For generations, plywood has been the default answer to an approaching hurricane. Hardware stores sell out of it before every storm, and boarded-up windows are a familiar sight in coastal towns. Plywood can work as emergency protection, but it has real limitations compared with tested hurricane shutters. Here is what homeowners and building managers should know before relying on it.
Why Window Protection Matters
Windows and glass doors are the weakest points in a building's envelope. Hurricane winds pick up roof tiles, branches, lumber and outdoor furniture and throw them at high speed. When debris breaks a window, wind rushes in and pressurizes the inside of the building. Combined with suction on the outside, that internal pressure can lift roofs and blow out walls. Rain then pours through the opening. Federal emergency management guidance stresses that keeping the building envelope intact is vital to the structural integrity of a home, and protecting openings is one of the most effective steps an owner can take.
What Plywood Can and Cannot Do
When no shutter system is available and a storm is imminent, emergency guidance from FEMA and state agencies recommends plywood panels at least 5/8 inch thick, cut to overlap the wall framing around the opening and fastened into the wall, not the window frame. Done properly and prepared in advance, plywood is far better than nothing.
But plywood has limits:
- It is rarely tested as installed. Hurricane shutters are tested as complete systems against specific missile impacts and wind pressures. A sheet of plywood screwed to a wall by a homeowner has no such approval, and performance depends heavily on fastener type, spacing and the wall material.
- It must be installed at the last minute. Panels have to go up when a storm is forecast, often in heat, rain and rising wind, from ladders, while every other household task is also urgent.
- It is heavy and awkward. A full sheet of 5/8 inch plywood is difficult for one person to handle, especially on second-floor windows.
- It degrades. Stored panels can warp, delaminate or rot, and pre-drilled holes and anchors wear over repeated use.
- It shuts out light. A boarded house becomes dark and stuffy, a real problem when power fails and occupants cannot see outside.
- It advertises an empty building. Boarded windows after a storm can signal that no one is home.
How Tested Hurricane Shutters Compare
Approved hurricane shutters are designed and tested to resist impact and wind pressure as a complete system, including the anchors that attach them to the building. Products for high wind areas are commonly tested to standards such as ASTM E1886/E1996 or the Florida TAS 201, 202 and 203 protocols, and carry product approvals that list the opening sizes and pressures they cover. That approval is what building officials, and often insurers, look for. See Miami-Dade NOA explained and ASTM E1996 missile levels.
| Factor | Plywood | Approved hurricane shutters |
|---|---|---|
| Tested performance | Not tested as installed | Tested and approved as a system |
| Installation time | Hours, at the last minute | Minutes, or none for permanent styles |
| Physical effort | Heavy panels, ladders, power tools | Light operation for permanent and hinged styles |
| Durability | Degrades in storage and use | Designed for years of service |
| Light and views | None | None to excellent, depending on type |
| Insurance and code credit | Usually limited | Often recognized with documentation |
| Everyday benefits | None | Security and shade with some designs |
The Real Cost of Plywood
Plywood looks cheap, but costs add up. Prices tend to rise sharply when a storm is forecast and supplies can run out. Panels must be cut, labeled, drilled and fitted with anchors, and may need replacing after a few seasons. If you hire someone to install and remove boards, labor is paid for every storm watch, including the ones that turn away at the last minute. Meanwhile, the building has no protection at all whenever the boards are in the garage.
A permanent or semi-permanent shutter has a higher upfront cost, but it removes most of these repeating costs and protects the building even when a storm intensifies faster than expected. Read our comparison of permanent vs removable hurricane shutters.
Safety Considerations
Installing plywood is a common source of injuries before hurricanes: falls from ladders, cuts and strains from handling heavy sheets. Boarding up bedroom windows can also block emergency escape routes if there is a fire while the boards are in place. Shutters designed for escape openings include releases that work from inside; see hurricane shutters and emergency egress.
A Homeowner's Experience
A Palm City, Florida homeowner featured in our news archive described growing tired of preparing for hurricane after hurricane with plywood while her husband was often away for work. After switching to STORM SHIELD barriers that could stay in place year round, the home came through Hurricanes Frances and Jeanne in 2004 and Wilma in 2005 with windows and doors intact. As Exeter's president put it, "No one should have to ride out a hurricane in a plywood box or aluminum can."
Moving Beyond Plywood
If you are ready to replace plywood, start by listing every opening, noting which are hard to reach, which are used for ventilation or escape, and which face the sun. Then match each opening to a shutter style. Permanent see-thru barriers such as STORM SHIELD Fixed Mount and Bahama Mount remove storm-day work entirely or reduce it to a few minutes, while Ready Mount offers a removable option that slides into permanent tracks. Because the perforated panel lets light and air through, occupants are not left in the dark.
Conclusion
Plywood is an emergency measure, not a long-term protection plan. It is untested as installed, labor-intensive, short-lived and leaves occupants in the dark. Approved hurricane shutters are tested as complete systems, can be ready in minutes or always in place, and with see-thru designs add everyday security and shade. If you live or work in a hurricane-prone area, investing in tested protection is one of the most effective ways to keep your building intact. Request free literature to compare options.