Acrylic and Polycarbonate Sheet

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Acrylic and Polycarbonate Sheet

The difference, where each suits, cutting and drilling, and safety glazing

Acrylic and polycarbonate look similar and behave very differently, and choosing the wrong one is the source of almost every problem with plastic glazing.

The key difference

Acrylic is rigid, optically excellent, scratch resistant and brittle — it cracks under impact. Polycarbonate is far tougher, effectively unbreakable in normal use, and scratches more easily.

For anything where impact matters — greenhouse panes, shed windows, machine guards, anywhere a ball might arrive — polycarbonate is the correct choice.

Safety glazing

Building regulations in the UK require safety glazing in critical locations, which includes doors, areas beside doors and low-level glazing. Plastic used in those positions must meet the impact standard.

Check what is required before replacing glass in a door, since this is a safety matter rather than a preference.

Expansion

Both expand and contract with temperature considerably more than glass. Drill oversized holes and never fix rigidly, or the sheet will crack in the first hot spell.

Leave the manufacturer's stated clearance in any frame.

Cutting and drilling

Keep the protective film on until the last moment. Cut acrylic with a fine-toothed blade at a moderate speed, supported close to the cut, since it chips and cracks.

Drill with a bit ground for plastic or an ordinary bit run slowly, backing the sheet with timber, and never drill close to an edge.

Cleaning

Warm soapy water and a soft cloth. Never use solvents, window cleaner containing ammonia, or abrasives, which craze acrylic permanently.

Where each is used

Acrylic for picture glazing, display cases, splashbacks away from heat and anywhere optical clarity matters. Polycarbonate for greenhouses, sheds, machine guards, roofing and anywhere impact is possible.

Both are far lighter than glass, which matters for anything overhead or handled regularly.

Finishing edges

Cut edges on acrylic can be flame polished or sanded smooth. Leave saw marks and the sheet will crack from them under stress.

Ordering cut to size

Measure twice and state whether the dimensions include or exclude any frame rebate, since cut sheets cannot be returned. Allow a small clearance for expansion rather than an exact fit.

Specify the thickness for the span, since a thin sheet over a wide opening flexes and eventually cracks at the fixings.

Other materials

Foamed PVC is rigid, light and easy to cut for signage and panels. Toughened glass remains the right answer where scratch resistance and heat matter, such as directly behind a hob.

Keep offcuts, since small pieces are useful for repairs and for testing a cut.

Ultraviolet

Check the sheet is UV stabilised for outdoor use, since unprotected polycarbonate yellows and becomes brittle within a few years.

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