Sofia Martinez
Corrugated plastic roofing is a cost-effective and easy-to-install roofing option. It is a popular choice for those seeking to let light into their space, such as in a greenhouse. Corrugated plastic roofing is also strong and durable, with the added benefit of being easy to cut to the required size. When installing corrugated plastic roofing, it is recommended to use special roofing fasteners or screws with flexible washers to secure the panels, as well as silicone sealant to prevent leaks. It is also important to ensure that the roof is square before beginning installation.
| Characteristics | Values |
|---|---|
| Materials | Corrugated roofing panels made of polycarbonate, metal, or fiberglass |
| Installation | Easy to install, lightweight, and strong |
| Tools | Common tools, angle grinder, ladder, tape measure, nail gun, silicone sealant, garden shears/scissors/fine-toothed saw, drill, roofing fasteners, screws, butyl tape, ridge cap, underlayment, flashing |
| Process | Measure the area, cut panels to size, roll out underlayment, install flashing on eaves, attach panels starting from eaves and overlapping by 3-4 inches, install peak caps, seal seams with sealant, pre-drill holes, fasten side panels, use aluminum nails with neoprene washers, apply mastic to overlap of one corrugation, adjust door construction, install vents, cut panels to fit pitch of roof, nail trim lumber to corners and where panels meet the roof, fasten aluminum ridge roll flashing |
| Tips | Pre-drill holes for fasteners at the high point of every fourth corrugation, holes should be 8-10mm in diameter and 2mm wider than fasteners, drill from underneath the roof, use a stick with a hole as a guide, ensure roof is square, use a ladder and do not overstretch when fastening sheets, use flashing for an attractive finish and additional weather protection, install gutters in high rainfall areas, use vinyl lap seal and/or mastic for effective sealing, install at temperatures above 60 degrees F, use weatherproof nails or wood screws with neoprene washers, self-tapping screws, or grommet-type fasteners |
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What You'll Learn
Measure the roof area
Measuring the roof area is a crucial step in installing corrugated plastic roofing. Here's a detailed guide to help you through the process:
Understand Your Roof Design
Before taking any measurements, it's important to have a clear understanding of your roof's design and dimensions. Sketch a rough outline of your roof to help visualise your measurements. If your roof is complex, break it down into smaller, more manageable sections.
Measure the Length and Width
Use a ladder and a tape measure to determine the length and width of the area requiring a roof. You can obtain these dimensions from the builder's plans or stretch the tape measure along the structural members of the roof for a direct measurement. Make sure to record these values accurately.
Account for Overhangs and Slopes
Roof overhangs or slopes will impact the amount of roofing material you need. Measure the area of any overhangs and slopes separately and add these values to your total roof area. This ensures you have enough roofing material to cover all aspects of your roof.
Calculate the Total Roof Area
To find the total roof area, multiply the length of your roof by its width. This calculation will give you the area in square units (e.g., square feet or square meters). Repeat this calculation for each section of your roof if it has multiple areas.
Determine the Required Roofing Material
Now that you have the total roof area, you can calculate the number of roofing sheets required. Divide the total roof area by the effective area of a single roofing sheet. Always round up the result to the nearest whole number to ensure you have sufficient sheets. Don't forget to factor in any vents, chimneys, or other features that will impact your roofing needs.
Add a Buffer for Errors and Wastage
It's wise to add a buffer to your calculations to account for errors, cuts, and future repairs. Typically, adding 5-10% to your total quantity is recommended, depending on the complexity of your roof and your level of experience. It's always better to have a few extra sheets than to run short during the installation process.
Measuring the roof area accurately is essential to ensure you purchase the correct amount of roofing material and avoid unnecessary wastage or budgetary concerns. Taking the time to carefully measure and calculate will make your corrugated plastic roofing project more efficient and cost-effective.
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Use a nail gun for speed
Using a nail gun is a great way to speed up the process of installing corrugated plastic roofing. Roofing nail guns have a shallower angle and hold coiled fasteners, reducing the need for frequent reloading, which would be a safety risk when working on a roof. They are distinct from nailers used for other tasks like framing.
Pneumatic nail guns are the most popular type, functioning with a compressed air supply. Roofing nail guns can also be solenoid-powered, operating with electromagnetic polarization. Some simply plug into 120-volt outlets. Powder-actuated nail guns use an explosive gunpowder charge to drive pins into hard materials.
There are several reliable roofing nail guns on the market, including the Ridgid 1-3/4 inch roofing nail gun, which combines ideal weight, speed, and power. This coil nailer is suitable for any roofing job. Another option is Grip-Rite’s lightweight nail gun, model GRTRN45. For a lower-priced option, consider Freeman’s pneumatic 15° 1-3/4″ rapid-fire coil roofing nail gun, which features a magnetic nail holder that prevents jamming and facilitates speed and accuracy.
Remember, while nail guns can significantly speed up the installation process, they can also be hazardous if not used with care and practice.
