Ethan Clarke
Corrugated plastic roofing sheets are a great, low-cost option for roofing a garden shed, shop, patio, or even a greenhouse. They are quick and easy to install, requiring just some common tools and a little bit of math. Before you begin, it's important to check local building codes to ensure there are no restrictions on using corrugated roofing. You should also decide on the thickness and type of roofing sheets you want, with common weights including lightweight (0.8mm), heavy-duty (1.1mm), and super weight (1.3mm). Plastic sheets tend to be less expensive than metal, but they are also noisier and less durable. Once you have your sheets, the first step is to cut the panels to size, using a circular saw, angle grinder, or fine-toothed saw. Then, you'll need to pre-drill holes in the sheets, before fixing them to the roof using screws.
Characteristics and Values of Fitting Corrugated Plastic Sheets
| Characteristics | Values |
|---|---|
| Tools | Circular saw, angle grinder, fine-toothed saw, drill, tin snips, fine-toothed handsaw |
| Sheet Thickness | Lightweight (0.8mm), heavy-duty (1.1mm), super weight (1.3mm) |
| Sheet Material | Polycarbonate, PVC, fiberglass, aluminium, terne |
| Sheet Colour | Clear, translucent tints |
| Installation Steps | Measure area, cut panels, install flashing, attach panels, seal seams, install caps |
| Installation Tips | Overlap sheets, pre-drill holes, use washers, avoid over-tightening screws, account for temperature changes, install gable trim |
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What You'll Learn
Cutting the sheets to size
Cutting corrugated plastic sheets to size is a crucial step in ensuring a precise fit for your project. Here is a detailed guide to help you through the process:
First, it is important to plan the layout of your sheets and identify any areas that require trimming or custom cuts. Mark these areas clearly, indicating where the sheets will overlap and where holes will need to be drilled. Remember to account for the width of the sheets and the corrugation overlap when designing your layout.
When it comes to cutting the sheets, it is recommended to use a circular saw with a fine-toothed blade. A high RPM saw is ideal, and cutting slowly will help you achieve the cleanest cuts. If using a power tool seems daunting, a fine-toothed handsaw can also get the job done. Just remember to saw at a shallow angle and apply light pressure for the best results.
To make the cutting process easier, you can try a handy trick. Sandwich the sheet you need to cut between two other sheets, allowing the part that needs to be cut off to protrude. This will provide stability and make it simpler to get a straight cut. Alternatively, you can clamp down the sheet if it's wobbling.
Safety should always come first, so remember to take the necessary precautions when operating power tools or handling sharp objects. Additionally, be mindful of the temperature when working with plastic sheets. Cutting them in cold weather can make them more prone to breakage, so it's advisable to keep them in a warm room until you're ready to cut.
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Tools for cutting
Corrugated plastic sheets can be cut using a variety of tools, depending on the thickness of the sheets and the precision required.
For thin corrugated plastic sheets, a sharp pair of scissors can be used to cut through the material. However, scissors may not be effective for thicker sheets, as they may require multiple passes and can result in an unclean cut. A utility knife is a good alternative, as it can achieve a smooth and clean cut on both thick and thin sheets. When using a utility knife, it is recommended to cut the sheet in halves first and then trace the outline until the board cuts through completely to ensure precise, smooth, and safe cuts.
Another tool specifically designed for cutting corrugated plastic sheets is the Coro-Claw flute cutter, which can easily cut through the flutes of the corrugated plastic. It features a mounted blade between two guide prongs and an ergonomic handle, allowing for precise cuts. The Coro Cutter is also mentioned as a good knife for cutting corrugated plastic sheets.
For thicker corrugated plastic sheets, an automatic flatbed cutter is recommended, especially for professional use. This eliminates manual labour and the risk of injury. An angle grinder or circular saw can also be used for thicker sheets, but they may not be accessible to everyone.
To enhance safety and efficiency, tools like the Pocket Reacher telescoping tool can be used. This tool can be attached to a belt or apron for easy access, and it provides assistance in various tasks such as merchandising and hanging items.
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$10.78 $13.41
Pre-drilling holes
When fitting corrugated plastic sheets, pre-drilling holes is an important step to ensure the sheets are securely fixed to the roof. Here's a detailed guide on how to approach this task:
Planning and Preparation:
Before you begin pre-drilling, it's crucial to have all the necessary materials and tools. Gather your corrugated plastic sheets, flashings, eaves fillers, fixings, and a drill with the appropriate drill bits. Ensure you have measured the area of your roof and determined the placement of the sheets. Mark the areas on the sheets where holes need to be drilled, following the recommended spacing guidelines.
