Clear PVC Screen Seams: What You Need to Know
If you’re ordering a clear PVC screen (Flexi 30 or Ultra 50), seams may be required depending on the size of the screen and how the material can be oriented. This guide explains why seams are sometimes necessary, what they look like, and how we minimise their visibility.
Why seams are sometimes needed
Clear PVC is supplied in fixed roll widths, which limits the maximum size of a single, seamless panel:
- Flexi 30: 1.3m roll width
- Ultra 50: 1.8m roll width
If your screen dimensions cannot be accommodated within the roll width once the material is optimally orientated, the panel must be heat‑welded to join multiple sections. This creates a seam as shown in the example below as supplied to our customer Michael S.
Key point
It’s not simply a case of one side exceeding the roll width. Because the material can be rotated, some large screens can still be made without seams.
For example, in the case of an Ultra 50 clear screen which uses material supplied on a 1.8m roll width:
- 3.0m wide × 1.8m high: No seam required because the material can be rotated to suit the roll width.
- 3.0m wide × 2.0m high: A seam is required because there is no orientation that avoids joining the material.
What seams look like
A seam appears as a visible join line where two pieces of clear PVC are overlapped and welded together. To help you understand exactly what to expect, we've provided real customer examples throughout this guide, showing seams on finished clear screens.
Where we place seams
In most cases, we use a single horizontal seam positioned on the lower third of the screen, as close to the ground as possible. This keeps the seam out of eye line and minimises visibility.
For a 2.2m tall Ultra 50 screen, the seam would typically be placed 1.8m from the top edge, leaving a 400mm section at the bottom, similar to that shown in the example pictured below, courtesy of our customer Michael C.
Alternative seam placements
The seam placement described above is the most cost‑effective option as it uses material in the most efficient way. However, where needed, we can adjust seam placement to suit your installation, such as:
- Single vertical seam: usually off‑centre, ideal if the seam can be hidden behind a post or feature.
- Multiple vertical seams: these can be symmetrically positioned left and right to provide more visual balance.
- Custom placement: designed specifically around your installation to align with fences, posts, railings, or other architectural features to minimise visual impact.
For options 2 and 3 some additional cost may be incurred due to the increased labour and/or material wastage.
Anita followed the fence line
Our customer Anita ordered an Ultra 50 screen measuring 2.4m wide × 2.2m tall (right) × 1.72m tall (left). The initial design included a horizontal seam positioned 1.8m from the top edge.
After learning that the screen would sit in front of a wooden fence finishing at 900mm high, we repositioned the seam to align with the top of the fence. This allowed the seam to follow the existing fence line, helping it blend in naturally and significantly reducing its visual impact once installed.
Alistair went vertical
Our customer Alistair ordered an Ultra 50 screen measuring 5.6m wide × 2.8m tall (left) × 2.2m tall (right). Rather than a single horizontal seam, he opted for vertical seams, as this created a cleaner, more balanced appearance across the full width of the screen.
The seams were positioned at 1.8m intervals from the left edge (matching the fabric roll width), resulting in three evenly spaced vertical seams that visually align with the proportions of the structure and make the joins less noticeable overall.
If seams are required
We provide clear, annotated design drawings showing the exact position of all seams, along with a brief explanation of why each seam is placed where it is. As with all our custom cover orders, your approval is required before production begins — giving you the opportunity to review the design and request any changes to seam placement.
You're also welcome to share details about your installation, such as posts, fences, or railings to help us place seams as discreetly and practically as possible, or avoid specific areas altogether. You’ll have the opportunity to include notes or upload photos and diagrams during the ordering process to help us better understand the job.
Seams Are:
- Strong and weatherproof
- Welded (not stitched)
- Covered by warranty (manufacturing defects)
- Unavoidable on some larger clear screens
- Visible on clear material (but we minimise visibility through smart placement)
Seams Are Not:
- A manufacturing defect
- A weakness in the screen
- As visible on coloured PVC (only really noticeable on clear)
Coloured PVC vs. Clear PVC
If seam visibility is a major concern and your screen doesn't need to be transparent, coloured PVC might be a better choice:
- Seams are barely visible on opaque coloured material
- Same durability and weatherproofing
- Available in multiple colours
- No compromise on quality or lifespan
Inset Clear PVC Windows within Coloured PVC
Another option to avoid seams is to inset clear PVC fabric windows within a coloured PVC fabric as shown in the example below.
Questions?
If you're concerned about seams or want to discuss placement options for your specific project:
- Before ordering: You're welcome to contact us with your dimensions and we'll explain if/where seams would be needed
- After receiving diagrams: Review our proposed seam placement and let us know if adjustments would help
- General questions: Feel free to get in touch with an questions and we'll be happy to assist!
We're here to make sure you're completely happy with your screen, seams and all.
FAQ Quick Answers
Q: Can I avoid seams entirely?
A: Only if your screen dimensions are within the roll width for your chosen material (130cm for Flexi 30, 180cm for Ultra 50).
Q: Do seams weaken the screen?
A: No. Our welded seams are as strong as the material itself and fully weatherproof.
Q: Can I choose seam placement?
A: Yes! We'll propose standard placement but we're happy to adjust based on your needs.
Q: Will the seam leak?
A: No. Seams are welded (not stitched) and are completely waterproof.
Q: Are seams covered by warranty?
A: Yes, if there's a manufacturing defect in the seam. Normal seam appearance is not a defect.
Downloads
You can download PDF and JPG information sheets about seams in clear fabrics via the links below: