Chloe Zhang
Corrugated plastic sheets, also known as Corflute panels, Correx sheets, and Coroplast boards, are made from polypropylene plastic. They are used in a variety of applications, from outdoor signage to food packaging. Joining these sheets together can be done in several ways, including using specialised adhesives, welding, rivets, and other mechanical fasteners. The choice of method depends on factors such as cost, ease of assembly, and the desired strength of the joint.
| Characteristics | Values |
|---|---|
| Materials | Corrugated plastic sheets, also known as Coroplast, Correx, Corflute, Danpla, Polyflute, Impraboard, Infraboard, Polypropylene Fluted Board |
| Use Cases | Temporary outdoor signage, recyclable food plastic packaging, automotive, construction, displays, point of sale, railways, pharmaceutical packaging, boat building |
| Joining Methods | Ultrasonic welding, polypropylene glue (Tecbond 261 or Tecbond 267), rivets, lacing or zip ties, tape, polyurethane construction adhesives, AC Super Glue, Loctite 406 glue |
| Notes on Joining Methods | Ultrasonic welding creates a seamless, smooth appearance. Polypropylene glue has good temperature resistance and is not dependent on moisture or humidity. Ordinary glue will not work. Rivets are permanent and must be destroyed to separate the sheets. Lacing or zip ties allow for the seam to be taken apart. |
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Using glue
Corrugated plastic sheets are made from polypropylene, which is resistant to most adhesives. Ordinary glue will not work, so you will need to use a specialised glue designed for bonding plastics. It is recommended to use a glue that is formulated for olefin plastics, such as a hot glue gun with a glue stick compound.
Before gluing, it is important to clean the surfaces with a methylated spirit and allow them to evaporate. Once dry, apply small spots of adhesive every half to three-quarter inch onto one surface. Place the two surfaces together and apply even pressure along the length of the join.
There are several types of glue that can be used for bonding corrugated plastic sheets. Loctite, a trade name for corrugated plastic sheets, is commonly used and recommended by many. Other successful glues include CA glue, 3M Scotch-Weld SF-100, and wheat glue.
It is important to note that some glues may not work for all corrugated plastic sheets, so it is recommended to test the glue on a small area first. Additionally, consider the purpose of the corrugated plastic, as some glues may not be suitable for certain applications. For example, silicone is not recommended for polypropylene as it does not grip the surface well.
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Ultrasonic welding
Joining corrugated plastic sheets requires specialized methods due to the material's composition. Ordinary glue, for instance, is ineffective, and specific adhesives formulated for polyolefin plastics must be used. One such adhesive is Tecbond 267, which can bond polypropylene and polyethylene. This glue has good temperature resistance, is not dependent on moisture or humidity, and can be cured at room temperature.
To insert nuts or metal strips into PP corrugated sheets, the ultrasonic welding process can be adapted. The high-speed vibration embeds the metal directly into the coroplast boards while simultaneously melting the plastic. Once solidified, the embedding is complete, creating a mechanical fastener.
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Nuts and metal strips
Corrugated plastic sheets, also known as corflute panels, correx sheets, corex sheets, danpla sheets, fluted plastic sheets, and coroplast boards, are made from polypropylene plastic. They are lightweight, flexible, durable, and shock-absorbing.
One method of joining corrugated plastic sheets is by using nuts and metal strips. Here is a step-by-step guide on how to do this:
Firstly, place the nuts or metal strips in the equipment. Vibrate the equipment at a high speed to embed the metal directly into the coroplast boards. Simultaneously, melt the plastic, and allow it to solidify, completing the embedding process. This method is known as a mechanical fastener and is a traditional and low-cost technique.
It is important to note that this process requires specialized equipment to vibrate and melt the plastic, and it may not be accessible to everyone. Additionally, the use of nuts and metal strips creates a permanent joint, and separating the joined sheets would require destroying the nuts or the plastic itself.
Another option for joining corrugated plastic sheets is by using rivets, which is also a type of mechanical fastener. Rivets can be used to permanently secure the sheets together, and the process, known as "riveting," involves creating holes in the sheets and using a tool to set the rivets in place. This method is also low cost and traditional but may leave visible marks on both sides of the joined sheets.
When choosing an adhesive for corrugated plastic sheets, it is important to use a specialized glue designed for polypropylene, such as a one-component synthetic resin composite glue, as ordinary glue will not work. These specialized glues have strong adhesion, stable performance, moderate viscosity, and can be cured at room temperature. They are suitable for both PP corrugated bonding and large-area bonding of PP with other materials.
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Rivets
To use rivets, you will need to drill holes in the sheets. To do this, you can use a drill, a punch, or a regular drill bit. If you are using a thinner sheet, you can also use a hollow-core paper drill to make a tidy hole. It is good practice to make smooth holes to allow for the rivets.
When riveting corrugated plastic, it is important to use washers to distribute the load. If you do not use washers, the screw head may tear out of the plastic as it stretches or tears. You can use fender washers, which are placed on both sides of the rivet, to help secure the joint. The size of the washers should match the size of the rivet. For example, a 3/16-inch pop rivet would use 3/16-inch ID, 3/4-inch OD fender washers.
When attaching two pieces of corrugated plastic together, you can use a pop rivet with a depth of 5/8 of an inch. This will ensure a strong and secure joint.
It is important to note that rivets cannot be tightened like bolts, and if they loosen over time, they will need to be replaced.
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Lacing or zip ties
When drilling holes, use a drill bit with spurs on the edge, like IRWIN Speedbor Bits, to make clean holes. A regular drill will work, but a hollow-core paper drill will make tidier holes. If you are drilling into thinner boards, use a Unidrill.
If you are using lacing, you can tack the seam using contact cement or hot glue to keep the pieces in position. Polypropylene can also be welded using heat, but this is usually done by professionals using ultrasonic or hot air tools.
Zip ties are often used to secure corrugated plastic sheets in DIY projects, such as guinea pig cages. They are also used in conjunction with plastic connectors to add rigidity to structures.
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Frequently asked questions
Ordinary glue will not work to join corrugated plastic sheets. You should use a specialised polypropylene glue, such as Tecbond 267, which is a one-component synthetic resin composite glue with strong adhesion and stable performance.
An alternative to glue is to use rivets, which are a type of mechanical fastener. You can use pop rivets with fender washers to join corrugated plastic sheets.
Another method is to use ultrasonic welding, which involves using ultrasonic waves to melt the interface of the sheets and then applying pressure to fuse them together.
