Question 1

What is the best roof pitch for SUNLITE DIY polycarbonate sheets?

Accepted Answer

A proper slope keeps water off the roof. It prevents leaks, keeps the roof clean, and ensures structural integrity.

Roof slope percentage indicates how much the roof falls over a given distance.

SUNLITE multiwall polycarbonate sheets require a 10% minimal slope.

This means a drop of at least 10 centimeters over one meter.

If you expect leaves or snow to accumulate on your roof, consider a deeper slope.

Question 2

What is the best polycarbonate panel for thermal properties and light transmission?

Accepted Answer

There is a trade-off between light transmission, transparency, and thermal properties in polycarbonate sheets. Multiwall polycarbonate sheets provide superior thermal insulation over solid sheets, but they are translucent, not transparent.

Clear polycarbonate panels will be fully transparent, but less thermally insulating.

Both options allow high light transmission, depending on their color.

If your main concern is light transmission, and not a glass-like appearance, you can achieve that with multiwall sheets, such as SUNLITE, or with the SUNPAL architectural multiwall panel system.

If your main concern is clarity, your best option is PALSUN solid polycarbonate sheets, or SUNGLAZE architectural solid panel system.

Another important factor to remember is that multi-wall sheets weigh significantly less than solid sheets. This can lower your construction and labor costs.

Question 3

Which side of SUNLITE roofing sheet should face up?

Accepted Answer

SUNLITE multiwall polycarbonate sheets are provided with a protective masking film that indicates which side is shielded from UV.

It is critical to install the sheets with the UV-protected side facing up.

Remove the marking strip after installation.

Question 4

What structural support is needed for SUNLITE polycarbonate sheets?

Accepted Answer

SUNLITE roofing support depends on several factors:

Support type: Some architectural projects may use four-sided clamps or frames, two-sided clamped glazing, or two-way clamped arched glazing. DIY and home renovation projects typically use purlins to support the roof.

Expected wind and snow loads should also be considered based on local building codes.

The SUNLITE Technical Guide in the downloads section contains a detailed tables for all scenarios.

Question 5

Can SUNLITE multiwall polycarbonate sheets be bent into arches?

Accepted Answer

SUNLITE sheets may be cold bent or curved. There is only one rule: stay within the allowed arch radius. Curving SUNLITE sheets beyond the permitted radius induces undue stresses and strains, causing premature failure.

The minimum bending radius is determined by the cell structure and thickness.

For example, the allowed bending radius of SUNLITE 8mm twin-wall is 1,400mm, while the allowed bending radius of SUNLITE 25mm X-Lite is 5,000mm.

The SUNLITE Technical Guide in the downloads section contains a detailed Arching Radius table for the complete SUNLITE range.

Question 6

What is the right saw for on-site cutting SUNLITE multiwall polycarbonate sheets?

Accepted Answer

Safety First: Protect yourself by using professional equipment, keeping your surroundings neat and tidy, and using tools with caution and care.

Power tools

Circular table saws are the most efficient and accurate way to cut plastic sheets. This option, however, isn't always available on home renovation sites.

A portable fine-toothed circular saw is ideal for cutting on-site. High blade speed and a moderate feeding rate will give you the most effective results.

A jigsaw also produces clean, accurate cuts, but requires better control. It is most suitable for cutting complex shapes and curved lines.

Manual tools

Working with manual tools is time-consuming, but it reduces the risk of sheet damage.

Manual handsaws or hacksaws with fine teeth provide accuracy and control.

Hand tools such as tin snips, scissors, or even a utility knife are useful for making small notches.

Additional tools

You will need a flat, stable workbench to work on.

To set guidelines, you will need a tape measure, a ruler, and a marking pen.

An air-compressor will help you remove chips that may have entered the sheets’ cells.

Question 7

How to Cut SUNLITE Multiwall Polycarbonate Roofing Panels

Accepted Answer

Multiwall polycarbonate sheets are strong, durable, lightweight, and provide excellent thermal insulation. These features make them ideal for professionals and DIY enthusiasts alike. On-site tailoring and trimming is simple. Follow these guidelines to ensure quality results.

