Maya Ellison
Corrugated plastic roofing is a popular choice for DIY enthusiasts and professionals alike, thanks to its versatility, durability, and ease of installation. It is a quick, low-cost roofing option for sheds, garages, greenhouses, decks, and other structures. With its distinct waved profile, corrugated roofing offers improved weight distribution, efficient water runoff, and unique aesthetic appeal. Before installing corrugated plastic roofing, it is essential to select the appropriate thickness, typically ranging from 0.6mm to 2.0mm, and ensure proper transportation, storage, and handling of the plastic sheets. This introduction sets the stage for a comprehensive guide on how to lay corrugated plastic roofing, covering essential steps, tips, and techniques for a successful installation.
| Characteristics | Values |
|---|---|
| Materials | Corrugated plastic roofing sheets, wood roof closure strips, sealant tape, screws, washers, cordless drill, staples, polyurethane, ridge cap, butyl tape |
| Installation tips | Store and transport sheets horizontally, secured to a pallet. Avoid dragging on the ground or scraping against sharp objects. Choose the correct thickness. Overlap panels by 3-4 inches. Screw through the hill for roofing. Screw through the valley for siding and paneling. |
| Uses | Suitable for skylights, side lights, metal-clad structures, agricultural greenhouses, decks, standalone or in conjunction with metal roofing. |
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What You'll Learn
Choose the correct plastic roofing type
When choosing the correct plastic roofing type, there are several factors to consider, including the desired level of light transmission, durability, and local building codes. Here are some options to consider:
PVC, Polycarbonate, or Vinyl Roofing
PVC, polycarbonate, or vinyl roofing panels are ideal if you want to let light in through the roof. These panels are translucent, allowing daylight to pass through them. This makes them a popular choice for applications such as chicken coops, greenhouses, or low-profile carports. However, it's important to note that polycarbonate panels expand and contract more than PVC panels, so they may not be suitable for extreme temperature variations.
Fiberglass Reinforced Panels (FRP)
FRP panels are reinforced with gloss fibers, making them highly durable and stable in both hot and cold conditions. They are also rot-proof, waterproof, and resistant to damage from ordinary cleaning solutions. Additionally, these panels can be easily installed using ordinary tools and can be drilled, sawed, punched, or nailed without causing harm to the material.
500 Series Panels
If you live in an area with heavy snowfall, consider using 500 Series or greater panels. These panels are designed to handle heavier snow loads and provide better protection against leakage and air infiltration. However, it's important to consult local building codes and authorities for specific recommendations and restrictions.
Thickness of Corrugated Plastic Sheets
The thickness of corrugated plastic sheets typically ranges from 0.6mm to 2.0mm. For outdoor skylights, a thickness of 1mm offers a good balance between price and performance. Thinner sheets may be flimsy, while thicker sheets provide more rigidity but less flexibility.
In conclusion, when choosing the correct plastic roofing type, consider the desired level of light transmission, durability, temperature variations, snow loads, building codes, and the thickness required for your specific application.
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Prepare the roof structure
To prepare the roof structure for installing corrugated plastic roofing sheets, follow these steps:
First, decide on the type of installation. For a portable structure, lay patio blocks as the foundation. For a permanent structure, pour concrete footers. Cut 2 x 4s to the proper lengths and nail studs every 24 inches on the center to form the front, back, and side framing. Nail the front and back frameworks to the side frames. Pre-cut roof rafters to the desired pitch and nail them into position. Pre-drill holes for fastening the side panels.
Next, choose the appropriate thickness for your corrugated plastic sheets. Thicknesses typically range from 0.6mm to 2.0mm, with 1mm being a common choice for a balance between price and performance. Ensure you have the correct number of sheets by measuring the roof dimensions and planning the overlap between sheets. Overlapping by one corrugation is recommended for leak protection. Transport and store the sheets horizontally on flat, sturdy pallets that are equal to or larger than the sheet dimensions. Secure and fasten the sheets to the pallets during transportation and handling to prevent damage.
Before installing the sheets, lay the drip edge along the structure's edges, fitting it tightly against the underlying structure. Use screws or staples to attach the drip edge to the purlins or blocking. Place fasteners about every foot for a secure hold.
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Lay the sheets
To lay corrugated plastic roofing sheets, follow these steps:
First, transport and store the sheets horizontally on a flat, sturdy pallet that is equal to or larger than their dimensions. Secure the sheets to the pallet during transportation and handling to prevent damage. When installing, lay the drip edge along the structure's edges, fitting it tightly against the underlying structure. Use screws or staples to attach the drip edge to the purlins or blocking, placing them about an inch from the edge and approximately every foot. When attaching the roofing, place the screws a little higher up to help seal the drip edge tighter.