Hole Spacing and Quantity:
The spacing between the holes is important for achieving a secure fit. As a general rule, it is recommended to space the holes approximately 6 to 8 inches (15 to 20 cm) apart along the exterior edges of the panels. This ensures that the fixings are evenly distributed and provide strong support for the sheets. Aim for at least 5 fixings per support across the width of each sheet.
Drilling Technique:
When drilling the holes, use a steady hand and apply light pressure to the drill. A drill bit size of 4.8mm (3/16th inch) is typically suitable for this task. Take your time and ensure the holes are straight and clean. If you need to drill through multiple sheets at once, consider clamping them together or sandwiching them between two other sheets to create a stable drilling surface.
Overlap and Placement:
When placing the sheets on the roof, ensure they overlap by a sufficient amount. For roofs with a 10-degree slope, aim for an overlap of at least 150mm, and for a 5-degree slope, double that overlap to 300mm. This overlap is crucial to prevent leaks and ensure the sheets are securely joined. Remember to start from the outside edge of your roof and work your way towards the peak.
Finalizing the Installation:
After pre-drilling the holes, you are almost ready to fix the sheets to the roof. Don't forget to fit the wall flashing at the top of the slope and insert foam eaves fillers underneath the sheets for added support and to prevent roof chatter. Once the sheets are secured with screws and fixings, ensure the screws are tight and capped.
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Adding sheets to the framework
Before you begin, ensure that you have all the materials you need, including the corrugated sheets, flashings, eaves fillers, and fixings. You will also need a drill, a circular saw or angle grinder, and a fine-toothed saw.
Once you have your framework in place, you can start adding the corrugated sheets. It is recommended to start at one end of the roof and use a wood or plastic strip under the end panel. This will help reinforce the end of the roof and prevent water and wind from getting in.
If your sheets did not come pre-cut, you will need to cut them to size. To do this, place the sheet across sawhorses and cut one panel at a time. You can clamp the sheet down if it wobbles. A high RPM circular saw with a fine-tooth blade is the best tool for cutting corrugated plastic sheets. Cut slowly and do not force the tool for the cleanest cuts. Remember to avoid cutting plastic sheets in cold weather as they are more likely to break.
After cutting, pre-drill the holes in the sheets. Use a 4.8mm (3/16 inch) drill bit and add a hole every 15-20 cm (6-8 inches) along the exterior edges of the panels. Ensure you have at least 5 fixings per support across the sheet's width.
Now you are ready to attach the sheets to the framework. Overlap each sheet by at least 15cm for a 10-degree slope or double that for a 5-degree slope. The sheets should overhang the roof by approximately 60mm to allow rainwater to run off smoothly. Use screws that are 25 x 5 cm (10 x 2 inches) with special polycarbonate washers to stop the wind from pulling them off. Do not overtighten the screws, and make sure the washer can be turned with your fingers as a gauge.
Continue adding sheets, screwing them down, and ensuring proper overlap until you reach the end of the roof. Make any necessary final cuts and install the last piece.
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Screw placement
When it comes to screw placement for corrugated plastic sheets, there are a few important considerations and steps to follow:
First, it is crucial to determine the appropriate screw size and type. For plastic sheets, screws with special polycarbonate washers are recommended. The washers should be placed between the screw head and the sheet to secure the panels and prevent wind damage. The ideal screw size is typically around 25 x 5 cm (10 x 2 inches).
Next, before drilling the screws into the plastic sheets, it is essential to pre-drill holes. This helps ensure that the sheets do not crack or break during the installation process. Use a drill bit that is appropriate for the material, typically around 4.8mm (3/16th inch) in diameter. Space the holes approximately every 15-20 cm (6-8 inches) along the exterior edges of the panels. Ensure you have at least 5 fixings per support across the width of the sheet.
When driving the screws, be careful not to overtighten them. The washers should be able to turn with your finger and thumb as a gauge of how much to tighten. This will help prevent denting or dimpling the panels. Drive the screws until the head meets the corrugated panel securely, holding the sheets in place without causing damage.
Additionally, consider the overlap of the sheets when placing the screws. Each sheet should overlap the next by at least one corrugation, and the amount of overlap will depend on the slope of your roof. For a 10-degree slope, maintain an overlap of at least 150mm, and for a 5-degree slope, double that overlap to 300mm.
Finally, when installing the screws, start from the end of the roof and work your way across, adding more sheets as you go. This will help ensure proper alignment and allow for any necessary adjustments as you progress across the roof.
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Frequently asked questions
The first step is to cut the panels to size.
A circular saw or angle grinder is best for cutting corrugated plastic sheets. If you don't have access to power tools, a fine-toothed saw can also be used.
After cutting the sheets to size, pre-drill holes in the sheets and then screw them down.
