, CA
Heller-Manus Architects, San Francisco, CA
Surface hardness approaching glass
UV resistance
Chemical resistance
Self extinguishing
Model building code compliance
Dade county approval
Market Areas
Schools
Psychiatric hospitals
Correctional institutions
Hurricane protection / shutters
Transit stations
Municipal & government buildings
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Slide 32 of 52
• About the Sponsor
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Polycarbonate Sheeting
Use in High Traffic/High Abuse Areas
Polycarbonate is a much safer
product to use in high traffic areas
due to its high impact resistance.
This application should specify AR
(Abrasion Resistant).
Stockbridge
School
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Slide 33 of 52
• About the Sponsor
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• Seminar Discussion Forum
Polycarbonate Sheeting
Ease of Replacement
Polycarbonate glazing
can be cut with your
standard rotary or jig
saw on site therefore
eliminating any safety
hazards of a broken lite
and eliminating any
downtime for the
facility.
This application should
specify AR (Abrasion
Resistant) and
Containment Grade 500.
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Slide 34 of 52
• About the Sponsor
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• Seminar Discussion Forum
Polycarbonate Sheeting
Safety
Polycarbonate glazing on light and
heavy rail cars is common due to
polycarbonate being half the weight
of glass and over 200 times the impact
strength.
This application should specify AR
(Abrasion resistant).
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Slide 35 of 52
• About the Sponsor
• About the Instructor
• Seminar Discussion Forum
Polycarbonate Sheeting
Polycarbonate Security Laminates
Threat Levels
Physical Attack
Smash and Grab
High Power handgun
Shotgun fire
Material Grades
Containment
Forced Entry Resistance
Bullet Resistant
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Slide 36 of 52
• About the Sponsor
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• Seminar Discussion Forum
Polycarbonate Sheeting
All Polycarbonate Laminates
Laminated polycarbonate process is done in a clean
room atmosphere, manually. Once the desired
polycarbonate configuration is complete the material is
placed in a bag where the air is vacuumed out then into
an autoclave where the final bonding between layers
occurs. The entire process takes approximately 8 hours.
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Slide 37 of 52
• About the Instructor
• About the Sponsor
• Seminar Discussion Forum
Polycarbonate Sheeting
Polycarbonate Security Laminates
1/8” Abrasion Resistant Sheet
½” Optical Grade
Polycarbonate Sheet
Polyurethane Interlayer Bond
The bonding layer used for laminated polycarbonate is urethane. The urethane
interlayer should be no less than .025” thick, this allows for maximum product
performance.
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Slide 38 of 52
• About the Sponsor
• About the Instructor
• Seminar Discussion Forum
Polycarbonate Sheeting
Polycarbonate Security Laminates
What to Specify:
• AR Exterior Coating
• Light Transmission
• Yellowness Index
• Haze
• Flammability Class
• Code Approval
• Safety Glazing Standards
• Burglar Resistant
• Bullet / Forced Entry
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©2004
•
•
•
•
•
•
•
•
•
Thermal cure primer and top coat
7% change - 7 years
Change in YI 10- 7 years
< or = 15%
CC-1/ ASTM D635
BOCA/ UBC / SBCCI / ICC /Dade County
CPSC: 16 CFR 1201, 1, 2 / ANSI Z97.1
UL 752
UL 752/ HPW TP0500.02 / ASTM F-1233
Next
Slide 39 of 52
• About the Sponsor
• About the Instructor
• Seminar Discussion Forum
Polycarbonate Sheeting
Polycarbonate Security Laminates - Summary
Characteristics & Advantages
AR / UV coating
Multi-shot capability
Light weight
Self extinguishing
No Spalling
No Spider Webbing
Market Areas
Correctional institution
Banks / savings and loans
Check cashing facilities
Embassies
High profile government
facilities
Border stations
Federal Institutions
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©2004
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Slide 40 of 52
• About the Sponsor
• About the Instructor
• Seminar Discussion Forum
Polycarbonate Sheeting
Architectural Grade Multi-wall Polycarbonate Sheet
Next Generation Translucent Daylighting Products
The next generation polycarbonate
for an architectural application is
Multi-wall sheet. The multiple layers
of polycarbonate adds to the
strength of the panel and is
substantially lighter in weight.
