Acrylic sheets are some of the most commonly used plastic materials used in commercial, industrial, and residential construction projects. Often used as a strong replacement for glass, acrylic sheets can be transparent or opaque and they come in a variety of custom colours to match the aesthetic of the structure to which they’re being applied. They work as a solid alternative to glass—which is heavy, expensive, and extremely fragile.
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Contrary to glass, acrylic sheets are completely lightweight, affordable, and versatile. They can be cut, resized, or reshaped on the spot to fit specific structural parameters and dimensions whereas glass would need to be transported back and forth on and off the jobsite to make modifications. Naturally, people have a lot of questions for acrylic sheet suppliers in terms of how well their products work, cost, and whether they hold up for long periods of time. We have the answers.
Applications for acrylic sheets can vary from home improvement to sporting equipment, aquariums, military technology, sculptures, fluorescent light fixtures, and so much more. Acrylic sheets are so durable and versatile that they serve a multitude of purposes depending on the specific application in question. When it comes to construction, for instance, acrylic sheets can replace glass windows and skylights. They’re easier and more lightweight to transport and install. Plus, acrylic sheets are not fragile like glass and won’t shatter if dropped. They’re completely scratch-, corrosion-, and UV-resistant.
Technically, acrylic sheets have a higher upfront cost than traditional glass sheets would. But, it’s still a worthwhile alternative for a number of reasons. As mentioned, acrylic is lightweight, durable, and a lot easier to install than glass. Acrylic and glass also share a lot of similar qualities in the sense that they’re both transparent and they both let in a lot of natural lighting. The reason acrylic costs more is because it’s a lot stronger and more weather-, scratch-, and impact-resistant than glass. Plus, acrylic is likely to last longer than glass and can endure exposure to all kinds of weather and environmental elements without showing signs of degradation, so you’ll definitely get your money’s worth.
Yes, acrylic Plexiglas is incredibly durable, especially compared to glass. It’s also about 50% lighter in weight than glass, which is another reason why it’s the more preferable choice for various applications. Acrylic Plexiglas can be manufactured using a cast or extruded method (free-form). Either way, it’s incredibly durable and the chemical compounds (polymethyl methacrylate) used in the manufacturing process make it shatterproof as well as temperature-, weather-, and impact-resistant. Even if it does sustain damages or breaks, unlike glass, acrylic Plexiglas pieces would have dull edges, and this minimizes the risk of injury. This is an important safety feature that makes acrylic the perfect material for a variety of applications that require human contact and use.
Contrary to what a lot of people think, acrylic isn’t an alternative to plastic. Actually, it’s a type of plastic material. The main difference is that acrylic is an industrial-grade thermoplastic that’s typically formulated for applications that require the utmost durability, temperature, and impact-resistance. For instance, if you’ve ever watched a hockey game and you see the players body-checking one another into the baseboards, then you’ve seen acrylic plastic in action. The baseboards, which are made of acrylic sheets, are designed to be able to take a hit without cracking in freezing conditions.
Acrylic is the superior alternative material to glass for a number of reasons. As mentioned, acrylic is more durable while weighing half as much as its glass counterparts. This makes for seamless transportation and installation. Accidents and human errors can happen on construction sites. While they’re not ideal occurrences, having versatile materials on hand makes it a lot easier to fix mistakes. If glass gets damaged, it needs to be replaced and this can cause a lot of delays in an industry where time is money. Acrylic is a lot less likely to get damaged. Even if damages do occur, acrylic can be cut down to size and reshaped onsite to make it more suitable for the project.
Acrylic is a type of plastic. In fact, it’s one of the most uniquely durable and versatile types of plastic material currently on the market, which is why it’s used for such a wide range of applications.
While the final product itself isn’t toxic for human contact and use, the manufacturing process of acrylic plastic can admittedly be harmful to the environment and workers in the facility. Factory workers must wear protective gear to avoid coming into direct contact with acrylic plastic in its liquid form as it can release toxic fumes into the atmosphere. Still, this is nothing compared to the very toxic fumes released by other similar commercial and industrial building materials. Compared to other materials on the market, acrylic actually has a relatively low fume output and in its final form, it’s classified as a non-hazardous material by the Occupational Safety and Health Administration (OSHA).
Discolouration isn’t a concern for acrylic plastic because it’s formulated to withstand extensive sun and UV ray exposure. Acrylic plastic is derived from natural gasses, which makes it UV-resistant. This quality is the main reason why acrylic plastic is typically used for skylights, greenhouses, shed windows, and any other structures that need to sustain long-term sun exposure.
Clear acrylic sheets are incredibly weather-resistant. Like their colour counterparts, there’s absolutely no risk of discolouration due to extensive sun and UV ray exposure. These panels have a general lifespan of about 10+ years and can withstand all kinds of weather conditions including snow storms, heavy rain, strong winds, hail, and more.
There are three types of acrylic sheets currently available on the market:
Are you planning to purchase plastic sheets for your next project? Cut to size plastic sheets can bring efficiency, flexibility, and a customized fit, but there’s more to getting it right than simply ordering a specific size.
Understanding how factors like material expansion and cutting tolerance impact sheet size is important, whilst also appreciating how in some cases cutting to size yourself may be a better option.
In this guide, we’ll walk you through three of the essential considerations to make with plastic cut to size, ensuring you’re equipped to make an informed choice and achieve the best results for your project.
Plastic, like most roofing sheet materials, can slightly change size due to fluctuations in temperature. Especially in extreme UK winters!
