Omar Khalid
Corrugated plastic roofing is a cost-effective, long-lasting and low-maintenance roofing option. It is also lightweight and easy to work with, making it a popular choice for those looking to save money on professional installation. Compared to corrugated metal roofing, plastic roofing is easier to install, as it can be drilled, sawed, punched, or nailed without damage. This guide will walk you through the steps of installing corrugated plastic roof panels, from measuring and cutting to sealing and weatherproofing.
| Characteristics | Values |
|---|---|
| Installation | Measure the area of the roof, trim the corrugated panels to size, roll out an underlayment, install flashing, attach roofing panels, install peak caps, seal seams with sealant |
| Tools | Common tools, ladder, tape measure, angle grinder, nails, aluminum nails with neoprene washers, mastic, butyl tape, sealants, screws, grommet-type fasteners, weatherproof nails, wood screws, self-tapping screws, roofing fasteners, silicone sealant |
| Tips | Pre-drill holes for fasteners, use a stick with a hole drilled in it as a guide, use special roofing fasteners to prevent leaks, overlap sheets by one corrugation, use a generous amount of sealant, start from the leeward end of the run and work to the windward, use galvanized nails to prevent rusting, use molding strips on top of rafters |
| Benefits | Quick, easy, low cost, durable, rot-proof, waterproof, can be drilled, sawed, punched, or nailed without damage, lightweight, easy to work with, long-lasting, low maintenance, allows light in |
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What You'll Learn
Measure and cut panels
To install corrugated plastic roof panels, you'll need to start by measuring the area of your roof. Use a ladder and a tape measure to determine the dimensions of your roof. Once you have the measurements, you can trim the corrugated panels to size using an angle grinder.
Measure the length and width of your roof to determine the total area that needs to be covered. It is important to be as accurate as possible. Ensure you have a helper to hold the ladder and spot you while you're on it. Take the measurements from multiple points on the roof to account for any variations or irregularities in the roof structure.
When measuring, consider the overlap of the panels. The standard overlap for corrugated roofing panels is about 3 to 4 inches (7.6 to 10.2 cm). This overlap helps create a durable and weather-resistant barrier. Take this overlap into account when calculating the number of panels needed and when trimming the panels to size.
After measuring the roof, lay out the corrugated panels on a flat surface and mark the cutting lines using a straight edge and a marker. Use the measurements you took to determine the length and width of each panel, remembering to include the overlap in your calculations.
Use protective gear, including eye protection and gloves, when operating the angle grinder. Angle grinders are powerful tools that can quickly cut through the corrugated plastic panels. Cut along the marked lines on each panel, ensuring that you follow all safety precautions provided by the manufacturer of the tool. Cut slowly and steadily to ensure a straight and accurate cut.
Finally, once all the panels are cut to size, you can proceed to install them on the roof, starting from the eaves and working your way up to the peak. Remember to overlap the panels as you install them and seal any visible seams with a recommended sealant.
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Seal and fasten
To seal and fasten your corrugated plastic roof panels, you will need to use specific fasteners and sealants.
For sealing, silicone sealants are recommended and should be applied generously to any visible seams and along the vertical length when joining panels. Vinyl lap seal and/or mastic should also be used to seal side-laps and end-laps effectively.
For fastening, it is recommended to pre-drill holes for fasteners, with a minimum of one corrugation overlap at the sides. The pre-drilled holes should be eight to ten millimetres in diameter and two millimetres wider than the fasteners to allow for expansion when the roof heats up. Fasteners should be placed at the high point of every second or fourth corrugation, with a spacing of six to eight inches at panel ends and twelve to sixteen inches for intermediate purlins and siding applications. Typical fasteners include weatherproof nails or wood screws with Neoprene washers, self-tapping screws, and grommet-type fasteners. When fastening, it is important to tighten screws until washers will not rotate, then tighten them one more turn to avoid deflection of the panels.
It is also recommended to use flashing to improve the seal, especially if the roofing adjoins another building. This provides an attractive finish and additional weather protection.
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Overlap panels
Overlapping the panels is crucial to installing corrugated roofing sheets. The sheets are designed to be overlapped, making them adaptable and easy to install. The overlap between the sheets helps seal the roof properly and prevents leaks.
When installing corrugated roofing, it is recommended to start at the leeward end of the roof and work towards the windward side. This is done to protect against prevailing winds and weather. It is also important to note that the direction of overlap should be away from the prevailing wind to increase the longevity of the roof.
