This article begins a series of short descriptions of sign material in order to help consumers choose between a large number of substrates for their signs. I have already discussed vinyl and magnetic materials in some detail in previous articles. Therefore, I will focus on coroplast, acrylic (Plexiglas), MDO Signboard, alumalite/alumacore, PVC, and aluminum.

One of the largest selling substrates is coroplast. The name comes from the leading manufacturer of these polypropylene sheets – Coroplast Inc. In fact, Coroplast Inc, claims that coroplast is the material “supplied through the largest number of plastics and sign supply distributors in North America”. It is most recognized as the material used in signs for candidates during elections or as “for sale” signs. It is lightweight yet durable and weather resistant. It can also be trimmed or cut into a variety of shapes.

Coroplast is also known as fluted plastic, twin wall plastic, and corrugated plastic, because of the corrugated groves (called fluting) that run through the material. The empty space between the fluting makes the board lightweight (as opposed to solid plastic) while giving it needed strength. The first known instance of corrugated material was in 1856 when a sweatband used as a liner in hats was patented. Cardboard soon followed and was used by Wells Fargo in packaging by the late 1890s. Once plastics were developed through the petroleum industry, corrugated plastics soon followed. They have been a mainstay of the sign industry ever since.

The sturdy flat surface of coroplast made it easy to apply vinyl lettering or ink via screen printing. Recently the digital printing industry has produced inks that are now absorbed by the plastic. The inks can be expected to last longer than the signs. Once someone realized that the flutes could be oriented vertically and stakes inserted into them, “yard signs” evolved. In fact, H-stakes were created specifically for coroplast signs. The lightweight of both make it easy to cart the signs in the back seat of a car. Of course, coroplast signs have been constructed to fit into more formal metal frames frequently replacing the more expensive and heavier aluminum. I might also mention that you can cut through one layer of the plastic which enables the sign to be folded for easier transport.

In summary, coroplast is inexpensive, fairly durable, and easy to transport. But beware. Their light weight also makes them susceptible to damage via even minor strong winds. So I recommend coroplast primarily to get your message out along highways and roads for special events (the sale of your house, the election of a candidate, a grand opening, etc). But remember to pull them in before a storm hits. Note that in some states it is illegal to post sinage along streets and there are battalions of civil servants patrolling the highways to remove signs. In fact, I know many companies that place the signs along the highway knowing that they will be picked up within a few days. Some feel that the low cost of the sign makes the loss cost efficient.

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