Safety First: Protect yourself by using professional equipment, keeping your surroundings neat and tidy, and using tools with caution and care.

Place a layer of cardboard or plywood on the workbench before placing the first sheet. This will protect the surface from scratches.

Place one multi-wall panel on your workbench. You should cut one sheet at a time, and not stack sheets together.

Multiwall polycarbonate sheets come with protective films. This film indicates which side of the panel is UV-protected. Do not remove it. You will need it later.

Use a measuring tape to measure the sheet, and make pen marks at each end. Join the marks with a ruler.

Do not rush measuring and marking. Once trimmed, you cannot patch the sheets together.

Secure the polycarbonate sheet to the workbench surface to prevent movement and vibrations.

Support the sheet near the cutting line. You can do this by placing a timber plank on top of it, parallel to the markings.

Cut along the marked pen line. The preferred method is to use a fine-tooth saw that rotates at high speed.

Advance the saw slowly and steadily and do not stop once you have begun. It will ensure a clean, consistent edge.

Clean the sheet’s channels with compressed air.

Remove leftover cuts and scraps from the cutting table.

Question 8

How to cold bend flat plastic sheets?

Accepted Answer

Industrial plastic sheets can be cold bent or curved, within their minimal permitted bending radius, without damaging their mechanical performance. The minimal permitted bending radius for a plastic sheet is a factor of its thickness.

A simple way to calculate the allowed cold bend radius is to multiply the sheet's thickness by 200. For example, for a 5mm sheet the arch radius should not be less than 1000mm (5X200).

Question 9

What kind of drill do you use for solid plastic sheets?

Accepted Answer

Regular, high-speed steel twist drills, or carbide-tipped drills are suitable for drilling holes in PALSUN sheets of various thicknesses, as long as they are sharpened well. They are used for bores up to 12 mm in diameter.

Larger holes may be drilled with flat, chisel edged drill blades with a triangular cutting tip, similar to those used in woodworking, kept sharp.

Rake angle should be about 5° to avoid side friction. They are used for bores from 12 to 20mm. Commercially available cutting cups or circle cutters of several types can be used for large round apertures.

Reduce the drill speed for large diameter holes or large gauge plastic sheets.

For detailed specifications and drilling tips and recommendations, look up the fabrication guide in the downloads section.

Question 10

How to CNC route solid plastic sheets?

Accepted Answer

CNC routing is a versatile process used for cutting and designing industrial plastics. Among its uses are signage, cabinetry, furniture, and architectural elements.

It's important to understand the material being machined, to select routers with plastic-specific geometry, and to apply them appropriately.

For detailed specifications, look up the fabrication guide in the downloads section.

Question 11

How to cut solid flat plastic sheets?

Accepted Answer

A variety of power saws, either table mounted or portable can be used to saw polycarbonate and PVC solid sheets.

A moving table, fixed blade bench saw is preferable for long, straight sawing.

Radial arm saws are generally used for “cross-cut” (width) or diagonal sawing.

Handsaws are slower and less accurate than table saws. These can be used for on-site trimming.

Laser or water-jet cutting is possible when cutting polycarbonate sheets, but not recommended for PVC sheets.

For detailed saw blade specifications, clearance angle, and detailed information, look up the product's fabrication guide in the downloads section.

Question 12

How to mechanically fasten plastic sheets?

Accepted Answer

Flat, solid plastic sheets such as PALSUN, PALCLEAR or PLOPAQUE can be fastened with nuts and bolts, provided several points are remembered:

Use EPDM and aluminum washers to distribute the load.

Do not use rivets, as they apply excessive force and cause sheet cracks.

Drill a slightly oversized hole by 2-3 mm, and tighten moderately.

When using mechanical fasteners, they should be evenly spaced to avoid stress accumulation at particular points.

Wherever possible, a floating frame, or H profile installation is preferable, similar to glass, and without mechanical drilled fasteners.

Question 13

How to store flat  plastic sheets?

Accepted Answer

Flat plastic sheets, either solid or foamed, should be transported and stored horizontally, on a flat, sturdy pallet whose dimensions are equal or larger than the largest of the sheets.

The sheets should be secured to the pallet during transportation and on-site handling.