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Seal with silicone
When installing corrugated roofing, sealing with silicone is an important step to ensure the roof is weatherproof and long-lasting. Here is a detailed guide on how to seal corrugated plastic roofing with silicone:
Prepare the Roofing Sheets:
Before sealing, it is important to prepare the corrugated plastic roofing sheets correctly. Measure and cut the sheets to the desired size, allowing for an overlap of approximately 3-4 inches (7.6-10.2 cm) when installed. Pre-drill holes in the sheets for fasteners or screws, ensuring the holes are slightly larger than the fasteners to allow for expansion and contraction due to temperature changes. The recommended overlap for side-laps and end-laps is 2.67" x 9/16", which provides the best protection against leakage.
- Join the Panels: When joining two corrugated plastic roofing panels, apply a generous amount of silicone sealant along their vertical length. Be sure to overlap the sheets by one corrugation to ensure a strong seal.
- Use a Ladder: For safety, it is recommended to use a ladder to reach the roofing sheets securely. Ideally, have an assistant hold the ladder steady and assist with the sealing process.
- Seal Visible Seams: Once the panels are joined and sealed, focus on sealing any visible seams or gaps. Apply a generous amount of silicone sealant along these seams to prevent leaks and ensure a watertight seal.
- Allow for Expansion: If installing the roofing in a cold climate, remember to factor in summer temperature changes. Leave a slightly larger expansion gap, as the plastic roofing will expand in the summer heat and then shrink back in the colder months.
- Use Flashing: For an attractive finish and added weather protection, consider using flashing. This is especially useful if your roof adjoins another building. Flashing will improve the seal and provide extra protection against the elements.
- Follow Manufacturer's Instructions: Always refer to the manufacturer's instructions for specific guidelines on sealing and installing corrugated plastic roofing. Different roofing systems may have unique requirements, so it is important to follow their recommendations.
By following these steps and sealing with silicone, you will create a strong and durable seal for your corrugated plastic roof, ensuring it is protected from the elements and providing long-lasting performance.
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Overlap the sheets
Overlapping the sheets is a crucial step in installing corrugated roofing. The sheets should be overlapped widthways and lengthways to cover the entire roof area. The amount of overlap depends on the pitch of your roof. For a pitch of 15 degrees or more, an overlap of 180 mm is recommended, while a pitch between 10 and 15 degrees requires an overlap of 220 mm, and a pitch between 5 and 10 degrees needs an overlap of 320 mm. It is also important to consider the prevailing wind direction when overlapping the sheets. By installing the sheets with the prevailing wind direction, you can reduce the chance of wind uplift and increase the lifespan of your roof.
When overlapping the sheets, it is essential to use a generous amount of sealant to ensure there are no gaps and to achieve optimal performance. Silicone caulk or silicone sealant can be used to seal the overlaps and prevent leaks. It is also recommended to use vinyl lap seal and/or mastic on the side and end laps for an effective seal.
For corrugated roofing, special roofing fasteners or weatherproof nails with neoprene washers are ideal for securing the overlapped sheets. Pre-drilling the holes for the fasteners is recommended, with the holes being eight to ten millimetres in diameter and two millimetres wider than the fasteners to allow for expansion when exposed to heat.
Additionally, it is important to note that the overlap should be installed with the prevailing wind direction to increase the longevity of the roof. This will ensure that the open side of the overlap and the fixings are not exposed to excessive wind and force over time.
Overall, by properly overlapping the sheets and following the recommended installation techniques, you can create a watertight seal and ensure the longevity of your corrugated roofing.
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Use special roofing fasteners
When installing corrugated plastic roofing, it is essential to use special roofing fasteners designed for this specific purpose. These fasteners differ from standard screws in that they have a waterproof seal underneath their heads, which effectively prevents leaks. This is particularly important when joining panels, as it ensures a seamless and watertight finish.
The process of installing corrugated plastic roofing can be simplified by drilling the holes for the fasteners in advance. This pre-drilling step is easier with a guide, such as a stick with a hole drilled into it, and should be done from the underside of the roof. The ideal placement for the fasteners is at the high point of every fourth corrugation. The diameter of the pre-drilled holes should be eight to ten millimetres, allowing for a two-millimetre expansion gap when the roof is exposed to heat.
Special fasteners like the Poly-Fast™ and PolyXpand™ screws are designed to accommodate the thermal expansion needs of plastic roofing materials. These fasteners create a thermal expansion hole, allowing for the movement of the plastic sheets when exposed to heat. This prevents cracking and ensures a secure fit. Additionally, these fasteners provide a weathertight seal, protecting your roof from the elements.
For corrugated plastic roofing, consider using VEGA™ fasteners, which are designed for polycarbonate panels. VEGA™ fasteners do not require pre-drilling and result in a smoother installation and a more aesthetic look. The special washer on these fasteners seals perfectly, and the ZYTEC™ M coating makes them suitable for typical outdoor use.
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Frequently asked questions
You will need common tools such as a ladder, a tape measure, an angle grinder, and a nail gun.
First, measure the area of your roof and trim the corrugated panels to size. Roll out an underlayment and install flashing on the eaves of the roof. Attach the roofing panels, overlapping them by about 3-4 inches, and working your way to the peak of the roof. Install the peak caps and seal any visible seams with sealant.
Use weatherproof nails or aluminum nails with neoprene washers.
Measure an X across each side of the roof and check if each diagonal length of the X is the same. Measure from the upper left (gable peak) to the bottom right (eaves) and then from the upper right to the bottom left. Repeat for the other side of the roof. If the measurements are different, your roof isn't square.
