Omar Khalid
Corrugated plastic sheets are a popular roofing option due to their ease of installation, durability, and cost-effectiveness. They are lightweight yet strong, and their simple overlap installation method requires minimal cuts. When installing corrugated roofing sheets, it is important to allow space for flashing, such as the Rock N Lock flashing system, to protect the sides and fixings, increase the lifespan of the roof, and reduce the risk of wind uplift. The amount of overlap required depends on the pitch of the roof, with a greater pitch requiring less overlap. While corrugated plastic sheets can be easily cut with a sharp knife, it is important to follow the correct cutting technique to avoid cracking or splintering.
| Characteristics | Values |
|---|---|
| Installation | Easy to install due to simple overlap installation method |
| Cutting | Cut with a sharp knife or tin snips; start at the edge, follow the guideline, and slow down at the end |
| Durability | Weather-resistant, lightweight, and long-lasting |
| Overlapping | Overlap sheets widthways and lengthways with a minimum of one or two corrugation peaks overlap depending on roof pitch |
| Flashing | Rock N Lock flashing is essential to protect the roof from wind uplift and increase lifespan; allow approximately 40mm for flashing on each side of the roof |
| Overhang | Overhang sheets up to a maximum of 70mm over the bottom edge of the roof, adjusting for the pitch of the roof |
| Uses | Suitable for lean-tos, pergolas, sheds, carports, garden pergolas, and school canopies |
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What You'll Learn
Cutting corrugated plastic sheets
Corrugated plastic sheets can be difficult to cut without the right tools. It is important to tailor your cutting tools to the specific thickness of the corrugated plastic sheet you are cutting. Metal blades, for instance, quickly dull when cutting across the grain of the plastic sheet.
There are a variety of tools available on the market that can be used to cut corrugated plastic sheets. For sheets thinner than 4mm, a sharp pair of scissors is a great option for kids, hobbyists, and DIY crafters. However, scissors may not be able to cut sheets thicker than 4mm in one go, resulting in an unclean cut.
Utility knives are another popular option as they can achieve a smooth and clean cut on corrugated plastic sheets of varying thicknesses. If you are a professional sign maker, an automatic flatbed cutter is recommended. While these machines are expensive, they can cut out complex designs from corrugated plastic sheets accurately and automatically without any manual labour.
Before cutting, it is important to stabilize the plastic sheet on a flat surface using duct tape. This will prevent the sheet from stretching and affecting your cut line. You should also measure and mark your desired cut carefully, using a straightedge if possible. If using a manual tool, it is recommended to draw an outline of your design first.
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Overlapping sheets widthways
Overlapping corrugated plastic sheets widthways is a straightforward process that can be carried out by even inexperienced DIYers. The sheets are popular for their ease of installation, cost-effectiveness, and ability to create a clear covering for outdoor areas.
To begin, measure your roof by calculating its width and length. Then, purchase corrugated sheets of the desired length, either pre-cut or in a longer slab that can be cut to size. When cutting the width of a sheet, remember to cut at the centre of the trough to ensure your Rock N Lock flashing still fits properly.
The amount of overlap between the sheets will depend on the pitch of your roof. For a pitch greater than 10°, overlap the sheets widthways by at least one corrugation peak. For a pitch less than 10°, overlap the sheets by two corrugation peaks. You can also overlap more than two corrugations if you don't want to trim the sheets at the edge. The recommended overlap measurements range from 18 cm to 32 cm.
It is also advisable to overlap with the prevailing wind direction to increase the longevity of your roof. This reduces the chance of wind uplift and protects the gables of the roof from the elements.
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Overlapping sheets lengthways
Overlapping Corrapol corrugated roofing sheets is a straightforward process. The sheets are designed to be overlapped widthways and lengthways to cover the full roof area, with minimal cuts required. This simple installation method is one of the main reasons corrugated roofing sheets are so popular.
When installing corrugated roofing sheets on a longer roof slope, they can be overlapped lengthways. The amount of overlap depends on the pitch of the roof:
- Pitch of 15 degrees or over: Overlap 180 mm
- Pitch between 10-15 degrees: Overlap 220 mm
- Pitch between 5-10 degrees: Overlap 320 mm
It is important to allow space for Rock N Lock Flashing when installing corrugated roof sheets. Rock N Lock flashings are an essential component that increases the lifespan of the roof by protecting the sides and fixings. The extra protection of the flashing also reduces the risk of wind uplift. You should allow approximately 40 mm for the Rock N Lock flashing on each side of the corrugated roof.
When cutting corrugated plastic sheets, it is important to follow the correct procedure. Start cutting from the edge, taking care of the first few millimetres to ensure a smooth cut. Follow the guideline across the sheet, keeping a steady hand to ensure a neat finish. Do not force the blade through the sheets. Slow down towards the end of the cut to create a clean finish.
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Rock N Lock flashing
To install the Rock N Lock flashing, simply lock the side flashing onto the end corrugation of the Corrapol sheets to secure it in place. This allows for a fast and easy installation process. Rock N Lock flashing is also highly durable and cost-effective, providing excellent longevity and superior protection for Corrapol sheets.
When cutting corrugated plastic sheets, it is important to ensure that the Rock N Lock flashing will still fit properly. To do this, cut at the centre of the trough when trimming down the width of the sheet. Additionally, start cutting from the edge of the sheet and follow the cutting guideline with a steady hand to ensure a neat finish.
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Trimming corrugated sheets
For sheets thinner than 4mm, a sharp pair of scissors is a great option for kids, hobbyists, and DIY crafters. It is important to note that scissors may not be able to cut sheets thicker than 4mm in one go, requiring multiple passes which may result in an unclean cut. Alternatively, a utility knife can be used for sheets of any thickness and will achieve a smooth and clean cut. When using a utility knife, cut the sheet halfway first, then keep tracing the outline until the board cuts through completely. This ensures precise, smooth, and safe cuts.
Another option for thin corrugated plastic sheets is a coral cutter, which has 2-centimetre-long stainless steel blades. However, these are not recommended for sheets thicker than 4mm. For thicker sheets, a commercial flatbed cutter is the best cutting tool, providing neat, smooth, and professional results. Additionally, for cutting small shapes, tin or tint snips can be used.
When cutting corrugated plastic sheets, it is important to start from the edge and take care of the first few centimetres or millimetres to ensure a smooth cut. Follow the cutting guideline with a steady hand, allowing the blade to do its work without forcing it. Slow down towards the end of the sheet to ensure a clean cut. If needed, run a sharp knife along the edge to remove any burrs, or use gloves to neaten the edge.
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Frequently asked questions
The best way to lock corrugated plastic sheets is to use Rock N Lock flashing. This flashing is available in both wall and gable options and is an essential component that increases the lifespan of your roof by protecting it from the elements.
You should leave approximately 40mm of space for the flashing on each side of your corrugated roof.
The Rock N Lock flashing is important as it significantly increases the lifespan of your roof by reducing the risk of wind uplift and protecting the gables of your roof from the elements.
It is recommended to install the first Corrapol Rock N Lock on one side to help guide the corrugated sheets across.
The best way to cut corrugated plastic sheets is to start cutting from the edge and follow the cutting guideline across the sheet. It is important to keep a steady hand and not to force the blade.
