PolyCarbonate Structured Sheet (PCSS)

Manufacture
Polygal PCSS is custom manufactured in a continuous extrusion process in widths up to 82" (2 meters). Stock widths are 48" and 72", with lengths limited only by shipping constraints.

Fabrication
Polygal PCSS can be easily drilled, cut, punched, sheared and bent using simple hand tools or sheet metal fabricating equipment. A razor knife can be used to cut most thicknesses. for heavier gauges, a hand held circular saw with fine teeth is recommended. chips and dust can be removed from the cellular structure with compressed air. When drilling holes it is necessary to allow for thermal expansion. Holes should be at least 1 1/2" from the edge of the sheet.

Design
Polygal PCSS is an engineered plastic. Specification of design criteria, the design of supporting structures and attachment of Polygal PCSS to a structure should be determined by an engineer. Polgal can provide design charts and prepare computer analysis of typical applications. Contact Polygal USA for additional information.

Impact Resistance
Polygal PCCS withstands the impact of 16 lbs. dropped 25 feet without breakage. Exceeds Gardener Falling Dart Impact Test limits. Exceeds ASTM E822.87 Hail Impact Test requirements. Impact Tests: Falling Dart, 220 ft-lb (1/2" radius tip): no rupture. Air Cannon, 100ft-lb (1 1/2 diam tip at 95 mph): no penetration.

Glazing Systems
Polygal may be installed in most aluminum, polycarbonate or wood glazing systems designed for glass. Standard metal sections can be used in various combinations.
Dry glazing systems are especially suited for Polygal sheets. Neoprene, Silicone, EPDM rubber or PVC gaskets of at leas 80 durometer are reccommended. (CAUTION: Compatibility of PVC gaskets with polycarbonate should be verified before use.)
Wet glazing systems are suitable for Polygal sheets when thermal movement is not expected. Polybutylene glazing filler tapes are acceptable, as are silicone and one- or two-part polysulfide non-hardening sealants. Amine and benzamid curing silicone sealants are not suitable for use with Polygal sheets. Compatibility with polycarbonate should be verified with Polygal USZ and the sealant or tape manufacturer. (CAUTION: Wet glazing systems must be designed and applied to accommodate thermal expansion of the glazing material.)

Flammability & Code Requirements
Polygal PCSS is classified as "Light Transmitting Plastic" with performance characteristics as follows:

  • Horizontal Burn Rate: ASTM D635, UBC 52-4 or UL 94HB. Light Transmitting Plastics are classified as either CC-1 (extent of burn 1" or less) or CC-2 (burn rate of less than 2.5"/minute). Polygal PCSS of 1/4" (6mm), 5/16" (8mm), 3/8" (10mm) and 5/8" (16mm) thickness are classified CC-1.
  • Smoke Density: ASTM E-84, or D-2843; UBC 42-1 or 52-2. Codes commonly require a Smoke Density Rating of not greater than 75 per ASTM D-2843. Polygal PCSS meets these requirements.
  • Ignition Properties: ASTM D-1929 or UBC 52-3. Model codes typically require Light Transmitting Plastic to have a self-ignition temperature of 650ºF or greater. Polygal PCSS meets this requirement with a self-ignition temperature of 986ºF. Melts at 800ºF.
  • Flame Spread: ASTM E-84 or UBC 52-3. Model building codes typically do not specify a flame spread requirement. Values for Polygal PCSS vary with thickness and range from 10 to 80.

Installation Guidelines
Co-extruded UV-stabilized surface layer must be installed to the exterior. The "Exposure Side" is indicated on the protective film covering.
Sheets should be installed with extruded ribs oriented vertically. Open ends should be sealed to prevent dirt and debris from entering sheet structure.
A 5º minimum slope is recommended.
Edge engagement or bite should be at least 1/2" for sheet thicknesses up to 3/8" (10mm). For 5/8" (16mm) sheets, edge engagement should be 3/4".
Rabbet depth of frame is calculated as edge engagement plus thermal expansion for the size of sheet being used (1/8" per 3' of length or widthper 100ºFtemp. differential).