Polycarbonate

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Contents 1 Material analysis 1.1 Traditional uses 1.2 Emerging uses / trends 1.3 Finish and aesthetic qualities 1.4 Surface forms / shapes 1.5 Cost analysis 2 Material properties 2.1 Structural use 2.2 Material performance 2.3 Dimensional and opening restriction 2.4 Acoustic property 2.5 Manufacturing process and assembly 3 Environmental impact 3.1 LEED 4 Life Safety & Rating Standards 4.1 Flammability rating 4.2 Coefficient of friction 5 References 5.1 Notes 5.2 Student contributions 6 See also 6.1 Similar materials 6.2 Building references 7 External links 7.1 Additional resources 7.2 Leading manufacturers

Material analysis

MasterFormat Number: 08 45 13 Structured-Polycarbonate-Panel Assemblies or 08 84 13 Decorative Plastic Glazing

Traditional uses

• Polycarbonate is an engineered plastic resin belonging to the polyester family of plastics. This thermoplastic has original uses in the areas of electronics and the automotive industries. It has been manufactured into bumpers for cars and head lamp lenses, along with battery box, mobile phones, and electrical chargers.

Emerging uses / trends

• This durable plastic resin has been successful for protective glaze in interiors as bullet proof glass. Polycarbonate is also used as a façade for exterior applications as well as interior partitions and slab to slab walls. For decorating purposes it is used for contemporary molded furniture.

Finish and aesthetic qualities

• There is variety of uses for polycarbonate resulting in a selection of finishes depending on the concept of the building.
• An option of transparency is largely used outside or inside from no tint to added pigments of any color.
• Transparency not only conveys interest, but can be functional too, whether it is to divide a space or allow for light to pass through.
• Decorative patterns are applied to the surface by adhering acrylic sheets for added interest of opaque color or motifs.

Surface forms / shapes

• Available in all shapes and sizes from cd’s, to bus shelters, to identification cards, to eye glasses.
• Most commonly used in interiors as sheets in all ranges of sizes and thicknesses.
• Typical thicknesses: 3/8”, ¾”, ½”, 1 ¼”.
• Sheets are available in any dimension upon request, possibly as large as 6’ x 38’ long.
• Depending on the piece of furniture, each item is manufactured as a solid piece from a mold.

Cost analysis

• Estimate starting at 1/16” is $14 Sq.Ft.

Material properties

Structural use

• Compression for structural uses.
• Tension for non structural, e.g. furniture.

Material performance

• Strong and durable.
• Good dimensional stability.
• High sound absorbency.
• Good chemical resistance to oils and acids.
• Poor resistance to alkalines.
• Abrasive resistance - ASTM D1044
• Yellowing occurs without a protective coating from UV light exposure.
• Untreated, not resistant to weathering.

Dimensional and opening restriction

• Polycarbonate sheets are available in a variety of sizes and thicknesses. Upon request excessively large sheets are custom made and attached to the facade for aesthetics.
• Furniture pieces must be made to the comforts of human dimension. Also, keep in mind the ability of each piece to fit through paths of egress for proper placement within the interior space.

Acoustic property

• 0.09/ in. for longitudinal compression of ultrasonic velocity.
• High sound absorption with recent applications of polycarbonate to string instruments for better acoustics.

Manufacturing process and assembly

• After a reaction between bisphenol A and phosgene, a polymerization (fusion) of 3 oxygens to a carbon results in an engineered thermoplastic.
• Formation of the final product of polycarbonate produced by the following techniques: injection molding, structural foam molding, extrusion, vacuum forming, or blow molding.
• Additives like ABS (Acrylonitrile Butadiene Styrene) are mixed with polycarbonate to strengthen material from stress or cracking.

Environmental impact

• Has a relatively long life span that exceeds ten years depending on its application and additives used during manufacturing.
• An environmental hazard are laminated acrylic sheets applied to polycarbonate for aesthetic purposes which causes off- gassing of VOC’s.
• Disposing of polycarbonate is hazardous as it takes a large amount of energy to heat and burn. Then the off gassing of carbon dioxide is visibly seen with black dense smoke during the breakdown of polycarbonate resulting in pollution.
• Since polycarbonate is relatively new synthetic, there is no evidence yet of the material decomposing in our natural environment that would cause contamination to water or soil.

LEED

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Life Safety & Rating Standards

Flammability rating

• Flammability rating is V0- V2.
• Self extinguishing.

Coefficient of friction

• Data not available.

References

Notes

Student contributions

• Ashley Pearson, Spring 2010

See also

Similar materials

• lightblocks
• Panelite
• Sensitile

Building references

• Laban Centre, UK

External links

Additional resources

• AGR Field Operations
• Design- Conscious, UK
• Hart Supply Co., Inc.
• Interior Design Architecture Furniture
• MasterFormat

Leading manufacturers

• AGR Field Operations
• Hart Supply Co., Inc.