Polycarbonate structures, everything you need to know

Polycarbonate buildings’ adaptability and durability have completely changed the construction sector. Polycarbonate, which is lightweight and extremely strong, is becoming a popular material for many building projects, including carports, awnings, and greenhouses and conservatories.

The outstanding impact resistance of polycarbonate makes it a safer substitute for glass, which is one of its main advantages. It won’t break or crack in the face of severe weather, such as hail, powerful winds, and a lot of snow. Because of its durability and capacity to block UV radiation, polycarbonate is a perfect material for outdoor constructions.

Polycarbonate is not only extremely flexible and durable, but it can also be molded into a variety of shapes and sizes. This adaptability creates countless opportunities for imaginative and inventive architectural designs.

SELECTION AND CALCULATION OF DESIGN

Polycarbonate roofs have a wide range of applications; canopies over verandas, swimming pools, garden gazebos, and parking lots are all made of this lightweight, durable material (a photo example is provided). The coating is frequently used to create a range of canopies that are affixed to a private home’s porch or placed next to a garage, country home, and other buildings.

Depending on their function and design, each of these structures is classified into one of several types:

1. By design – a partition, an open canopy and a completely enclosed structure (for example, a country greenhouse, a winter garden).
2. Shape – single-pitch, gable, arched and domed.
3. By location – free-standing and attached.

The two primary components of any kind of structure are the polycarbonate coating and the supporting frame. The computation’s goal is to determine the best roofing material thickness and sheathing arch or rafter installation pitch based on the amount of snowfall.

Citation. Manufacturers create polycarbonate in sheets that are 6 and 12 meters in size, with thicknesses ranging from 6 to 16 mm. Products’ prices are directly correlated with their thickness.

If you choose the least expensive 6 mm sheet in an attempt to save money, you will need to create reinforced lathing with beams spaced 60–70 cm apart in order to increase the load-bearing capacity. You will consequently incur losses in terms of labor and material costs for the supporting structure.

Conversely, a cheap frame with a big jumper pitch will need to have thick, pricey polycarbonate covering it. How to select the optimal option:

1. Decide on the dimensions of the building and sketch out a sketch of the street canopy on paper, focusing on the example drawing.
2. From the regulatory documents (available in the public domain via the Internet), find out the thickness of the snow cover and the maximum load per 1 m2 for your area.

3. Choose the ideal purlin pitch to polycarbonate thickness ratio based on the snow load using the table provided by the well-known Polygal brand.

4. Determine how many lintels the rafters, foundation supports, and sheathing have.

Note: Most polycarbonate manufacturers whose products are sold in construction stores have similar load tables available.

MATERIALS FOR MANUFACTURING A CANOPY

Depending on the size of the structure, each case will require a different quantity of building materials. The following supplies must be bought in accordance with the drawing if you wish to construct a polycarbonate car canopy yourself:

• racks made of wooden beams 15 x 15 cm or a profile pipe with a cross-section of 80 x 80, 80 x 100 or 100 x 100 mm, depending on the height of the canopy;
• beams, purlins and trusses are made from metal profiles of 40 x 20 and 40 x 40 mm or lumber with a cross-section of 50-60 mm;
• polycarbonate sheets of selected thickness; decorative end profiles made of aluminum or galvanized steel;
• plastic sheet connectors;

• shaped elements – corners, ridge profiles;

• aluminum adhesive tape;

• special thermal washers and fastening self-tapping screws.Advice. A proven way to make the task of calculating and selecting materials easier is to contact the company where you plan to order polycarbonate. Specialists with sales experience can offer several design options; all you have to do is choose the appropriate project.

An industrial machine is required to create arches from profile pipes, making the assembly of an arched canopy more challenging than that of a single-pitch canopy. It’s wise to take into account an alternate option when organizing an independent installation: building a canopy out of a prefabricated set of ready-made metal structures. You can order individual frame elements if the building’s design and dimensions deviate from the suggested standard range of products.

You must get ready brackets and anchor bolts for wall attachment before assembling a canopy mounted on a balcony or fastened to a home. When selecting polycarbonate sheets, look for UV protection in the form of a colored film that includes installation instructions and information about the manufacturer. Watch the video for additional helpful information about polycarbonate.

FRAME CONSTRUCTION

Building a supporting structure for a polycarbonate canopy supported by supports is the first task. A strong, deep foundation is not required because of the structure’s light weight. The base needs to be strong enough to support wind loads and snow loads in the winter without allowing the racks to bow or fall.

Three methods exist for creating a superior visor foundation:

1. Drill holes in the ground to a depth of 0.8-1 m, install supports and secure with rubble stone. Other options are full and partial concreting, used in the process of building fences.
2. If the carport is being built for 1-2 cars, pour a reinforced concrete slab according to the size of the car, and attach the pillars to the monolithic base with anchor bolts. A similar solution is used to install a canopy over the entrance with a finished concrete porch.
3. Supports for a covered terrace, a greenhouse with beds or a carport can be placed on screw piles screwed into the ground to a depth of 1-1.5 m. Further work depends on the selected project. A common option: pairs of racks can be connected by trusses, which are connected into a single structure by purlins, as shown in the drawing. The elements are fastened together with bolts or by welding; upon completion of work, they are primed and painted in 2 times.

For a range of construction projects, polycarbonate structures provide a flexible and long-lasting alternative. Because of their lightweight yet durable design, they are a great option for both residential and commercial applications, from skylights and facades to greenhouses and carports.

Because of the material’s exceptional light transmission and resilience to impact, polycarbonate structures are guaranteed to be both functional and visually beautiful. They are therefore a well-liked option for rooms that need natural light without sacrificing longevity or safety.

The simplicity of installation of polycarbonate is another important benefit. Because the panels are lightweight and easily trimmed to size on-site, construction is made easier and labor costs are decreased. Furthermore, the material’s adaptability fosters imaginative and creative designs, enabling architects and builders to explore uncharted territory.

Polycarbonate structures are easy to maintain; all that is needed to keep them looking their best is a little bit of basic cleaning. Their ability to withstand weather and UV rays also means that

Because of their strength, portability, and low weight, polycarbonate structures are seeing a rise in popularity in the construction industry. Everything you need to know about using polycarbonate will be covered in this article, including common applications, installation and maintenance advice, and key benefits. Whether you’re thinking of using it for a patio cover, greenhouse, or any other project, you’ll find helpful tips and insights to maximize this cutting-edge material.

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