Omar Khalid
Plastic roofing sheets are a popular choice for homeowners due to their ease of installation, durability, and cost-effectiveness. They are lightweight, flexible, and low maintenance, making them a great alternative to traditional corrugated metal roofing. With some basic tools and careful planning, installing plastic roofing sheets can be a straightforward DIY project. However, it's important to follow safety guidelines and take necessary precautions to ensure a secure and attractive finish. In this article, we will provide a comprehensive guide on how to fit plastic roofing sheets, covering everything from material selection to step-by-step installation instructions.
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What You'll Learn
Choosing the right plastic roofing sheets
Climate and Weather Conditions
Take into account the climate and weather conditions in your region. Consider whether your area experiences extreme weather, such as hurricanes, snowstorms, or frequent hailstorms. Plastic roofing sheets made from polycarbonate are known for their durability and resilience against extreme weather conditions. They can withstand impact from hail, rain, sleet, snow, and even tropical storms.
Durability and Longevity
Consider the lifespan and durability of the roofing material. Some materials, like metal roofing sheets, are known for their longevity and may last up to 50 years or more. Plastic roofing sheets made from polycarbonate are also highly durable and can withstand high and low temperatures. However, keep in mind that plastic roofing sheets may need to be changed out sooner than metal and are susceptible to scratching.
Maintenance Requirements
Understand the maintenance requirements of different roofing materials. Metal sheets, for example, require minimal upkeep, while other materials like PUF may need more attention to maintain their effectiveness. Plastic roofing sheets generally require low maintenance and are resistant to corrosion and extreme temperatures.
Environmental Sustainability
If sustainability is a priority for you, consider the ecological impact of different roofing materials. Metal roofing and natural slate have a smaller environmental footprint due to their recyclability. Plastic roofing sheets, particularly those made from recycled plastic materials like acrylic roofing sheets, offer a more eco-friendly alternative to traditional roofing materials.
Aesthetics and Design
Think about the desired aesthetics and design of your roof. Plastic roofing sheets can be designed to resemble other materials such as glass or wood, offering a range of aesthetic possibilities. They also come in various configurations and colour options, allowing you to customise your roof to suit your preferences.
Budget and Cost Considerations
Finally, consider your budget and the initial cost of the roofing material, as well as long-term maintenance costs. Plastic roofing sheets are often more affordable than traditional roofing materials and can provide long-term savings due to their durability and low maintenance requirements.
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Measuring the roof area
Identify the Type of Roof:
First, determine the type of roof you have. Is it a simple gable roof, a hip roof, or a more complex design? This will help you plan how to measure and calculate the area.
Measure the Width and Length:
Using a ladder and a tape measure, find the width (horizontal measurement) and length (from the peak to the lowest point) of your roof. Make sure to measure each section of the roof, including any dormers or unusual shapes. Record these measurements for each part of the roof.
Calculate the Area of Each Section:
To find the area of each section, multiply the width by the length. For example, if a section has a width of 15 feet and a length of 10 feet, the area is 150 square feet. Repeat this calculation for every unique section of the roof.
Determine the Total Square Footage:
Add up the areas of all the individual sections to find the total square footage of the roof. This is an important baseline measurement.
Account for Overlap and Waste:
To determine the total amount of roofing material needed, you must account for overlap and waste. Add 15% of your total square footage to the previous total. This allows for the necessary overlap of the roofing sheets and any waste that may occur during installation. If you want to be absolutely sure you have enough material, you can add another 5-10% as a buffer.
Plan for Fasteners and Cutting:
Remember that you will need to fasten the roofing sheets securely. Plan to space the fasteners about every four corrugations. You will also need to cut the sheets to fit the roof, so consider the layout to minimise waste and ensure you have the right tools for cutting.
Measuring and calculating the roof area is a critical step in the process of fitting plastic roofing sheets. It ensures you purchase the correct amount of material and helps you plan the installation process, including the placement of fasteners and cutting of the sheets.
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Cutting the sheets
When it comes to cutting the sheets for plastic roofing, there are several important considerations and techniques to keep in mind. Firstly, it is recommended to avoid cutting whenever possible by carefully planning the layout of the sheets and selecting the appropriate sheet sizes. This can be achieved by arranging the sheets loosely on the roof to determine the required overlaps and the positions of fixing screws and cuts.
If cutting cannot be avoided, it is important to use the appropriate tools and techniques to ensure a clean and accurate cut. Mark the cutting line by laying one sheet on top of the sheet that needs to be cut. When cutting across a sheet, use a fine-toothed hand saw at a shallow angle, supporting the sheet to minimise vibration. To prevent cracking or splitting, ensure that the sheets are warm before cutting, especially if working in cold weather. This can be done by leaving the sheets in a warm room for 2 to 3 hours prior to cutting.
