Three roofing materials over time
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Material
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3 years
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5–8 years
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Beyond 10 years
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Coated steel sheet
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Rust at cuts and drill holes
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Spreading rust, coating peel
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Wholesale replacement
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|
GRP roof light
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Surface yellowing
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Chalking, exposed fibre, embrittlement
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Severe transmission loss, replacement
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|
PC roof light
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Essentially unchanged
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Slight yellowing with UV layer
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Still serviceable, gradual transmission loss
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The failure mechanisms differ: steel corrodes electrochemically, GRP degrades its resin, and PC mainly photo-oxidises — and photo-oxidation is precisely what a UV co-extruded layer controls.
What PC resists
Salt spray, which is the coastal concern; dilute acids and alkalis in short contact; water and humidity, since PC does not absorb water; and most inorganic salt solutions found in industrial settings.
What it does not resist
Suppliers often omit this, and it is where incidents originate: strong alkalis at high concentration cause surface attack and stress cracking; ammonia and amines crack it quickly; ketones, esters and aromatic hydrocarbons — acetone, thinner, toluene — dissolve or craze it; prolonged contact with concentrated alcohols swells and whitens it; and chlorinated disinfectants left standing cause fine surface cracks, common in cold-store cleaning.
So "does not rust" is true; "resists all chemicals" is not. For chemical plants or frequently washed areas, list the contact media first.
The economics over ten years
Illustrative, not a quotation: a coated steel roof light costs less initially but needs refurbishment around year five, and with scaffolding, labour and downtime that typically exceeds half the original installed cost. PC sheet costs 30–50% more up front and needs essentially no maintenance within ten years. Two refurbishments usually exceed the original price difference, before counting lost production and the hazard of a corroded roof light collapsing.
Three corrosion details at installation
Use stainless or coated screws and washers — the panel will not rust but the fastener will, and it will leak. Keep dissimilar metals apart, since copper or steel in contact with aluminium profiles drives galvanic corrosion. And seal cut edges and drilled holes: an open multiwall end lets salt spray and dust into the flutes.
FAQ
Can PC be used on offshore platforms? Salt spray is not the issue; assess UV intensity, wind load and cleaning regime, and avoid strong alkali and solvent cleaners.
How does it compare with aluminium? Aluminium does not rust but its oxide layer and coating age, and it transmits no light. Different jobs: daylight calls for PC, metallic appearance for aluminium.
Is yellowing a form of corrosion? No. It is photo-oxidation, a different mechanism with different consequences — affecting transmission and appearance, not structural integrity.