Next, lay sealant tape along the edge of the flashing and peel away the back paper. Place the closure strips—foam bits that block the underside of the panels—along the adhesive, ensuring they match the specific corrugated roofing sheets. Draw a line of sealant on top of the closure strip, then lay the panels, overhanging the edge by about 4 inches (10 cm). Overlap the panels by 3-4 inches (7.6-10.2 cm) or one ridge, screwing them in with washers and screws. Drive the screws so that the head meets the corrugated panel to hold it securely without denting or dimpling the panels.
When screwing the panels, you can choose to screw into the channels or the ridges. Screwing into the channels may provide a tighter fit, while screwing into the ridges is more common and allows for movement as the panels heat and cool. For roofing, screw through the hill (the crest); for siding and paneling, screw into the valleys (the gully). However, some sources recommend screwing into the valleys for roofing to avoid warping the metal and to make solid contact with the roof sheathing. It is important to follow the manufacturer's instructions and local regulations, as these may vary.
Continue laying and screwing down the panels, ensuring each new panel overlaps the previous one by at least one corrugation. Screw down the overlapping panels for a tight fit, and wait to screw down the last corrugation of each panel until after the next panel has been overlapped.
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Overlap and fasten the sheets
Overlapping and fastening the sheets is a crucial step in ensuring the durability and weather resistance of your corrugated plastic roof. Here is a detailed guide on how to do it:
First, determine the direction of the overlap. The overlap should be away from the prevailing wind to provide better protection against the elements. Overlap the sheets by at least one corrugation, or follow the manufacturer's recommended overlap specifications for optimal protection against leakage and air infiltration.
Next, secure the sheets with screws. If your sheets are horizontal or diagonal, place the screws in the "hill" or ridge of the corrugation. If the sheets are vertical, place the screws in the "gully" or valley. Do not overtighten the screws, as this can cause warping and the screws may eventually pull out. When fastening the sheets, work from one corner, screwing them in with wood screws and washers. Drive the screws so that the head of the screw just meets the corrugated panel to hold it securely without denting or dimpling the sheets.
You can also use butyl tape or a polyeurathane sealant to secure the sheets and provide added protection against leaks. Apply the sealant on top of the screws or use it to secure the overlap between sheets.
When working with corrugated plastic roofing, it is essential to follow the manufacturer's instructions and local regulations, as specifications may vary depending on the brand and region.
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Seal the roof
Sealing your roof is a crucial step in ensuring its longevity and preventing leaks. Here are the steps you should follow to effectively seal a corrugated plastic roof:
Firstly, understand the importance of screw placement. When installing corrugated roofing sheets, the placement of screws can vary depending on the sheet's orientation and the specific product. If your sheets are horizontal or diagonal, place the screws in the "hill" or ridge. For vertical sheets, place them in the "gully" or valley. Avoid overtightening the screws, as this can cause warping and pulling. Instead, leave a slight gap to allow for the expansion and contraction of the panels due to temperature changes.
Next, use the appropriate sealant. Apply a dab of polyurethane or butyl sealant on top of the screws to provide an extra layer of protection against water ingress. This is especially important if you are using a screw placement pattern that may be more susceptible to leaks, such as screwing into the valleys.
Additionally, pay attention to the roof seams. Once you've installed the panels and screws, seal any visible seams with a suitable sealant. This will help prevent water ingress and improve the overall durability of the roof.
Finally, consider a protective coating. If you wish to further enhance the protection of your corrugated plastic roof, you can apply a coat of clear polyurethane. This will increase UV protection and delay degradation, which is beneficial for translucent panels that are exposed to sunlight.
By following these steps and paying attention to the manufacturer's instructions, you can effectively seal your corrugated plastic roof, ensuring it is weather-resistant and long-lasting.
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Frequently asked questions
Before you begin, make sure you have the right thickness of corrugated plastic roofing sheets. Thicknesses typically range from 0.6mm to 2.0mm. For outdoor skylights, 1mm is a good balance between price and performance.
Plastic sheets should be transported and stored horizontally on a flat, sturdy pallet that is equal to or larger than the sheets. Secure and fasten the sheets to the pallet during transportation and handling to prevent damage.
You can use screws or nails to fasten the sheets. If using screws, do not overtighten them—leave a small gap to allow for the movement of the panels as they heat and cool. You can also use staples, but make sure they are long enough to securely attach the sheets.
Overlap the sheets by 3-4 inches (7.6-10.2 cm) and use sealant tape and closure strips to block the underside of the panels and prevent leaks.