It is recommended to stack the sheets with the longer sheets at the bottom and the shorter on top, leaving no unsupported overhang.

Palram's products leave the factory in packages, wrapped in white, watertight film. The wrapping should be removed as close to use as possible.

Avoid leaving sheets stored unwrapped. Dirt may accumulate on the sheets and/or their edges, attracted by electrostatic charges in the sheets

Sheets should be stored in a covered, dry, ventilated place away from direct sunlight.

If storing sheets temporarily in an open area, cover the entire pallet with a white opaque film, sheet, cardboard or any other protective material.

Question 14

Are PVC sheets recyclable?

Accepted Answer

All of Palram's PVC sheets are REACH and RoHS compliant, and are 100% recyclable.

Depending on local regulations and facilities, recycling options may vary. It is possible to recycle PVC sheets mechanically or chemically.

Because of its recyclable properties, it can be reformed into new products.

While minimising environmental impact, this increases the product's life cycle and reduces waste.

Question 15

Are PVC sheets water-resistant and chemical-resistant?

Accepted Answer

Yes, PVC sheets are highly resistant to moisture and chemicals. They can withstand rain and repeated cleaning without warping or cracking.

Question 16

How to laminate PVC sheets?

Accepted Answer

Depending upon the type of application and the equipment available, the techniques recommended for lamination of PALBOARD multilayered panels or PALIGHT foam PVC are cold press using adhesive-backed paper, cold vacuum press, hand laminating with transfer adhesive, and using spray adhesive.

None of these processes involve heat. Because PVC may warp at temperatures above 65°C or when heated from one side only.

For ideal results, the sheet should be cleaned with isopropyl alcohol, and allowed to dry, prior to adhesion. When laminating with pressure-sensitive adhesives, a force of 25–40 psi is required. Proper spacers are also critical. Because force must be applied equally across the material.

For further information, download the Product Fabrication Guide in the downloads section.

Question 17

Is PVC suitable for UV printing / UV curing?

Accepted Answer

PVC is a good substrate for UV inks.

Wide format and flatbed printers employ various ink and ink curing technologies to allow high quality printing at high speeds.

PALIGHT is suitable for use with UV curing and solvent-based digital inks, and for IR drying when water-based inks are required. It retains superb whiteness, even after intense UV curing.

UV Screen Printing Inks also work well on PVC. The most critical factor to consider when using UV systems is the curing oven. Low-wattage bulbs should be used to keep temperatures below 65°C. UV curing systems with variable speed conveyors are ideal.

Question 18

How to screen print on PVC sheets?

Accepted Answer

Screen printing on PVC sheets is simple.

It is recommended to consult the ink manufacturer regarding required ink additives for proper adhesion. In addition, it is recommended to test screen printing inks before production begins.

Before screen printing, the sheet's surface should be cleaned with isopropyl alcohol and a clean white cloth.

To remove small scratches or dents, fan a heat gun over the affected area. However, do not overheat, to avoid surface deformation.

After printing is completed, screen printing ink should air dry, rather than heat dry.

For further information, download the Product Fabrication Guide in the PALIGHT Downloads section.

Question 19

How to paint PVC sheets?

Accepted Answer

There are a variety of paints that can be used on PVC sheets.

Some examples of suitable paints include vinyl, acrylic lacquers, and two-part polyurethanes.

Before painting, the sheet's surface must be dry, clean, and grease-free.

When applying dark color paint to PVC sheets intended for outdoor use, it is imperative that the paint has a light reflectance value of 55 or higher in order to avoid excessive heat absorption, which will result in deformation.

For further information, download the Product Fabrication Guide in the PALIGHT Downloads section.

Question 20

How to heat-bend PVC sheets?

Accepted Answer

PVC sheets such as PALIGHT, PALABOARD, PALCLEAR and PALOPAQUE, can be bent with Calrods, radiant heaters, strip heaters or air-circulated ovens. Heat guns can also be used in small areas.

To ensure successful results, a thermostat should be employed to regulate the sheet temperature so that the surface temperature does not exceed allowed limits.

When using a metal contact strip heater, cover the heater strip with Teflon spray to prevent marking the sheets.

