Sofia Martinez
Installing plastic roof sheeting is a great DIY project that can save you money and give your home a unique look. Plastic roof sheeting, commonly made from polycarbonate, PVC, uPVC, or fiberglass, is a popular choice for those seeking durability, strength, and transparency. Before installing, it is crucial to understand key factors such as proper alignment, securing methods, and drainage optimization. This will ensure a long-lasting and effective installation. In this article, we will guide you through the process of installing plastic roof sheeting, covering everything from choosing the right materials to step-by-step instructions for a safe and successful installation.
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What You'll Learn
Choose the correct thickness
Choosing the correct thickness for plastic roof sheeting is critical for the structural stability of your roof. The sheeting needs to be thick enough to support the weight of the roofing material and any additional expected weight, such as snow or ice. Thicker sheeting can provide more stability, especially in areas with heavy snowfall or strong winds.
The necessary thickness will depend on local building codes, the specific roof design, and the materials used. For example, steeper-sloped roofs may require thicker sheeting to support the weight of heavier roofing materials. Wider spacing between roof trusses typically requires thicker sheathing to prevent sagging between support points.
Common roofing materials such as plywood and oriented strand board (OSB) have different thickness options and weight-bearing capacities. Plywood, which is often used in wetter climates due to its ability to dry quickly, typically ranges from 1/2 to 3/4 of an inch in thickness. Oriented strand board, which is structurally stronger, ranges from 7/16 to 5/8 of an inch.
For corrugated plastic roofing sheets, the thickness typically ranges from 0.6mm to 2.0mm. A thickness of 1mm is often recommended as the best balance between price and performance for outdoor skylights.
It's important to carefully consider the intended purpose of your structure and the weather conditions it will face. Thicker sheets will provide more rigidity but may be less flexible, while thinner sheets may be more prone to damage from the elements. Consulting a structural engineer can help determine the optimal thickness for unique situations.
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Prepare the sheets
When preparing to install plastic roof sheeting, there are several key steps to follow to ensure a successful installation process. Firstly, it is important to choose the correct thickness for your sheets. Corrugated plastic sheets typically range from 0.6mm to 2.0mm in thickness. For outdoor skylights, 1mm thick sheets offer the best balance between price and performance. Thinner sheets may be flimsy, while thicker sheets provide more rigidity but are less flexible.
Once you have selected the appropriate thickness, the next step is to measure and cut the sheets to size. Use common tools like a ladder and a tape measure to determine the dimensions of your roof. Then, utilise an angle grinder to trim the corrugated panels accordingly. Remember to leave an overhang at the lower end and the gutter end of the roof. When cutting, always use a fine-toothed saw blade and cut at a high speed without forcing the blade, to achieve a clean cut without damaging the sheet.
Transportation and storage of the sheets is another crucial aspect of preparation. Plastic sheets should be transported and stored horizontally on a flat, sturdy pallet that is equal to or larger than the sheets themselves. Securely fasten the sheets to the pallet during transportation and handling to prevent damage. Avoid dragging the panels on the ground or scraping them against sharp or rough objects, as this can cause scratches.
Before installing the sheets, it is essential to seal the edges. Use solid polycarbonate tape for the top end and anti-dust tape for the bottom end. This step prevents dust, dirt, insects, and water ingress, ensuring the longevity of your roof. Additionally, if your roof has shingles, remove any damaged ones before proceeding with the installation.
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Measure and cut
To install corrugated plastic roofing sheets, you must first measure the area of your roof. Use a ladder and a tape measure to note your roof's dimensions. Measure an X across each side of the roof to see if each diagonal length of the X is the same. On each side of the roof, measure from the upper left (gable peak) to the bottom right (eaves) and then from the upper right (gable peak) to the bottom left (eaves). Repeat for the other side of the roof. If the measurements are different, your roof isn't square.
Once you have the measurements, you can cut the roofing sheets to size. Use a fine-toothed saw blade and cut at a high speed without forcing the blade through the material. This will help you achieve a clean cut without damaging the sheet. Cut the sheets to the right length, ensuring they overlap by at least one corrugation or as recommended by the manufacturer.
