Omar Khalid
Corrugated roofing is a great way to top a garden shed, shop, or patio. It is quick, easy, low-cost, and can be done without professional help. Corrugated plastic roofing is a long-lasting and low-maintenance alternative to corrugated metal roofing. It is much lighter and easier to work with, making it a popular choice for homeowners. Corrugated plastic roofing sheets are normally installed either standalone or in conjunction with metal roofing sheets, often as skylights. Before installing corrugated plastic roofing, it is important to prep the plastic panels by removing any protective films and stickers from the surface. Then, you should measure the area of your roof and trim the corrugated panels to size. Finally, you can attach the roofing panels, starting from the eaves and working your way to the peak of the roof.
| Characteristics | Values |
|---|---|
| Materials | Corrugated plastic roofing sheets, Polycarbonate, PVC, uPVC, Fiberglass |
| Tools | Ladder, tape measure, angle grinder, circular saw, tin snips, fine-toothed handsaw, drill, silicone sealant, butyl tape, universal seal tape, screws, washers, hinge screw caps, roofing fasteners, galvanized nails |
| Installation Steps | Measure roof area, trim panels to size, roll out underlayment, install flashing, attach roofing panels, install peak caps, seal seams, drill holes, fasten panels, install gutters (optional) |
| Tips | Allow for expansion and contraction at fasteners, pre-drill holes for fasteners, use silicone sealant along panel lengths, overlap sheets by one corrugation, accommodate for temperature changes, ensure proper drainage with a pitch of at least one inch per foot, use flashing for improved seal and appearance |
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What You'll Learn
Cutting corrugated plastic
Corrugated plastic boards are easy to cut and trim. They can be cut with a range of tools, from a sharp scissor to a fine-toothed handsaw.
If you are using a manual tool instead of a flatbed cutter, create an outline first. A sharp scissor is a good option for thin corrugated plastic sheets up to 4mm thick. However, scissors may not cut thicker sheets in one go, resulting in an unclean cut. For thicker sheets, a utility knife is a better option as it can achieve a smooth and clean cut. If you need to make special cuts, you can use tin snips or a fine-toothed handsaw.
When using a utility knife, cut the board in halves first, then keep tracing the outline until the board cuts through completely. This ensures precise, smooth, and safe cuts. Avoid putting too much pressure, as it can bend the board and hurt your hand.
For complex designs and professional projects, an automatic flatbed cutter is recommended. These machines are expensive but can cut out intricate shapes from corrugated plastic boards accurately and safely.
Additionally, you can use a power drill to cut corrugated plastic. Start with a small pilot hole and gradually increase the drill bit size, allowing the drill to heat the plastic and cut through smoothly.
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Trimming to size
Trimming corrugated plastic roofing sheets to size can be tricky, as the material can shatter if not cut correctly. Before you start cutting, measure the area of your roof and the plastic sheets to determine how much you need to trim. Use a ladder and a tape measure to note the dimensions of your roof. Measure the width (horizontal) and length (from the peak to the lowest point) and multiply those numbers to get the area.
When trimming corrugated plastic roofing sheets to size, it is important to use the right tools. A high RPM circular saw with a fine-tooth blade is the best tool for making straight cuts on the plastic sheets. Clamp the sheet down to prevent it from wobbling and cut slowly, allowing the saw to do the work. If you need to make special cuts, you can use tin snips or a fine-toothed handsaw.
Drilling holes in the corrugated plastic sheets can be challenging, and it is recommended to use a normal drill bit set (3mm, 5mm, 8mm, 10mm) rather than a masonry drill. Start with a small pilot hole and increase the drill size gradually, allowing the drill to heat the plastic and cut through more easily. You can also use a serrated table knife heated on a gas stove to cut through the plastic.
When drilling holes for fasteners, it is ideal to pre-drill the holes at all fastening points to allow for expansion and contraction. The holes should be eight to ten millimeters in diameter and two millimeters wider than the fasteners. It is easier to drill the holes from the underside of the roof, and you can use a stick with a hole drilled in it as a guide.
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Positioning and fastening
Positioning the corrugated plastic sheets involves laying them across sawhorses and cutting them to size. The sheets should be positioned with the corrugated channels sloping downwards, which will reduce the accumulation of dirt and moisture. The sheets should also be overlapped by about 3-4 inches (7.6-10.2 cm) to create durable, weather-resistant protection.
Before fastening the sheets, it is recommended to drill the holes for the fasteners in advance. The pre-drilled holes should be eight to ten millimeters in diameter and two millimeters wider than the fasteners to allow for expansion when exposed to heat. It is also important to use special roofing fasteners with a waterproof seal to prevent leaks. When joining panels, use silicone sealant along their vertical length to ensure there are no gaps.