Different sizes of rectangular heating bars can be applied to produce bends of different radius. The larger the heated area of the sheet, the broader the radius can be created.

When heat-bending PVC sheets at a gauge thicker than 4 mm, the sheet should be warmed from both sides.

PVC sheets require heating approximately 30 to 40 seconds per millimeter prior to being bent.

To form tighter bends with smaller radii, use a small heated area on the upper surface (inside the bend) of the sheet and a larger heated area on the bottom surface (on the outside of the bend) of the sheet.

A minimum radius of twice the sheet thickness is necessary to avoid breakage.

When bending PVC sheets into an angle, the extension of the sheet on either side of the angle should be at least 20 times the panel thickness.

Once heat-bent, place the panel to cool down in a fixture, such as a jig or clamp. Fans and/or compressed air will speed up cooling. For detailed guidance, look up the Product Fabrication Guide in the Downloads section.

Question 21

Are PALIGHT and PALBOARD sheets suitable for outdoor use?

Accepted Answer

Yes, both PALIGHT foamed PVC sheets and PALBOARD multilayered sheets are suitable for outdoor use. However, it's essential to select the appropriate thickness and grade for prolonged exposure to direct sunlight and heat.

Question 22

How to make a V-groove in PALBOARD?

Accepted Answer

V-grooving PALBOARD is an excellent method that helps industrial designers turn a 2D panel into a 3D object.

For V Groove Milling\Routing, use a machine bit designed for bending applications. Such bits offer top angles of 90°, 120° or 135°.

A 90° bit produces rectangular bends with almost no gaps.

120° or 135° rounded tip bits produce acute angled bending of up to 90° with approx. 2 mm gap between the sides.

Make sure not to route through the PALBOARD panel. Leave 0.6 mm to 0.8 mm, so you can benefit from the structural strength of this material.

Question 23

Can PVC foam sheets and PALBOARD panels be routed?

Accepted Answer

PALBOARD and PALIGHT sheets can be routed using multi-fluted carbide tools on standard woodworking routers. Standard tools and machines can be used without altering equipment. Adjust feed and speed rates as needed to achieve the most precise edge finish.

Using standard milling machines, follow these guidelines:

Relief angle: 5° to 10°

Rake angle: -10° to 0°

Cutting speed: up to 18,000 RPM

Cutting feed: 0.3-0.5 mm / revolution

Question 24

What drill bit do you use for PVC foam or for PVC multilayered sheet?

Accepted Answer

PALIGHT and PALBOARD can be drilled with carbide-tipped bits using metal twist drills.

The following settings are recommended:

Point angle: between 90° and 110°

Spiral angle: 30°

Cutting speed: 1000 - 3000 RPM

Feed rate: 0.2 - 0.5 mm / revolution

The minimum distance from the edge should be 2 times the hole diameter.

To reduce heat build up when drilling thick gauge sheets, it may be necessary to periodically remove the drill bit from the material.

Question 25

How to cut PVC foam or PVC multilayered sheet?

Accepted Answer

PALBOARD and PALIGHT sheets up to 3 mm thick can be cut with a utility knife or blade.

A jigsaw with rough-cut blades designed for plastics can also be used. Smooth metal cutting blades are not recommended.

Another manual option is table top or vertical cutters. In such cases, it is recommended using cutters with twin wheel head blades suitable for cutting ACP (Aluminum Composite Panel).

For industrial volumes, use a bridge saw or a circular table saw.

Saw blade specifications, clearance angle, and detailed information are available in the Product Fabrication Guide in the downloads section.

Question 26

Can polycarbonate light transmittance be degraded over time?

Accepted Answer

SUNTUF roofing sheets are made with a UV protection layer. This layer protects the sheets from UV radiation harm and maintains light transmittance and quality for many years.

Question 27

PALRUF PVC or SUNTUF polycarbonate corrugated sheets: when to use which?

Accepted Answer

PVC corrugated sheets are typically used in highly-corrosive environments such as port warehouses, cowsheds, and dairies for opaque roofing and siding. When natural daylight illumination is needed, polycarbonate corrugated sheets are used as roofing or siding.

Question 28

Is PALRUF resistant to UV radiation?

