When it comes to protecting your home with hurricane storm panels, you have a few options: multiwall polycarbonate, aluminum, and plywood. Your decision will come down to some key considerations: strength, durability, ease of installation, budget, etc. We compare these top three materials used for hurricane protection to help you find the right protection for you.
Regardless of which materials hurricane storm panels you ultimately purchase, you want a product or system that has been tested and certified as passing one of the large missile (i.e. 9-lb 2×4 wood member striking end on at a specified impact speed) impact-resistant standards. See Local and National Standards to get more information on the various test standards and performance requirements.
1. Multiwall Polycarbonate vs. Aluminum vs. Plywood: Which Hurricane Panel is the Best?
So, which hurricane storm panel is the best for you? It depends on personal preference as well as budget. Here, we break down some differences between multiwall polycarbonate, aluminum, and plywood to help you decide. But first, here’s a quick round-up of the three materials and their top characteristics.
Multiwall Polycarbonate
Best for: strength and translucency. Multiwall polycarbonate hurricane storm panels, available in sheets of 48” and 96”, are made from multiple layers of polycarbonate that withstand extreme weather conditions. Its benefits include being lightweight, durable, transparent, impact resistant, UV resistant, and corrosion resistant. The panels can also be cut easily.
Virtually unbreakable, multiwall polycarbonate panels provide superior protection for windows and doors against hurricane force winds, flying debris, and severe weather, while still allowing natural light to enter. This makes them an aesthetically pleasing choice for hurricane storm panels.
Aluminum
Best for: strength and durability. Aluminum hurricane shutters are also lighter than plywood. They are extremely durable and are corrosion- and rust-resistant so they last for many years while offering storm protection. They are a popular choice for securing windows and door openings in homes and building in hurricane-prone areas because of their durability, light weight, and longevity
Plywood
Best for: strength and affordability. The traditional images of hurricane preparations show windows and doors boarded with plywood. There’s good reason for that. They’re inexpensive, readily available, and simple to install. Their thickness matters, though. A 5/8” thick piece of plywood is now recommended, and that can be a hinderance for some due to their weight. Some people opt to double up on ½” boards to increase protection without having to handle the heavier, 5/8” thick sheets of plywood. Despite its heft, people choose it for its affordability and if they are in a region with lesser hurricane wind speeds.
2. Strength and Durability
No matter which material you use, you need to be rest assured that it has the impact resistance to keep destructive winds from entering your home.
Multiwall Polycarbonate: Polycarbonate’s multiwall construction provides strength and impact resistance to protect against high winds and flying debris. One-quarter-inch thick panels have resisted impacts of 9-pound 2″x4″ lumber missiles at speeds over 60 miles per hour in testing, making it is 200 times more impact resistant than ½” plywood sheets.
Aluminum: Aluminum shutters will last for years, due to their corrosion and rust-resistant properties. Also, their corrugated design adds about 25% more strength against flying debris than flat panels or plywood.
Plywood: A minimum thickness of 1/2’” is recommended when using plywood. While a 1/2″ piece of plywood can be easily penetrated by the 9-pound 2″x4″ lumber test missile at impact speeds less than 27 mph, the resulting hole would not be big enough for wind damage (which can pressurize and lift the roof of a structure). If plywood is not secured correctly, it will be blown off the structure in high winds.
3. Weight and Ease of Installation
All three materials are fairly easy to handle, but there are a few key differences:
Multiwall Polycarbonate: Polycarbonate is lightweight, making it easier to handle and install than plywood (polycarbonate is five times lighter than plywood.) Once an anchoring system is set up, multiwall polycarbonate hurricane panels can be installed and taken off the house quickly, year after year. They can be professionally installed or can be installed by the homeowner in approximately 20 minutes per window. Removing the panels after the storm takes just a few minutes. The panels are easy to cut to size with basic tools, and stack for storage when not in use.
Aluminum: Aluminum hurricane shutters are also much lighter than plywood and other metal shutter options. This makes them easier to handle when installing and removing. Like polycarbonate, they are easy to put up whether they are mounted on tracks or bolted in place and take about 20 minutes per window to install. They also stack for space-saving storage.