When fastening the corrugated sheets, it is important to position your ladder securely and not to overstretch. Ideally, have an assistant hold the ladder steady. Fasteners or screws should be placed near the edges of the roof panels, both vertically and horizontally, and evenly spaced apart. For a secure and attractive finish, use molding strips on top of the rafters, with rounded molding strips on vertical rafters and corrugated ones on horizontal cross-braces. Attach the moldings using galvanized nails to prevent rusting.
If your roof has a pitch shallower than one inch per foot, you may need to use additional weatherproofing measures. Gutters can also be installed after the plastic roof is in place, especially if you live in an area with a high level of rainfall.
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Weatherproofing
Installing corrugated plastic over lightwells can be a great DIY project, but it's important to take the necessary steps to ensure that your installation is weatherproof. Here are some detailed, step-by-step instructions to help you achieve that:
Prepare the Corrugated Plastic Panels:
Before you begin, make sure you have the right tools and materials, including the corrugated plastic panels, protective gear, and installation hardware. Remove any protective films and stickers from the panels. Use a product like Goo Gone and a scrub brush to remove any stubborn stickers.
Measure and Cut the Panels:
Measure the area of your lightwell and the panels. Cut the panels to size using a high RPM circular saw with a fine-tooth blade. Cut slowly and with control for the cleanest, straightest cuts. You may also need to use tin snips or a fine-toothed handsaw for any special cuts. Ensure you take the necessary safety precautions when operating power tools.
Install Flashings and Underlayment:
Roll out an underlayment, which will provide a layer of protection between the lightwell structure and the panels. Install flashings on the eaves of the lightwell, which will help direct water away and prevent leakage.
Attach the Panels:
Start attaching the panels from the eaves, overlapping them by about 3-4 inches (7.6-10.2 cm) as you work your way up. This overlap is crucial to prevent water seepage and accommodate for temperature-induced expansion and contraction. Drill pilot holes and use screws with plastic washers and hinged screw caps to secure the panels.
Install Ridge Caps:
Place the ridge caps over the peaks of the panels, ensuring they overlap the panels adequately to prevent water seepage. Seal all visible seams and joints with a suitable sealant to further enhance the weatherproofing of your installation.
Final Checks:
Once your installation is complete, inspect it during different weather conditions, especially rainfall, to ensure that there are no leaks. If necessary, make adjustments, such as applying additional sealant or checking for gaps.
By following these steps and paying attention to the details, you can effectively weatherproof your corrugated plastic installation over lightwells.
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Maintenance and durability
Corrugated plastic sheets are known for their durability and low maintenance. They are made from a natural thermoplastic that can withstand chemicals, oils, water, and UV radiation at room temperature. They are also corrosion-resistant, making them suitable for a range of outdoor projects.
However, it is important to note that corrugated plastic sheets can become brittle at low temperatures and soften and melt at high temperatures. Therefore, it is crucial to consider the temperature and weather conditions when installing corrugated plastic sheets.
To ensure the durability of corrugated plastic sheets, proper installation is key. When cutting the sheets, it is recommended to use a high RPM circular saw with a fine-tooth blade. This will ensure straight cuts and the best results. Overlapping the sheets by about 3 to 4 inches (7.6 to 10.2 cm) will provide adequate coverage and protection from the elements.
For additional durability, you can use a ridge cap that overlaps the panels to prevent water seepage. Accommodating for temperature changes is crucial, as the panels will shrink in the winter and expand in the summer.
Corrugated plastic sheets are known for their ease of maintenance. They are non-absorbent and simple to clean, requiring very little upkeep. Their lightweight and versatile nature makes them easy to transport, store, lift, assemble, and set up.
In terms of durability, corrugated plastic sheets are impact-resistant and sturdy. They can withstand extreme weather conditions and perform well in rain, wind, and hail. When treated, they can also withstand direct sunlight. Additionally, corrugated plastic sheets offer excellent electrical insulation and resistance to chemical or acid exposure.
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Frequently asked questions
A high RPM circular saw with a fine-tooth blade is the best tool for cutting corrugated plastic sheets. You can also use tin snips or a fine-toothed handsaw for special cuts.
You can attach the sheets using normal screws, silicone, and a thick "washer" with a hinged screw cap. You can also use special roofing fasteners instead of standard screws as they have a waterproof seal that prevents leaks.
Measure the area of your roof and use an angle grinder to trim the corrugated panels to size. Roll out an underlayment, then install flashing on the eaves of the roof. The roof should have a pitch of at least one inch per foot to allow for proper water drainage.
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