When cutting and handling the sheets, it's important to be careful not to scratch them. Plastic sheets can be scratched easily, so avoid dragging them on the ground or scraping them against sharp or rough objects. Keep the protective film on the sheets until you are ready to install them.
In addition to measuring and cutting the sheets, you will also need to cut and install purlins, which are supporting structures for the roofing sheets. The spacing between the purlins will depend on the load-bearing capacity required for your roof. A load support chart usually comes with the polycarbonate sheeting to help you determine the spacing and number of purlins needed. The purlins should be attached to the rafters using screws, with the top purlins about two inches down from the ridge so that the roofing material will line up.
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Install flashing
Roof flashing is a thin material, usually made of galvanized steel, that directs water away from critical areas of the roof, such as where the roof meets a vertical surface like a wall or a dormer. It is typically installed under roofing materials, such as shingles, and is used to surround roof features like vents, chimneys, and skylights.
To install step flashing, start by placing a piece of step flashing on top of the first row of shingles that butt up against a vertical wall or structure. Embed each step flashing piece in a 3-inch-wide application of asphalt plastic cement and nail it to the roof deck with two nails. Do not nail the flashing pieces to the vertical wall; instead, allow them to move with any differential expansion and contraction between the roof deck and the wall. As you work your way up the roof, position the metal flashing piece in each course so that the overlaying shingle will completely cover it. The end of each shingle adjacent to the wall should also be embedded in a 3-inch-wide application of asphalt plastic cement. Install flashing pieces and shingles in each course, alternating between the two and following the overlapping pattern up the roof. Ensure that flashing laps do not obstruct the flow of water.
For pipe flashing around soil stacks, shingle up to the bottom of the stack, then slide the flashing over the soil pipe and into place. Use nails sparingly and only where the flashing manufacturer recommends. Avoid driving nails close to the pipe. Continue shingling, cutting the shingles to fit around the stack. Lay each cut shingle in a bead of asphalt plastic cement, and seal exposed nails with a dab of asphalt plastic cement to prevent leaks.
When installing polycarbonate roof flashing, it is crucial to understand how to seal the back wall. While flashing tape or lead roof flashing were traditionally used, they have significant disadvantages. Flashing tape degrades over time, and lead flashing is difficult to install, time-consuming, and may not fully seal around the roof, allowing moisture to seep in. A Top Wall Flashing bar is a more effective solution, providing a single solution to these challenges. To install, first, select a hacksaw or chop saw with a metal-compatible blade and trim the roof flashing to size. Next, trim the foam gasket to match the flashing size and slide it into the gasket channel. Optionally, you can mark and cut out notches on the foam gasket where each glazing bar meets the flashing to ensure a snug fit. Predrill fixing holes into the Top Wall Flashing at regular intervals along the fixing guideline, using a drill with an HSS or other metal-compatible drill bit.
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Secure the sheets
When securing plastic roof sheets, it is important to use the correct type of screws and washers. Polycarbonate-compatible screws should be used, and washers should be compressed but still visible. Do not overtighten the screws, as this can cause water leakage and prevent the sheets from expanding and contracting.
The sheets should be attached starting from the eaves, with an overlap of about 3-4 inches (7.6-10.2 cm). Work your way up to the peak of the roof, and install the peak caps on top of the sheets. Seal any visible seams with a silicone sealant to prevent water leakage.
If installing flashing, this should be placed over the joints where two sheets meet on a roof peak, and sealed on both sides with silicone sealant. Flashing helps with waterproofing and adds a neat finish to the roof.
When placing screws, they should be placed at the crest of the corrugations for roofing and in the valleys for walls. Screwing on the crest for roofing helps to prevent water leakage.
Finally, inspect your work thoroughly. Make sure all screws are tightened appropriately, without being overtightened, and that all joints are sealed.
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Frequently asked questions
The first step is to measure the area of your roof and use an angle grinder to trim the corrugated panels to size.
The optimum corrugated plastic sheet thickness that offers the best balance between price and performance is 1mm.
You will need common tools such as a ladder, tape measure, and an angle grinder.
Measure an X across each side of the roof to see if each diagonal length of the X is the same. Measure from the upper left (gable peak) to the bottom right (eaves), then repeat on the other side from the upper right to the bottom left.