Accepted Answer

Yes, PALRU corrugated PVC roofing sheets are UV resistant.

Question 29

Can I step on SUNTUF skylights during or after installation?

Accepted Answer

Although SUNTUF is remarkably strong and can support extreme loads, for your safety, do not stand directly on the sheets. If it can’t be avoided, use stepping ladders, platforms or crawling boards.

Question 30

How to clean polycarbonate roofing?

Accepted Answer

Here are some steps to clean your polycarbonate roofing sheets:

Remove any loose debris, such as leaves or twigs, from the sheets surface using a broom or leaf blower.

Dip a soft cloth or sponge into a bucket of warm water and gently scrub the sheets, working in small sections at a time.

Rinse the sheets thoroughly with water to remove any remaining dirt or soap suds.

Dry the sheets with a clean and soft cloth, or allow them to air dry.

Avoid using high-pressure water or a pressure washer. High pressure can damage the sheets' surface.

Avoid using harsh chemicals or abrasive cleaners, as they can damage the sheets' surface. Before using a detergent, ensure it is polycarbonate-compliant.

If the sheets are particularly dirty or have stains that are difficult to remove, you may need to repeat the cleaning process a few times to get them fully clean.

In addition to cleaning the sheets, it is also worthwhile to regularly inspect the roofing for damage or wear.

Question 31

How do I combine SUNTUF rooflights or sidelights with corrugated metal roofing?

Accepted Answer

Palram's MetalMatch technology enables a precise match of corrugated SUNTUF to almost any industrial metal sheet. Contact your local Palram office for more details.

Question 32

Can I use PALRUF clear PVC corrugated sheets for industrial skylights?

Accepted Answer

PALRUF is an excellent skylight panel. It can overlap corrugated metal sheets and other types of corrugated roofing panels. PALRUF skylights are resistant to chemicals and fumes, and are an ideal solution for the chemical industry.

Question 33

Can corrugated SUNTUF polycarbonate and PALRUF PVC sheets be used for wall siding?

Accepted Answer

Yes. Make sure you start installing from the bottom up so overlaps prevent water from penetrating indoors.

Question 34

What kind of gasket is suitable for corrugated SUNTUF and PALRUF sheets?

Accepted Answer

Flexible EPDM gaskets with metal washers.

Flexible EPDM gaskets allow just enough free movement for the sheets as they contract and expand. This ensures an effective seal against leaks and reduces stress and micro cracks. The metal washers will distribute the fastener load and will support the gasket.

Gaskets should conceal holes properly.

Use a 25mm gasket for a 10mm drill. A 19mm gasket is the alternative when the corrugation profile does not allow a wider gasket (if the valley or crest is too narrow).

Question 35

Which screws to use for fixing corrugated SUNTUF and PALRUF roofing sheets?

Accepted Answer

Use corrosion-resistant screws for optimal long-term service

Use screws with an outside thread diameter of ¼”

Screw shaft length varies with corrugation profile and fixing location (crest or valley).

Use self-tapping screws for timber purlins, and self-drilling screws for metal purlins.

Question 36

Why do polycarbonate roofing sheets require pre-drilling oversized holes?

Accepted Answer

Polycarbonate sheets are typically attached to support structures using screws or other fasteners. It is necessary to pre-drill oversized holes in the SUNTUF sheets to allow for expansion and contraction due to temperature changes. This is critical to ensuring the roof's quality and performance over time.

Question 37

How to accommodate SUNTUF polycarbonate roofing sheets' thermal expansion?

Accepted Answer

Polycarbonate roofing sheets can accommodate thermal movement by following these guidelines:

Keep a small gap where the SUNTUF sheets meet another object. Sheets expand most along their length, so pay attention to this direction.

Pre-drill oversize holes around the fixings. In this way, the screws won't stress the sheets.

Polycarbonate ridge caps, wall connectors, and flashings should also be predrilled with oversized holes.

Applying foam tape along structural elements that come in contact with sheets will reduce friction noise.

Leave a 5cm-10cm overhang over the lower purlin.

Question 38

How to Cut SUNLITE Multiwall Polycarbonate Roofing Panels?

Accepted Answer