An angle grinder can also be used to trim corrugated panels to size and shape them to fit the roof. When joining panels, use silicone sealant along their vertical length and overlap the sheets by one corrugation. Additionally, pre-drilling holes for fasteners is recommended to make the installation process easier. These holes should be eight to ten millimetres in diameter and two millimetres wider than the fasteners to allow for expansion due to heat.
Remember to prioritise safety when cutting the sheets. Wear appropriate safety equipment such as safety glasses and filter masks to protect yourself from debris and dust. Additionally, be cautious when working on a ladder, ensuring it is securely positioned and having an assistant to hold the ladder steady if possible.
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Preparing the roof
The roof structure should comprise rafters and purlins, with rafters bearing the weight of the roof material and any environmental build-up, such as snow. For a secure and attractive finish, use moulding strips on top of the rafters, with rounded moulding strips on vertical rafters and corrugated ones on horizontal cross-braces. Attach these mouldings with galvanised nails to prevent rusting in case of leaks.
If your roof has a pitch shallower than one inch per foot, you may need additional weatherproofing measures as this pitch is necessary for proper water drainage. Drilling the holes for fasteners in advance is recommended, and these should be placed at the high point of every fourth corrugation. The diameter of these holes should be eight to ten millimetres, and two millimetres wider than the fasteners to allow for expansion when the roof is heated.
When working with plastic roofing sheets, avoid windy conditions as even light breezes may require temporary weights to hold the sheets in place. Some plastics may crack or split if sawn or drilled when cold, so it is advisable to leave the sheets in a warm room for 2-3 hours before sawing or drilling.
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Installing the sheets
Installing plastic roofing sheets is a straightforward process, but it requires careful planning and attention to detail. Here is a step-by-step guide to help you through the installation process:
Prepare the Sheets and the Roof Structure:
Before beginning the installation, measure the width and length of the roof to determine the area. Add 15% to this number to account for the overlap of the sheets. Cut the sheets to the desired length using an angle grinder. Avoid working in windy conditions, and temporarily weight the sheets if necessary. Arrange the sheets loosely on the roof to determine the correct positioning and identify where cuts and overlaps will be needed. Mark the positions of fixing screws and any required saw cuts on the sheets.
Secure the Sheets:
Drill holes for the fasteners before placing the sheets. The holes should be eight to ten millimetres in diameter and two millimetres wider than the fasteners to allow for expansion when exposed to heat. Use special roofing fasteners with a waterproof seal to secure the sheets and prevent leaks. Place the fasteners at the high point of every fourth corrugation. When joining panels, use silicone sealant along their vertical length and overlap the sheets by one corrugation. Use a generous amount of sealant to ensure there are no gaps.
Finish the Edges:
Use flashing to improve the seal, especially if the roof adjoins another building. Secure the edging to the eaves with a roofing nailer. Overlap each section of flashing by 0.25-0.5 inches (0.64-1.27 cm) and drive a nail every 16 inches (41 cm). Apply a line of caulk to the edge of the bottom flashing for added sealing.
Overlap the Sheets:
The amount of overlap between sheets depends on the pitch of the roof. A steeper pitch will require less overlap. The sheets should overlap by approximately 3-4 inches (7.6-10.2 cm). This overlap will create durable, weather-resistant protection and help drain water properly.
Finalize the Installation:
Install peak caps on top of the panels and seal any visible seams with sealant. If desired, install gutters after the roof is in place to manage rainwater runoff.
Remember to follow local building codes and safety guidelines when installing plastic roofing sheets. With careful planning and execution, you can successfully install a long-lasting and low-maintenance plastic roof.
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Frequently asked questions
Plastic roofing sheets are a long-lasting and low-maintenance alternative to corrugated metal roofing. They are much lighter and easier to work with, making them a popular choice for homeowners looking to save on professional installation costs. Plastic roofing sheets are also translucent, allowing daylight to enter through them.
Measure the width (horizontal) and length (from the peak to the lowest point) of the roof. Multiply those numbers to get the area. Repeat this for every section of the roof. Add 15% of that number to get your approximate required square footage of roofing. Cut the panels to the desired length using an angle grinder. Gather enough panels to cover the roof, accommodating for about 3–4 inches (7.6–10.2 cm) of overlap on each side of the panel.
Common tools such as a ladder, tape measure, angle grinder, roofing nailer, and safety equipment such as safety glasses and filter masks are required. Materials include roofing panels, sealant tape, closure strips, flashing, gutters, moulding strips, and fasteners or screws.
Secure the edging to the eaves with a roofing nailer. Fit the flashing over the underlayment on the roof edges, overlapping each section by 0.64–1.27 cm and driving a nail every 41 cm. Apply sealant tape and closure strips to the edge, taking care not to stretch them out. Drill holes for the fasteners in advance, with pre-drilled holes of eight to ten millimetres in diameter and two millimetres wider than the fasteners. Use roofing fasteners with a waterproof seal to secure the corrugated sheets, placing them near the edges of the roof panels both vertically and horizontally, evenly spaced apart.
