When to Use Corrugated Plastic Panels

Aug 04, 2022

Corrugated plastic panels are sheets of plastic made of polypropylene, polycarbonate, or polyethylene in three layers.

The corrugated plastic panels have three layers. There are two external layers, which is why they are also called twin-wall plastic panels or sheets. The zigzagged internal layer is held by the external ones and shaped like a honeycomb.

Corrugated plastic may also be plastic sheets with a wave-like profile that may be strengthened with glass fiber.

Corrugated plastic panels usually go by other names such as Coroplast sheets, thin-walled plastic, fluted plastic board, twin-wall sheets, or corrugated plastic boards.

The leading brands of corrugated plastic panels include Coroplast, FlutePlast, Correx, Corflute, Twinplast, Polyflute, Corriboard, Proplex, and Corriflute.

The structural profile of corrugated plastic sheets makes them highly shock-absorbent, lightweight, and limitlessly versatile material on roofs and walls.

The following are instances when you can use corrugated plastic panels or flat sheets across various industrial or residential applications.

1. When Erecting Outdoor Structures to Withstand Extreme Weather

Corrugated plastic panels can withstand extreme weather conditions like heavy rain, snow, intense heat, hail, and freezing temperatures. They are also able to withstand mildly strong winds.

If you plan to build an outdoor structure in a home, hotel, or other suitable places, you can use corrugated plastic sheets on the sides, the roof, or both.

The panels are ideal for carports, pergolas, patios, and porches.

2. When You Want Panels with Optical Properties

transparent corrugated plastic panels


You might want to use translucent corrugated plastic panels on the roof or sides of a structure to maximize their optical properties.

The translucent panels will allow light to pass through them, which can be an excellent way of saving electrical energy by relying on the natural light that flows through them into your structure.

Translucent corrugated panels are used in greenhouses to allow some light to pass through while blocking direct heat from the sun.

The suitability of the panels in greenhouses also stems from their ability to withstand extreme weather conditions. They will protect your crops and harvested agricultural produce from snow, hailstones, heavy rain, excessive heat, and wind.

3. When Making Temporary Humanitarian Shelters

The same properties mentioned above for the suitability of corrugated panels in erecting outdoor structures apply when you want to make a temporary humanitarian shelter.

In addition to the above properties, the ease of transportation, ease of cleaning, lightweight nature, and ease of installation further make corrugated plastic panels ideal for temporary shelters.

Such shelters include people identification shacks, first aid points, treatment booths, and temporary mini-houses. The design will depend on the purpose the structure will serve and how long you intend to use it.

4. When Erecting Temporary Signage

Most temporary signs use corrugated plastic sheets that can withstand extreme outdoor conditions like rain.

You can use the plastic panels to make construction site signs, election campaign signs, real estate signs, trade show displays, business advertising signs, yard sale signs, and lawn signs.

You can also use corrugated plastic panels to make social-supportive signage (such as those people place in front of their property to support COVID-19 healthcare workers).

5. When Constructing Houses for Pets with Corrosive Waste Matter

Pets like rabbits have corrosive urine that eats into metallic sheets. If you plan on building a hatch with a urine collection system, you can install corrugated plastic panels at an incline under each level.

The urine from the rabbits flows down the panels and becomes harvestable with gutters placed at the lower end of the panels.

Each level will have several corrugated panels flowing under it, so rabbits from upper levels won’t be urinating on those on lower levels of the hutch.

Besides rabbit houses, corrugated plastic sheets are also used in cages for small animals like domesticated hedgehogs and guinea pigs.

6. When You Want a Reusable Packaging Material

You’ve probably seen plastic containers constructed using corrugated plastic panels. The panels are ideal for this application because they are reusable, lightweight, and easy to cut.

If you transport lightweight but bulky commercial goods, containers made from corrugated plastic panels are a good option. The added advantage is that the panels are recyclable and can be upcycled.

Because of their shock-absorbing properties, you can also use corrugated plastic sheets as product padding material. The hollow spaces in the internal layer trap air to provide a reliable shock-absorption effect.

7. When You Want a Splash of Color

corrugated plastic panels

Although plastic panels are typically translucent, colored panels are also available. The colored ones are usually installed on roofs when you want a highly visual spectacle with either a single color or a creative combination of different colors.

8. When Making Simple Plastic Aircraft

The use of corrugated plastic panels to make Simple Plastic Airplane Design (SPAD) aircraft is more common among hobbyists. But you can also make such aircraft as an architect, construction company, mining company, farmer, designer, or contractor.

The uses of such SPAD aircraft may vary from user to user, but the most common is photography or videography by attaching cameras to the radio or remote-controlled model aircraft.

High-level SPAD model airplanes are commonly made by people who put money into the hobby to have the feel of flying a self-made model plane.

Commercially, you could use such small planes to monitor construction sites, warehouses, or small farms.

9. When You Want to Protect Walls and Floors in Construction Sites

knit plastic nets

Traditionally, sand is used to protect floors and knit plastic nets are used to protect walls on construction sites. Where shock absorption or a thicker layer of protective material is required, you can use corrugated plastic panels.

Laying the panels close to each other on the floor or attaching them to a wooden base and propping this on the walls can save your floors and walls from damage caused by falling or flying lightweight objects.

The same setup of plastic panels is useful as a temporary floor covering when doing home or office improvements and renovations.

Such floor coverings are also used in events with high foot traffic, but it’s rare that you’ll need that. Well, unless you need to host your business associates!

10. When Making Construction Estimates

In the residential or commercial construction industry, corrugated plastic panels are ideal as placeholders for building templates.

You might need to make a temporary structure to mimic the real one you want to construct, such as a house.

Since the panels are easy to cut and install, it will be easy to construct the dummy structure to gauge how much permanent material you’ll need.

Using the panels to make the dummy structures saves you time and helps you cut down costs by avoiding waste. It also saves you time caused by delays or project changes.