DIY Corrugated Plastic

Written by bob haring
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Corrugated plastic is often confused with corrugated fibreglass, but they are different materials. Fibreglass is composed of glass fibres tightly bonded with resins and moulded into forms; for home construction, the most common form is corrugated, with wavy alternating ridges and valleys. Corrugated plastic is high density polythene or polypropolene formed into sheets or rolls. It resembles corrugated cardboard in structure, with outside liners covering a fluted interior. Some is double-faced, with a liner on both sides, and produced in sheets. Some is single-faced, with only one liner, and produced in rolls or sheets.

Skill level:

Things you need

  • Corrugated plastic
  • Utility knife or fine-toothed saw
  • Adhesive

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  1. 1

    Use corrugated plastic panels to make signs of various types. Sign-makers use plastic for faces of outdoor signs, either as panels with vinyl lettering and pasted on designs or as faces for signs with lighting behind, such as channel letters. Corrugated plastic comes in various thicknesses, in many fade-resistant colours and is sturdy and weatherproof. Cut into any shape with a utility knife or fine-toothed saw.

  2. 2

    Make skylight or plant windows or even home greenhouse tops and sides with clear corrugated plastic. Unlike glass, it won't shatter in hail or windstorms and allows light to enter freely. Install it in wood, metal or plastic frames with adhesives or screws. It is ideal for building a plant box window, which extends out from the house wall, or a small home greenhouse. Replace glass with clear corrugated plastic sheets in any places subject to dangerous breakage.

  3. 3

    Build storage containers of corrugated plastic. They are more durable than corrugated cardboard, can be made in colours to identify contents and can be formed in any square or rectangular shape. Fold corrugated plastic and fasten with adhesive or heat welding. It resists a wide variety of chemicals, grease and dirt, can be cleaned and used over and over and is totally recyclable.

  4. 4

    Roof small sheds or storage buildings with corrugated plastic panels. Drill, staple, nail or screw the plastic to framing. The plastic is waterproof, won't rust, rot or mildew and resists tears, punctures and impacts, like hail or falling limbs. Install it like corrugated metal or fibreglass, cutting panels to fit and nailing or screwing to rafters or roof strip sheathing, the boards nailed across rafters to hold roof covering.

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