Corrugated Plastic Roofing: Installation Cost Guide

Corrugated roofing is a cost-effective, quick and easy roofing option for sheds, shops, patios, and greenhouses. It can be made from various materials, including metal, fibreglass, and plastic, with prices typically ranging from £3 to £4 per square foot. The installation process involves measuring, cutting, and fastening the panels, with some key considerations to ensure a successful and long-lasting roof. The choice of tools, fasteners, and sealants, as well as adherence to safety precautions, are crucial steps in the process.

Characteristics and Values of Corrugated Plastic Roofing Installation

Cost of corrugated plastic roofing

Corrugated roofing is a cost-effective roofing option that is easy to install. It is a great way to cover a garden shed, shop, or patio. The cost of installing corrugated roofing is relatively low compared to other roofing options, and it is a popular choice for those looking for an affordable solution. The price of corrugated roofing materials can vary depending on the type of material used, with prices ranging from £3 to £4 per square foot. Corrugated steel, metal, or aluminium roofing sheets are usually the most affordable option, while other popular types of corrugated materials include fibreglass and various forms of hail- and impact-resistant plastic.

The cost of corrugated plastic roofing will depend on several factors, including the size and complexity of the roof, the type of plastic used, and the labour costs associated with installation. Plastic roofing is a cost-effective option for those who want a quick, easy, and low-cost roofing solution. It is also a popular choice for DIY enthusiasts as it can be installed with common tools and basic carpentry skills.

When installing corrugated plastic roofing, it is important to consider the additional costs that may be incurred. For example, if you live in an area with a high level of rainfall, it may be wise to invest in gutters, which can be installed after the roof is in place. Additionally, flashing can be used to improve the seal and provide an attractive finish, especially if the plastic roofing adjoins another building.

The lifespan of corrugated plastic roofing is typically between 10 and 20 years, which is shorter than that of other materials such as zinc or steel. However, with proper installation and regular cleaning and inspection, corrugated roof sheets can last for several decades. It is worth noting that corrugated roofing is highly susceptible to wind damage, as strong gusts can lift and tear the sheets. Therefore, it is important to consider the potential costs of repairs or replacements in the future when calculating the overall cost of corrugated plastic roofing.

DIY installation

Installing corrugated plastic roofing is a straightforward process, but it requires careful planning and attention to safety. Here is a step-by-step guide for a DIY installation:

Planning and Preparation:

Before beginning any installation, it is crucial to check local building codes and regulations to ensure compliance. Some areas may have specific restrictions or requirements for roofing materials and installation methods. Additionally, always refer to the manufacturer's instructions for specific guidelines related to your roofing product.

Gather Tools and Materials:

For a DIY installation, you will need standard tools such as a ladder, tape measure, gloves, safety glasses, and a drill. You will also require roofing panels, screws or nails with flexible washers, and other necessary components like flashing, peak seals, closure strips, and edging or finishing materials.

Measure and Cut the Panels:

Measure the area of your roof and use an angle grinder to trim the corrugated panels to size. If you need to cut the panels, clamp them down and use a high RPM circular saw with a fine-tooth blade. Remember to take the necessary safety precautions, such as wearing gloves and safety glasses, to avoid injury.

Install the Panels:

Starting from the eaves or sides of the roof, attach the roofing panels by overlapping them by about 3 to 4 inches (7.6 to 10.2 cm). Work your way towards the peak of the roof. Pre-drill holes on the end and side ridges of the panels, spacing the holes 6 to 8 inches apart. Place each panel directly onto the purlins attached to the roof trusses and screw them down using the pre-drilled holes. Ensure the purlins are installed correctly and parallel to the eaves for a smooth installation process.

Seal and Finish:

Once all the panels are in place, install the peak caps on top and seal any visible seams with a suitable sealant. For a more secure roof, apply caulk or sealant between overlapping sheets.

Safety Considerations:

Always prioritize safety during the installation process. Avoid walking or standing on the panels, and use approved roof ladders and planking for support. Additionally, be cautious when cutting or drilling by observing fire precautions and wearing appropriate safety gear, including filter masks to protect yourself from dust and debris.

By following these steps and instructions, you can successfully install corrugated plastic roofing on your DIY project, ensuring a durable and functional roof.

Cutting corrugated plastic roofing

Prepare the Workspace and Gather the Right Tools

Before starting, it is essential to set up a dedicated workspace that provides ample space to work freely and safely. Ensure you have the necessary tools, including a workbench, a pen or permanent marker, a straight-edge ruler, a tape measure, and the chosen cutting tool. The most suitable cutting tools for corrugated plastic roofing are a Stanley knife, a circular saw, or an angle grinder.

