How should polycarbonate sheets be properly connected with U-profiles? Why should silicone be avoided? Why should drilling polycarbonate panels also be avoided, and how should it be done correctly when necessary? Everything about the proper selection of UV protection for polycarbonate sheets. When should the protective film be removed from polycarbonate sheets?
Polycarbonate sheets are a very popular material for covering terraces. They allow light to pass through, and you can even choose transparency levels and colors according to your preference. They are also lighter than glass and resistant to breakage. However, polycarbonate sheets require experienced installers who will follow some basic rules during installation.
Related Aricles:
Polycarbonate Sheet – All About the Advantages and Disadvantages of “Plastic Glass”
Are PVC Windows Toxic and Harmful to Health?
When installed correctly, polycarbonate sheets can literally last for decades. However, some installation mistakes and lack of experience can lead to problems such as leaks and dirt entering the channels of the polycarbonate sheets very quickly. If you are undertaking the installation yourself or hiring a handyman, here are some basic rules to follow.
Pay Attention to Polycarbonate Sheet’s UV Protection
First and foremost, polycarbonate sheets should be installed with the side that has UV protection facing the sun. The label indicating which side has the UV protection is found on the protective film that covers the polycarbonate sheet. There are polycarbonate sheets designed for installation in special positions that have UV protection on both sides, but these are up to 40% more expensive. For standard canopies, UV protection on both sides is not necessary.
Another rule for installing polycarbonate sheets that installers must adhere to is that protective films should only be removed after the installation is complete. While the polycarbonate sheets are being transported, cut to size, and handled on-site, the film should remain in place. Although polycarbonate sheets are resistant to breakage, they are not scratch-resistant, so the film serves as protection.
Once the installation is completed, the film must be removed immediately. It should never be left for later because prolonged exposure to sunlight can cause the adhesive used to fix the film to the polycarbonate sheet to change composition, dry out, and leave residue on the sheet. The same applies to aluminum and PVC window profiles—the protective film should be removed immediately after installation.
How to Join Polycarbonate Sheets with U-Profiles
Polycarbonate sheets have a sandwich construction with a series of longitudinal channels. This gives them an ideal strength-to-weight ratio but also has a drawback: when dirt enters the channels, it spreads quickly along the entire channel, creating lines along the polycarbonate sheet. Therefore, the cut edge of polycarbonate sheets with open channels must be sealed with a special aluminum tape and U-profile.
When inserting polycarbonate panels into the supporting U-profiles, the panel should never reach the bottom of the groove. Polycarbonate expands and contracts with temperature changes, so space must be left to avoid stress and warping of the panel due to its expansion in the sun.
The joint between the polycarbonate panel, the rubber sealing strip, and the U-profile must be tight, but no oils or lubricants should be used during installation to facilitate the “insertion” of the polycarbonate panel into the U-profile groove. Oils and greases can damage polycarbonate or the sealing rubber.
How to Properly Bend Polycarbonate Sheets for Curved Forms
For creating a curved canopy, polycarbonate sheets should be bent only along the channels, i.e., along the longer side of the panel. Bending across the channels causes significant stress in the material structure and increases the risk of breakage. Similar to wood, polycarbonate handles bending along the channels better than across them.
Polycarbonate panels are joined using double U-profiles by inserting the panels into the U-profile. To ensure waterproofing and a firm connection, rubber sealing strips should be used. Many people use silicone for sealing during polycarbonate installation, but this is not a long-term solution for waterproofing. Polycarbonate forms a weaker bond with silicone compared to glass.
How to Properly Drill Polycarbonate Sheets: The Less, the Better
Another trick for ensuring the long life of polycarbonate sheets is to design the structure in such a way that polycarbonate is not drilled, or if necessary, only at a minimal number of points. Every hole represents a weakened spot and a position where dirt can enter the channel.
When drilling, the hole must go through the channel, i.e., through the center of the chamber, without damaging the chamber walls, as this would compromise its strength. When a screw passes through the hole, it must have a cap with a washer of at least one inch in diameter and a rubber gasket on the top side.
The larger washer reduces the load on the polycarbonate sheet during screw tightening, while the rubber gasket prevents water and dirt from entering the polycarbonate channel. To avoid future cracking, holes in polycarbonate sheets should never be drilled less than two inches from the edge of the panel.