This is called expansion and contraction. It is relatively simple to understand when heated, it can expand; when cooled, it contracts. However, the degree to which this occurs will vary depending on the type of plastic you’re using, but it’s a shared trait across all varieties, including acrylic, perspex, polycarbonate, and PVC.
Why does plastic sheet expansion matter?
If you’re using plastic sheets in an environment where temperatures fluctuate - such as outdoor installations, pool covers, or even certain indoor spaces - it’s crucial to account for these changes.
For example, a perspex sheet installed in autumn with lower temperatures, if thermal expansion is not considered when selecting your cut sizes, you may find that this is installed without the required allowance for this expansion. This will cause issues down the line when the weather warms up, potentially putting the sheet under strain.
In contrast, a sheet used for roofing where temperatures can be expected to drop considerably may contract leaving small gaps for water ingress if this contraction is not accounted for.
To prevent these kinds of issues from occurring, it’s a good practice to leave a small gap between the plastic sheet and its surrounding fixings or structure. This space allows the plastic to expand and contract as needed.
The specific gap you should allow for expansion and contraction will vary based on the type and thickness of the plastic sheets but in general, allow 2 mm on either side minimum.
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When ordering plastic cut to size, discuss your intended use with the manufacturer to determine how much of an allowance might be necessary. They may be able to advise on best practices and considerations based on the specific material you’re using.
A concept that might surprise some, is the idea of a tolerance in cut-to-size plastic sheets. Tolerance is essentially a slight margin of error that occurs during the cutting process of your sheets. While professional cutting machines are very precise, achieving perfect measurements down to the millimetre isn’t ever feasible, especially when working with large sheets.
Bear in mind, the larger the plastic sheet you are ordering the bigger tolerance you should allow.
When ordering cut to size plastic, most suppliers will provide a tolerance range. For example, most twinwall polycarbonate sheets will have a cutting tolerance of approximately 10mm (1cm), meaning the final size could vary slightly within this range.
It is important to note that this is generally a ‘plus or minus’ tolerance, meaning it may be slightly shorter, or slightly longer than your exact measurements.
Tolerances are necessary due to the mechanical processes used in cutting, particularly on sheets with internal structures.
The actual tolerance range can vary based on the type of plastic, the sheet’s thickness, and the cutting method used during manufacturing. Solid polycarbonate, for instance, often has tighter tolerances than twinwall or multiwall, due to being a solid material.
While a small tolerance may not seem like a big deal, it’s essential to account for it when planning your project. In certain applications, such as a roof installed with glazing bars with a tight-fitting assembly, even a minor size discrepancy can affect the outcome. Knowing the tolerance range allows you to adjust your measurements or installation method to accommodate any potential variation.
If your project requires extremely precise measurements, it can be best to leave yourself some play in the measurements you select with a view to trimming these down more accurately on site once your sheets arrive. This can depend of course on the specific material and how easy it is to work with – see the next point below.
If as mentioned above you choose to work with your sheets on site, one of the significant advantages of plastic sheets generally speaking is their ease of trimming, which allows for this. Unlike materials like sheet metal or glass, plastic can be trimmed using basic tools, even in a non-professional setting, if you choose the right type of plastic.
Polycarbonate sheets are generally considered the easiest type of plastic to cut, whereas perspex, petG, and acrylic can shatter during cutting.
This feature makes polycarbonate an excellent choice for most projects, as adjustments are usually necessary.
Depending on the type and thickness of the plastic sheet, you have several options for trimming on-site. For thinner sheets, like acrylic, a scoring knife or utility blade can often do the job. However, acrylic can split and crack when cutting so it is sometimes best to opt for a higher-quality polycarbonate option.
Polycarbonate is a great option as it will not go brittle or shatter when cutting like other, cheaper alternatives. It is incredibly easy to cut down or drill on site.
To cut polycarbonate sheets you will require:
This quick How to cut polycarbonate sheets video will walk you through the steps required!
The ability to trim plastic sheets on-site offers flexibility that is especially useful if you encounter obstacles, you did not foresee. For example, if you’re installing a roofing sheet and find you have measured incorrectly or have a pipe to work around, you can quickly adjust to achieve a perfect fit. This is a significant advantage when working with custom-cut plastic sheets because you can ensure that every piece aligns just right with your installation needs.
Cut-to-size plastic sheets offer convenience, versatility, and an array of practical applications, making them an excellent choice for various projects. However, understanding a few essential points before making a purchase can make a world of difference in the success of your project.
The three important things to know when buying plastic cut to size are:
First, remember to allow for expansion and contraction in the plastic, especially if your project will be exposed to temperature changes. This simple consideration can prevent warping and cracking over time.
Second, be aware of tolerance ranges, which account for slight variations in size due to the cutting process. While usually minimal, tolerance can impact projects requiring precise measurements.
Lastly, take advantage of polycarbonate sheets’ easy-to-trim quality. Being able to make minor adjustments on-site gives you greater control over the outcome, ensuring every panel fits perfectly.
By keeping these three factors in mind, you can confidently purchase plastic cut to size, knowing you’re fully prepared to work with the material effectively. Whether you’re tackling a large construction project or a small DIY endeavour, understanding these aspects will help ensure your project goes smoothly and meets your expectations.
Please contact us if you have any further questions with our plastic sheet range. Our Live Chat Teams are always happy to discuss any questions with you. Alternatively, you can contact us where our Teams will provide you with all the advice and support you require for your projects.
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