Is Polycarbonate Sheet Unbreakable? Understanding Its Incredible Strength
Discover why Lexan polycarbonate is known as "virtually unbreakable" and where its limits actually are.
The Short Answer: Virtually Unbreakable
Polycarbonate is not technically unbreakable, but it's close enough that it's used in applications where failure could be catastrophic: bulletproof glass, police riot shields, hockey rink barriers, and fighter jet canopies.
Impact Resistance by the Numbers:
- 200x stronger than glass
- 30x stronger than acrylic
- Can withstand impacts up to 300 times its own weight
- Won't shatter - it bends before breaking
What Does It Take to Break Polycarbonate?
Standard 3mm-6mm polycarbonate sheets used for roofing and glazing would require:
- Extreme blunt force: Multiple strikes with a sledgehammer or similar heavy tool
- Sharp concentrated force: Power tools, diamond blades, or specialized cutting equipment
- Projectiles: High-velocity impacts like bullets (though thick sheets can stop these too)
Real-World Applications of Polycarbonate's Strength
Security and Safety Glazing
Polycarbonate sheets are the standard for:
- Bank teller windows and ATM shields
- Prison and courthouse glazing
- Machine guard protection
- Bus and subway vandal-resistant windows
Bulletproof Glass Systems
Thick polycarbonate (25mm-75mm) is laminated with glass and other materials to create bullet-resistant glazing systems rated to stop:
- Level 1: Small handgun rounds (9mm)
- Level 2-3: Large handgun rounds (.357 Magnum, .44 Magnum)
- Level 4+: Rifle rounds and multiple shots
Sports and Recreation
Polycarbonate protects spectators and players in:
- Hockey rink barriers (resists puck impacts at 100+ mph)
- Baseball dugout protection
- Motorcycle and racing car windscreens
When Can Polycarbonate Break?
Despite its strength, polycarbonate can fail in these scenarios:
- UV degradation: Uncoated sheets exposed to sunlight become brittle over time (all our sheets have UV protection)
- Chemical exposure: Certain solvents can weaken the material structure
- Improper installation: Over-tightened fasteners can create stress fracture points
- Extreme cold: Below -40°C, even polycarbonate becomes more brittle
Polycarbonate vs Acrylic for Impact
While acrylic is also stronger than glass, polycarbonate is 30x tougher than acrylic. Acrylic will shatter under impacts that polycarbonate simply absorbs. For any application where breakage could cause injury or security concerns, polycarbonate is the only choice.
The Bottom Line
For all practical purposes, polycarbonate sheets from Plastics Canada are unbreakable in normal use. Whether you're building a patio roof, greenhouse, or safety barrier, you can count on polycarbonate to withstand hail, falling branches, impacts, and weather that would shatter glass or acrylic.