Measure and Mark the Cutting Line

Measure the required length for the corrugated plastic roofing panel using a tape measure. Mark the cutting line on both sides of the panel with a straight-edge ruler and a permanent marker. Creating a straight line is crucial for achieving clean and accurate cuts.

Secure the Panel

Place the corrugated plastic roofing panel on a stable work surface. If possible, use clamps or weights to secure the panel and prevent unwanted movement during the cutting process. This step helps ensure straight and precise cuts.

Choose Your Cutting Tool

You can use either a Stanley knife or a circular saw for corrugated plastic roofing. A circular saw is generally faster and more suitable for larger projects, while a Stanley knife or utility knife allows for more controlled and precise cuts. For the circular saw, adjust the blade depth to match the thickness of the corrugated plastic panel.

Cut Along the Marked Line

If using a Stanley knife, firmly press the roofing against the flat surface while cutting to minimize chipping and wandering. For a circular saw, align the blade with the marked cutting line and maintain a steady and controlled motion. Use a straight edge or guide to assist in following the marked line.

Finishing Touches

After cutting, inspect the edges for any roughness or unevenness. Use fine-grit sandpaper or a utility knife to smooth out any imperfections. It is important to ensure that the edges are smooth and even to maintain the durability and aesthetics of the corrugated plastic roofing.

Drilling and fastening corrugated plastic roofing

Planning and Preparation:

Before you begin drilling and fastening, there are a few important considerations:

• Check local building codes: Ensure that your use of corrugated roofing complies with local regulations.
• Measure and cut panels: Measure the area of your roof and cut the corrugated panels to the required size. You can use tools like an angle grinder or a fine-toothed saw for a cleaner cut.
• Prepare the roof structure: Ensure that the roof trusses and purlins are correctly spaced and installed. The spacing for roof trusses should not exceed 24 inches (61 cm), and purlins should be no more than 36 inches (91 cm) apart.

Drilling and Fastening Process:

• Pre-drill holes: Starting from the outside edge of your roof, pre-drill holes on the end and side ridges of the panels. Space the holes 6 to 8 inches apart, and ensure they are a minimum of 1/16" larger than the fastener diameter for fiberglass panels and 1/8" larger for PVC and polycarbonate panels.
• Place panels on purlins: Position each panel directly onto the purlins attached to the roof trusses.
• Screw down the panels: Use roofing fasteners with a waterproof seal or galvanized nails to secure the panels through the pre-drilled holes. Tighten the screws until washers rotate, then give them one more turn to avoid deflection of the panels.
• Seal the panels: When joining panels, use a generous amount of silicone sealant along their vertical length to ensure a leak-proof seal. Overlap the sheets by one corrugation.

Additional Tips:

• Work safely: Use a ladder and have someone assist you by holding it steady.
• Avoid leaks: Do not drill holes for screws in the valley of the ridges to prevent leaks.
• Protect the roof edges: Install a drip edge to protect the roof's edges from water damage by guiding water away from the structure.
• Ensure proper roof pitch: The roof should have a pitch of at least one inch per foot to allow for proper water drainage.

Corrugated roofing is a cost-effective and relatively easy material to work with, making it a popular choice for DIY projects.

Benefits of corrugated roofing

Corrugated roofing is a popular choice for contractors, businesses, and DIY home renovators due to its many benefits. Here are some of the advantages of corrugated roofing:

Longevity and Durability

Corrugated roofing is designed for longevity and is highly durable. The ridges and grooves of corrugated metal roofs make up for their lightweight nature, ensuring they last longer. Corrugated roofing resists corrosion, pests, mould, wear, and tear more effectively than other roofing materials. This means that corrugated roofing requires very little maintenance and upkeep. At most, you may need to re-coat the panels occasionally to address any corroded portions and re-tighten exposed fasteners to maintain water-tightness.

Energy Efficiency and Cost Savings

Corrugated metal roofing is highly energy efficient. It reflects sunlight and reduces heat absorption, helping to keep properties cooler. This results in lower energy costs, especially in warmer climates, as you won't need to use as much energy to control the temperature inside. Corrugated roofing can also help commercial buildings command higher rents and selling prices, as they are seen as a valuable feature.

Lightweight and Easy Installation

The lightweight nature of corrugated roofing makes it easier and quicker for contractors or installers to work with. It also reduces the load during installation. Corrugated roofing is also relatively easy to install, with some basic tools and math skills required. This makes it a great option for DIY projects, saving you money on installation costs.

Weather Protection and Resilience

Corrugated roofing offers reliable protection from the weather and can withstand heavy weather conditions and extreme weather patterns. Its non-combustible properties ensure that it can withstand fire, providing enhanced occupant comfort and safety. Additionally, with the appropriate coatings, corrugated roofing can enhance its waterproof properties, keeping the building dry and protecting it from leaks.

Frequently asked questions