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Slide 41 of 52
• About the Sponsor
• About the Instructor
• Seminar Discussion Forum
Polycarbonate Sheeting
Architectural Grade Multi-wall Polycarbonate Sheet
Cold Formable
Multi wall sheet can be used in
applications where the design calls for a
cold formed or arched application. The
proper fabrication technique is to bend
the panel across the flutes.
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Slide 42 of 52
• About the Sponsor
• About the Instructor
• Seminar Discussion Forum
Polycarbonate Sheeting
Architectural Grade Multi-wall Polycarbonate Sheet
Product Offering
Thickness
Configuration
16mm
3 Wall
16mm
M Wall
16mm
XP Wall
25mm
4 Wall
25mm
XP Wall
32mm
XX Wall
Like monolithic and laminated polycarbonate, multi wall sheet comes in various solar
and translucent tints.
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Slide 43 of 52
• About the Sponsor
• About the Instructor
• Seminar Discussion Forum
Polycarbonate Sheeting
Product Comparison
Item
Insulated Glass
1”
0.625”
0.236”
16mm XP
25mm 4
32mm XX
lbs./sf
6.25
3.20
1.46
0.55
0.72
0.78
U-Value
0.48
0.78
0.96
0.39
0.33
0.26
LT % Clear
78
80
83
61
55
50
Structural
Heavy
Heavy
Light
Light
Light
Very Light
Field Fab
NO
NO
Yes
Yes
Yes
Yes
Thickness
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©2004
Polycarbonate
UV Enhanced
Multiwall
Monolithic
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Slide 44 of 52
• About the Sponsor
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• Seminar Discussion Forum
Polycarbonate Sheeting
Weight Comparison
Product
lbs./sf
Material Only
1” Insulated Glass
6.25
200 lbs.
16mm 3
0.55
15.36
16mm XP
0.55
17.60
25mm 4
0.70
22.40
32mm XX
0.90
28.80
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©2004
Total lbs.
4’ x 8’ Skylight
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Slide 45 of 52
• About the Sponsor
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• Seminar Discussion Forum
Polycarbonate Sheeting
Design With Light
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Slide 46 of 52
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Polycarbonate Sheeting
Light Weight & Weatherability
Due to the strength of the fluted
internal structure multi wall sheet
provides it is an ideal lightweight,
translucent; UV protected solution for
large span designs.
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Slide 47 of 52
• About the Sponsor
• About the Instructor
• Seminar Discussion Forum
Polycarbonate Sheeting
Excellent Insulation Characteristics
Along with being over 200 times
more impact resistant and half the
weight of glass, polycarbonate has
approximately 20% better insulating
characteristics versus glass of
equivalent thickness.
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Slide 48 of 52
• About the Sponsor
• About the Instructor
• Seminar Discussion Forum
Polycarbonate Sheeting
Hurricane Andrew
A much more aesthetic look to this
building using multi wall sheet in
their windows for protection instead
of over glazing with wood.
Extech in Pittsburgh designed this
system.
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©2004
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Slide 49 of 52
• About the Sponsor
• About the Instructor
• Seminar Discussion Forum
Polycarbonate Sheeting
Architectural Grade Multi-wall Polycarbonate Sheet
Thin Gauge Multiwall - Summary
Market Areas
Characteristics & Advantages
Skylights
Pool enclosures
Monumental skylight
Barrel vaults
Stadiums
Atriums
Industrial glazing
Outstanding impact resistance
UV resistant
Extremely light weight
Naturally diffused light
Long service life
Excellent insulation properties
Won’t support ignition
Complies with major building codes
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Slide 50 of 52
• About the Sponsor
• About the Instructor
• Seminar Discussion Forum
Polycarbonate Sheeting
Polycarbonate Sheeting
• The extruded sheet polycarbonate material offers a full line of
architectural grade products.
• From general purpose, UV enhanced, abrasion resistant grades of
polycarbonate sheet to high-security laminates products,
polycarbonate materials offer innovative design solutions.
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Slide 51 of 52
• About the Instructor
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Polycarbonate Sheeting
CONCLUSION OF THIS MODULE
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©2004 Sheffield Plastics. The material
contained in this course was researched,
assembled, and produced by Sheffield
Plastics and remains their property.
Questions or concerns about this course
should be directed to the instructor.
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