Polypropylene Corrugated Plastic Sheet: Thickness Options and Applications

In the world of modern packaging, signage, and industrial protection, the polypropylene corrugated plastic sheet stands out as a durable, lightweight, and versatile solution. Often referred to as coroplast, correx, or corflute, this double-wall structured plastic board is made from high-quality polypropylene resin. Its hollow core design provides excellent rigidity while keeping the material extremely lightweight, making it an ideal choice for countless commercial and industrial uses.

One of the most important factors to consider when selecting a polypropylene corrugated plastic sheet is thickness. The thickness of the sheet directly affects its strength, flexibility, weight, and cost — and therefore determines where and how it can be used.

Let’s explore in detail the various thickness options, their performance characteristics, and typical applications across different industries.

1. Understanding Polypropylene Corrugated Plastic Sheet Thickness

The polypropylene corrugated plastic sheet is available in a wide range of thicknesses, typically from 2mm to 12mm. Each thickness range serves a specific purpose — from lightweight indoor signage to heavy-duty industrial protection.

Here are the most common thickness categories:

Depending on the manufacturing process and customer requirements, customized thicknesses between 2mm and 12mm are also available. Many manufacturers offer custom colors and sizes, allowing clients to order sheets tailored for specific branding or functional needs.

2. Thin Sheets: 2mm–3mm Lightweight Options

2mm and 3mm polypropylene corrugated plastic sheets are the lightest options in the category. Despite their minimal thickness, they provide excellent flexibility and are easy to cut, fold, or print on.

• 2mm Sheets:
  These are widely used for temporary indoor signs, event displays, disposable packaging, or protective separators. Their ultra-light structure makes them ideal for one-time use applications.

  • Example: 2mm Correx Sheets – Custom Size and Color

  • Typical size: 4×8 feet (1220×2440mm)

  • Custom colors available: white, blue, red, green, yellow

• 3mm Sheets:
  Slightly thicker and stiffer, 3mm polypropylene corrugated plastic sheets are used for retail advertising boards, shelf displays, product packaging, and graphic printing.

  • Example: 3mm Corrugated Plastic Sheets – Fire-Retardant Option Available

  • Benefits: better surface for printing and moderate impact resistance

These thin sheets are often die-cut or creased easily, allowing for fast assembly into display boxes or signage panels.

3. Medium Thickness: 4mm–6mm Multi-Purpose Sheets

The 4mm to 6mm range represents the most commonly used segment of polypropylene corrugated plastic sheet products. They balance strength and flexibility, making them suitable for both packaging and signage applications.

• 4mm Sheets:
  Known for their versatility, 4mm corrugated polypropylene sheets are used for real estate signs, construction safety boards, and advertising displays.

  • Example: 4mm Corrugated Plastic Sheets – Custom Color & Size

  • Available in flame-retardant versions for enhanced safety

  • Applications: indoor/outdoor advertising, box manufacturing

• 5mm Sheets:
  When more durability is required, 5mm polypropylene corrugated plastic sheets are the preferred choice. They are thicker, stronger, and reusable — perfect for industrial packaging, storage bins, dividers, and protective panels.

  • Example: 5mm Corrugated Plastic Sheet, Custom Size & Color

  • Benefits: high compressive strength, moisture resistance, long service life

• 6mm Sheets:
  These are robust and rigid, used for automotive parts packaging, protective wall panels, and layer pads in palletizing systems.

  • Example: 6mm Corflute Boards – Custom Size and Color

  • Available in ESD or anti-static versions for electronic product handling

  • Optional edge sealing for added hygiene in food or pharma industries

This range of sheets is also used as construction site floor protection, temporary wall cladding, and warehouse flooring, thanks to their excellent load-bearing and waterproof properties.

4. Thick Sheets: 8mm–12mm for Heavy-Duty Applications

For demanding environments requiring strength and rigidity, 8mm to 12mm polypropylene corrugated plastic sheets deliver superior performance.

• 8mm Sheets:
  Used for outdoor signage, reusable transport containers, and industrial partitions.

  • Example: 8mm Corflute Sheets – Custom Size and Color

  • High tensile strength, weatherproof, and UV-resistant options available

  • Perfect for large-format digital printing and construction protection panels

• 10mm Sheets:
  At this level, the sheet is thick enough to act as a pallet layer pad or floor protection board.

  • Example: 10mm Correx Sheets Boards – Custom Size and Color

  • Extremely rigid and durable

  • Suitable for heavy machinery packaging or transportation layer separation

• 12mm Sheets:
  The thickest category, 12mm polypropylene corrugated plastic sheet, provides maximum rigidity and impact resistance. These are used for industrial storage systems, automotive assembly line protection, and building site applications.

  • Often custom-manufactured to specific size requirements

  • Can be conductive, fire-retardant, or anti-static

5. Specialty Types by Functionality

Thickness isn’t the only customization option — polypropylene corrugated plastic sheets also come in special functional grades. These specialized variants offer enhanced properties suited for specific industries.

• Conductive Corrugated PP Sheets
  Used in electronic component packaging, these sheets dissipate static electricity to prevent circuit damage.

  • Example: Anti-Static Corrugated PP Sheets / ESD Corflute Sheets

  • Thickness range: typically 3mm–6mm

  • Surface resistance: 10⁴–10⁶ Ω

• Fireproof or Fire-Retardant Corrugated PP Sheets
  These sheets meet fire-safety standards for construction and transportation use.

Example: Fireproof Coroplast Corrugated Plastic Sheets

Available in 3mm–10mm thickness

Excellent for indoor environments requiring flame resistance

• Edge-Sealed Coroplast Layer Pads
  Used in food, beverage, and pharmaceutical logistics, these customized pads prevent dust or liquid ingress.

• Thickness range: 3mm–6mm
• Custom sizes and edge colors available

6. Customization Options

Modern manufacturers offer complete customization for polypropylene corrugated plastic sheets based on project needs. You can specify:

• Thickness: 2mm–12mm (customizable)
• Sheet Size: Standard 4×8 ft (1220×2440mm) or tailor-made
• Colors: White, black, blue, yellow, green, grey, or custom Pantone color
• Surface Finish: Glossy, matte, or embossed
• Additives: UV protection, flame retardant, anti-static, or conductive

This flexibility allows companies to design unique, functional, and brand-matching products for every sector — from advertising to automotive.

Conclusion

Choosing the right polypropylene corrugated plastic sheet thickness is essential for optimal project performance. Whether you need 2mm lightweight sheets for signage or 10mm heavy-duty boards for packaging, there’s a type to fit your needs.

With options from conductive and fire-retardant sheets to custom color and edge-sealed boards, polypropylene corrugated plastic sheets offer exceptional versatility. Their durability, cost-effectiveness, and eco-friendly nature make them ideal for packaging, advertising, construction, and industrial uses.

For custom polypropylene corrugated plastic sheets from 2mm to 12mm, professional manufacturers provide OEM/ODM services with flexible size, color, and performance options.

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