Plywood: While it’s easy to cut to fit window and door openings, plywood is bulky and can be hard to handle when installing. Some people opt to double up on ½” boards to increase protection without having to handle heavier, 5/8” thick sheets of plywood, which are now recommended for optimal wind and impact resistance. Mounting consists of nailing the boards over the window and door openings. While it is simple, it can be a cumbersome task—both installing and removing. Also, there’s a risk of damaging a home’s exterior when removing the boards after the storm.
4. Cost Analysis
As a general rule of thumb, the costs of materials and labor to install hurricane storm panels vary greatly depending on your location. But there are some guidelines to use when considering budgets for hurricane storm panels.*
Multiwall Polycarbonate: Panels cost about $10 to $20 per square foot (or $115 to $240 for a seven-square-foot window). The price may be worth it for the ability to see through the panels if installed before a storm or in case of power outages during a storm. There is also an added cost for labor if you choose to have the panels installed. The panels are easy to maintain—simply wash with soapy water to remove residue from debris and replace when deeply scratched or damaged—but you can expect years of use with multiwall polycarbonate.
Aluminum: These panels also cost about $10 to $20 per square foot. The price may be worth it for the longevity and durability of the panels. The material’s resistance to rust and corrosion from saltwater and debris provides long-term value. Like multiwall polycarbonate, there may be added costs for installation.
Plywood: Boards will cost $2-$6 per square foot (about $15 to $45 for a seven-square-foot window). While you may pay someone to board up your windows and doors, the sheets are typically a DIY installation, further saving money. Also know that the wood warps from the water and moisture exposure so the panels will need to replaced after just one use.
You can’t discuss costs without mentioning insurance implications and potential discounts. There is no insurance discount for using plywood to protect your home from hurricanes. But there may be a discount for using multiwall polycarbonate or aluminum shutters. Check with your insurance carrier to find out if they offer any discounts.
5. Aesthetic Appeal
It might seem frivolous to worry about how your looks during a storm, but some panels are put up days in advance, warranting a more polished look.
Multiwall Polycarbonate: The visual appeal of polycarbonate is well, clear. Its transparency allows the panels to be installed a few days before a storm without hindering curb appeal. It also allows natural light into your home during daylight hours.
Aluminum: While the metal does not blend in with its surrounding, its neat appearance on windows and doors provides a more polished aesthetic for a hurricane shutter. Aluminum storm panels are also available in a variety of colors, including custom colors to match your home.
Plywood: None. Plywood is purely a functional aesthetic sensibility. But its affordability trumps its lack of aesthetics for many.
6. Environmental Considerations
Lastly, there are some sustainability issues to consider when selecting hurricane storm panels.
Multiwall Polycarbonate: Polycarbonate is a recyclable material. Its strength and impact resistance provides longevity, and at the end of its life cycle can be melted down and repurposed or shredded into granulation and used to manufacture new polycarbonate sheets.
Aluminum: Aluminum is infinitely recyclable. That means it can be recycled over and over again. In fact, recycled aluminum makes up 80% of US aluminum production.
Plywood: Wood is a recyclable material. (That’s a good thing since plywood can only be used once as storm panels.) Plywood is often shredded and used into mulch.
Move Forward with Polycarbonate Hurricane Panels with Acme Plastics
Selecting storm shutters requires careful consideration. We hope the above information outlining the advantages and disadvantages of polycarbonate, aluminum, and plywood have helped you narrow your choices. If you’ve decided on polycarbonate for your hurricane storm panels, let Acme Plastics help you secure your home against damage. Our 16 mm multiwall polycarbonate hurricane panels are approved by Florida State and Miami-Dade County for direct mount installation and have successfully passed the Miami-Dade County Hurricane test, withstanding a Large Missile Impact test where a 9 lb 2” X 4” missile was shot out of an air cannon without causing any damage to the panel or the glass behind it.
Contact us today. We’d love to help you secure and protect your home from damage.
Sources:
Angi. How Much Do Hurricane shutters Cost? 2024 Data. https://www.angi.com/articles/how-much-hurricane-shutters-cost.htm
