Polycarbonate Greenhouse Glass Replacement Panels
Replace broken, cracked or ageing greenhouse glass with clear polycarbonate glass panels cut to your required dimensions. Polycarbonate provides glass-like transparency with significantly greater impact resistance, making it a practical choice for repairing existing greenhouse walls and roof sections.
Our clear, solid polycarbonate sheets are lightweight, UV-resistant and suitable for outdoor use. Choose the thickness and measurements required for each pane, and we will cut your replacement greenhouse panels to size, ready for installation.
Suitable materials
The best material for a greenhouse depends on factors such as durability, insulation, and cost:
- Impact-resistant
- UV-resistant
- Lightweight
- More expensive than acrylic
- Sensitive to scratches
- Traditional appearance
- Good light transmission
- Heavy
- Fragile
- Costly to install
Why replace greenhouse glass with polycarbonate?
Polycarbonate is a strong, transparent plastic commonly used as an alternative to glass. It is particularly suitable for greenhouse glazing where panels may be exposed to hail, falling branches, footballs or accidental impacts.
The main benefits of using polycarbonate greenhouse glazing include:
- High impact resistance: Polycarbonate is far less likely to break or shatter than conventional greenhouse glass.
- Lower weight: The sheets are easier to lift, position and secure within an existing greenhouse frame.
- High transparency: Clear polycarbonate allows natural light into the greenhouse while providing a glass-like appearance.
- Outdoor suitability: UV-resistant sheets are suitable for prolonged exterior use.
- Cut-to-size ordering: Individual panels can be ordered to match the dimensions of the panes being replaced.
- Safer handling: The material does not break into sharp glass fragments during installation or accidental impacts.
Is polycarbonate suitable for your greenhouse?
Polycarbonate sheets can normally be used to replace flat glass panes without replacing the entire greenhouse. However, check the following before ordering:
- The greenhouse frame is structurally sound.
- The glazing channel can accommodate the selected sheet thickness.
- Existing clips, glazing bars or rubber seals are suitable for reuse.
- The replacement panel is flat rather than curved.
- Adequate clearance can be left for thermal expansion.
- Roof panels have sufficient support for the selected thickness and panel size.
Inspect each opening individually. Even when panels appear identical, their dimensions can vary slightly across an older greenhouse.
Where the frame, clips or glazing seals are damaged, repair or replace them before fitting the new panel.
What thickness of polycarbonate should you use for greenhouse panels?
The correct thickness depends on the size and position of the panel, the amount of support provided by the frame and the width of the existing glazing channel.
| Thickness | Typical application |
|---|---|
| 4mm | Smaller en standard-sized greenhouse panels |
| 5mm | Larger panels or areas where additional rigidity is required |
| 6mm | Larger panels and some roof sections, where the fram can accommodate the additional thickness |
Always check the thickness of the existing panel and the depth of the greenhouse frame before ordering. A thicker panel provides greater rigidity but may not fit into glazing bars designed for thinner horticultural glass.
For particularly large roof panels or exposed locations, use the sheet tickness calculator.
| Feature | Polycarbonate | Traditional greenhouse glass |
|---|---|---|
| Impact resistance | Highly resistant to impacts | More easily cracked or shattered |
| Weight | Lightweight and easier to handle | Heavier |
| Transparency | Clear with high light transmission | Very clear |
| Installation | Easier to lift and position | Requires more careful handling |
| Safety | Does not break into sharp glass fragments | Broken panels can create sharp edges |
| Scratch resistance | More susceptible to scratching | More scratch-resistant |
| Thermal movement | Expands and contracts with temperature | Less thermal movement |
| Appearance | Clear, modern appearance | Traditional appearance |
Polycarbonate is generally the better choice where impact resistance, weight and safety are the main priorities. Glass may remain preferable where scratch resistance or a completely traditional finish is more important.
How to measure replacement greenhouse panels
Measure each greenhouse opening separately rather than assuming that every pane is identical.
- Check how the existing pane is secured
Identify whether the greenhouse uses spring clips, glazing bars, rubber seals or another fixing system. - Measure the opening
Measure the internal width and height at more than one point. Use the smallest measurement where the frame is not completely square. - Check the required thickness
Measure the existing pane or glazing channel to confirm which thickness the frame can accept. - Allow for expansion
Polycarbonate expands and contracts as temperatures change. Do not order the panel as a tight friction fit. Allow a small clearance in both the width and height, following the greenhouse manufacturer’s instructions where available. - Label each panel
Record where each measurement belongs, particularly when replacing several panes of different sizes.
How to order polycarbonate greenhouse glass
You are ordering individual replacement polycarbonate panels rather than a complete greenhouse.
- Choose your sheet thickness Select the clear polycarbonate sheet that is appropriate for the frame and panel size.
- Enter your measurements Add the required width and height using the online sheet calculator.
- Select any additional processing Add drill holes, cut-outs or a custom shape where required. A DXF file can also be uploaded for more complex panel shapes.
- Review and order Check the measurements, thickness and quantity before completing the order.
Each panel will be cut to the dimensions entered during the ordering process.