The recommended overlap for corrugated roofing sheets is approximately 3-4 inches (7.6-10.2 cm) or by one ridge. This applies to both the overlap between the individual panels and the overlap between the roof cap and the panels. The roof cap is the bent piece of metal that covers the peak of the roof, and it should overlap the panels by the same amount, which is about 3-4 inches (7.6-10.2 cm).
For roofs with a pitch of less than 4 inches in 12, provide an 8-inch end-lap. For roofs with a pitch of more than 4 inches in 12, a 6-inch end-lap is sufficient. Additionally, it is recommended to allow for a slight overhang at the bottom or gutter edge of the roof to facilitate drainage into the gutter. The maximum recommended overhang for corrugated sheets is 70mm.
To ensure a proper seal, use vinyl lap seal and/or mastic on the side-laps and end-laps. This will provide the best protection against leakage and air infiltration.
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Install flashing
Installing flashing on a corrugated roof is an essential step in safeguarding your roof's surface and diverting water flow from key areas. It acts as a barrier, preventing water from seeping into the roof structure and causing leaks and serious damage. Here's a step-by-step guide to installing flashing on a corrugated roof:
Prepare the Materials and Tools:
Before you begin, gather the necessary tools and materials, including roofing nails or screws, roofing cement or sealant, flashing material (galvanized steel) or plastic head fixings, closure strips, and a sealant tape.
Install the Flashing:
Start by rolling out an underlayment along the eaves of the roof, as instructed in the previous section. Then, follow these steps:
- Secure the flashing in place: Use roofing nails or screws to attach the flashing to the corrugated metal. Place the fasteners in the flat sections between the ridges for a secure attachment.
- Seal the edges: Apply roofing cement or sealant along the edges of the flashing to prevent water seepage. Pay close attention to corners and connections for comprehensive protection.
- Overlap flashing pieces: When installing multiple sections, overlap flashing pieces by at least 6 inches. This adds an extra layer of defence against water infiltration.
- Inspect for gaps: Once the flashing is secured, carefully inspect for any gaps or potential entry points for water.
- Apply additional sealant: If you find any gaps or potential entry points, apply more sealant to ensure a complete barrier against leaks.
- Cut flashing for valleys: Measure the length of any valleys on your roof and cut the flashing accordingly. It should extend at least 8 inches on both sides of the valley centreline.
Tips for a Professional Finish:
- Use colour-matched fixings for corrugated bitumen or clear corrugated roofing sheets to maintain aesthetics.
- Ensure the plastic cap is flexible so it curves around the contoured top of the corrugations.
- Corrapol®-BT Flexi Screw Cap Fixings offer better torque control than nails and are available in colours to match your roofing sheets.
- For metal roofs, use drip edges to ensure a watertight seal and prevent water from getting under the roofing material.
- Foam closure strips are essential for corrugated metal roofs to seal any gaps and create an extra tight seal.
Remember, precision is critical when installing flashing on a corrugated roof, so take your time and ensure a neat finish to increase the lifespan of your roof and reduce maintenance costs.
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Choose roofing material
When choosing roofing material, there are several options to consider. Corrugated roofing is a great, low-cost option for sheds, shops, or patios, and it can be installed as a DIY project. Corrugated plastic roofing is a cost-effective, long-lasting and low-maintenance option that is also lightweight and easy to work with. It is also rot-proof, waterproof, and durable. For these reasons, it is a popular choice for those who want to avoid the additional cost of hiring professional installers.
However, if you are looking for greater durability, you might consider corrugated aluminum panels. Aluminum is more durable than plastic, often more affordable than other metal panels, and lightweight. It is also non-rusting, making it ideal for humid, salty air. On the downside, aluminum is more susceptible to dents and divots.
Another option is terne roofing, which is one of the strongest and most durable roofing materials. It can withstand extreme weather conditions and can last over 100 years. However, it is typically the most expensive and difficult to work with.
If you are looking for a roofing material that lets light in, you might consider PVC, polycarbonate, or vinyl roofing. These materials are translucent, making them ideal for chicken coops, greenhouses, or low-profile carports. However, they expand and contract more than fiberglass-reinforced panels, which can provide greater stability in hot and cold conditions.
Finally, you might consider fiberglass-reinforced panels (FRP), which are reinforced with gloss fibers. These panels provide greater stability in hot and cold conditions, as they expand and contract less than PVC and polycarbonate panels. They also offer the added benefit of light transmission.
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