How to Cut & Install Lexan Corrugated Panels & Technical Data
Corrugated polycarbonate allows 90% of sunlight in
Greenhouse plans / kits with Corrugated side wall
Lexan Corrugated sheets are the product of choice for cost effective, high light transmitting, long lasting greenhouse coverings. Suitable for Gable and Quonset style greenhouses, Lexan Corrugated panels are easy to install with simple woodworking tools. Tough & lightweight they can be cold formed to gentle curves or rolled up for easy and safe handling. Manufactured from polycarbonate a high performance thermoplastic, Lexan Corrugated sheets provide the clarity of glass transmitting up to 90% of visible light while filtering out ultraviolet rays.
High Light Transmission: Clear Lexan Corrugated sheet transmits visible light as well as glass, providing an optimal growing environment. Up to 90% of visible light. Lexan Corrugated provides the crystal clarity of glass without the heavy weight, high cost or risk of breakage.
High Impact Strength: With 20 times the impact resistance of fiberglass and over 40 times the impact resistance of glass. Lexan Corrugated sheets resists hail, wind and vandalism. With a thickness of .033, Lexan Corrugated sheet can withstand over 240 inch pounds of impact. This equates to a 3/4" hailstone falling at 96 miles per hour! Lexan Corrugated sheet maintains this superior impact resistance at temperatures ranging from -40F to 250F.
Light Weight: Lexan Corrugated reduces labor costs because its light weight simplifies handling, transportation and installation particularly of long spans in high places. Lexan Corrugated sheet is only one-quarter the weight of greenhouse glass on a square-foot basis. Lexan Corrugated sheet can be used on both gable and quonset-style greenhouses. Easy-to-install panels can be attached directly to the greenhouse frame using one of the recommended fastener methods.
Thermally Insulating: Lexan Corrugated can help save energy because of its thermal insulating capability. Compared to fibreglass, which has a U value of 1.56, Lexan Corrugated sheet insulates with a U value of 1.2. As an example, this means that a greenhouse located in Denver, Colorado, would save an average of 300 gallons of oil annually for each 1000 sq. ft. of glazing with Lexan Corrugated over fiberglass. Using an energy curtain/ blanket, the U value of Lexan Corrugated sheet is .70 equal to double polyethylene film.
Chemically Stable: Although Lexan Corrugated is unharmed by many chemical substances, it is important to avoid contact with adhesives, paints or solvents which are incompatible with polycarbonate. Chemicals to avoid include:benzene, gasoline, acetone, carbontetrachloride, among others. Only recommended cleaners should be used to clean Lexan Corrugated panels(see Cleaning). When considering shade and thermal cloths, it is important not to use vinyl materials which are incompatible with polycarbonate. Polyester shade cloths such as those sold by Wadsworth Control Systems* are acceptable, provided they are installed according to manufacturer's specifications. For other cloths, please contact GE Technical Marketing prior to using. Although many of the commercially available shading compounds can bc used with Lexan Corrugated sheet, care must be taken to apply compounds that are compatible with polycarbonate. Prior to applying the substance to the greenhouse, it is best to test the compound you are considering in a non-critical location to ensure that it can be removed from the Lexan Corrugated sheet. Lexan Corrugated polycarbonate meets the requirements of an approved light-transmitting plastic as described by all three model building codes (ICBO, BOCA and SBCCI). These include ASTM D 635, D 1929 and D 2843. Lexan Corrugated exhibits superior flammability performance when compared to typical fibre reinforced polyester (FRP) and acrylic sheet materials.
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Sheet Orientation: Install Lexan Corrugated panels with the UV protected side facing out (exposed to the weather) as indicated by the sticker affixed to the UV-protected side of each sheet. To facilitate removal, remove sticker immediately after installation. Always position Lexan Corrugated sheet so that the ribs run vertically.
Overlaps: On horizontal overlaps, the upper panel should overlap the lower panel by 3" to 4". Vertical overlap should be a single corrugation and should be overlapped in the direction of the prevailing wind. Since the finished width of Lexan Corrugated is 51", the yield is 48".
Storage: Lexan Corrugated panels should be stored on a flat surface out of direct sunlight. Do not stand or place heavy objects on the sheet. How to cut Lexan: Lexan Corrugated sheet can be cut with a variety of common hand-held and table-mounted equipment. In general, sharp tooling with fine cutting teeth should be used to minimize vibration and clatter Sheets should be properly supported along the trim line before cutting. Circular Saws: Use a fine-tooth, hollow ground panel blade with 10-12 teeth per inch. Sabre saws equipped with a fine-tooth blade can also be used, but proper support is recommended.
Drilling: Drill with a high-speed steel or carbide-tipped twist drill. Drill holes slightly larger than the fastener to allow for expansion and contraction (e.g., drill a 1/4" hole for a 3/16" screw). Place holes at twice the fastener diameter or 1/2" from the edge of the sheet, whichever is greater.
Accessories: A number of different accessories are available to simplify installation of Lexan Corrugated sheet. Self-drilling, self-tapping screws with neoprene washers are for aluminums or steel substructures; wood grip screws are for wood sub- structures. Self-tapping screws with sharp points should be used with no-drip spacers. All-aluminum Bulb-TiteTM * rivets with EDPM washers and low clamp-up pressure (80 lbs. or less), such as those made by Olympic Fastening Systems, can be used to join the sheets.
Sealing: To seal the pitched-roof ridge from the elements, a ridge cap may be formed from aluminum or other suitable material . The ridge cap should be sealed with foam weather seal. Foamed or wood closures may be used at the ridge peak and gutter to seal the greenhouse. Closures should have a profile and be made of materials compatible with Lexan Corrugated. Use a high-quality, compatible sealant such as silicone rubber to seal holes or overlaps.
Cleaning: Clean Lexan Corrugated polycarbonate panels with any mild soap or detergent and warm water, using a soft cloth or sponge. Abrasive cleansers, brushes or squeegees should not be used. The following cleaning agents have been found compatible with Lexan Corrugated. The manufacturer's recommendations and instructions should be followed.
Warranted to Perform: Manufactured by GE Plastics, the inventor and polycarbonate technology leader for over a quarter-century. The Lexan Corrugated sheet is backed by a 1O-year limited warranty' against yellowing and loss of light transmission.
Materials Technology: Backed By Hands-On Support: Lexan Corrugated sheet's design versatility, outstanding physical properties and long-term durability outperform other greenhouse materials. When you specify Lexan Corrugated polycarbonate sheet, you capitalize on polycarbonate technology backed by unmatched technical support. From initial concept through design, fabrication and end use, GE Plastics is a working partner in innovation.
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From Wikipedia: Lexan is a registered trademark for SABIC Innovative Plastics' (formerly General Electric Plastics) brand of polycarbonate resin thermoplastic. Polycarbonate polymer is produced by reacting bisphenol A with phosgene. Lexan is the brand name for polycarbonate sheet and resin in a wide range of grades. Lexan is mainly used in three domains: building (glazing and domes), industry (machine protection and fabricated parts) and communication and signage. Common usages include space and sports helmets, clear high-performance windshields and aircraft canopies, motor vehicle headlight lenses, and bullet-resistant windows. Dr. Hermann Schnell of Bayer in Germany invented the polycarbonate resin in 1953, just one week before chemist Dr. Daniel Fox of GE independently made the same discovery while working on a wire coating. They had created a gooey substance that, once hardened, could not be broken or destroyed without great effort. Both teams were impressed by the remarkable toughness of the material. Both companies applied for U.S. patents in 1955. Before it was clear which would win the patent, both agreed that the patent holder would grant a license for an appropriate royalty. This agreement allowed both companies to concentrate on developing the polymer and was particularly advantageous to GE, since GE would not otherwise have been able to sell a product during the life of the original patent. In the 1960s, NASA used Lexan-brand polycarbonate for astronaut helmet assemblies and visors which became known as "bubble helmets", including those used by the Apollo moon astronauts. Lexan is also one brand of polycarbonate used to make football and other sports helmets. In 1968, Lexan brand polycarbonate sheet could be used in windows, signs, greenhouses and other large applications. By laminating sheets up to 1.25" thick in the 1970s, a material tough enough to stop bullets was created. By 1969 taillights made from Lexan brand polycarbonate were used on the Dino Ferrari. It was also used not only in industrial safety glasses, but also to make lightweight traditional eyewear.
For technical specifications, how to apply, cut and clean twin-wall polycarbonate visit our Lexan Thermoclear info page. Interested in our hobby Greenhouse Kits and Greenhouse Plans? We have Free Solar greenhouse plans for an eco friendly greenhouse, Lean-to or attached greenhouse plans for a greenhouse that connects to your home and Gambrel greenhouse plans for a barn shaped greenhouse. Information on lighting, ventilation, pests and diseases as well as free greenhouse potting bench plans at Gardening Tips.
Compare: the Clarity of Lexan Twin-wall with Lexan Corrugated.
Lexan Corrugated Sheet Installation Guide Technical Data Sheet
Our Lexan Corrugated freestanding greenhouse kit