Maya Ellison
Corrugated plastic roofing is a cost-effective, long-lasting and low-maintenance roofing option that is easy to install. It is also lightweight and easy to work with, making it a popular choice for homeowners who want to save on professional installation costs. If you're considering replacing your corrugated plastic roof yourself, it is important to note that this project will require patience and attention to detail, and it may be helpful to enlist the assistance of one or two friends. This guide will provide you with an introduction to the process of replacing a corrugated plastic roof, covering topics such as removing the old roof, preparing the surface, cutting and installing the new roofing sheets, and ensuring proper drainage and weather protection.
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What You'll Learn
Measure roof and cut sheets
To measure your roof and cut sheets for a corrugated plastic roof, follow these steps:
First, measure the width (horizontal) and length (from the peak to the lowest point) of your roof. Multiply these two numbers to get the area. Repeat this process for each section of your roof, then add 15% of the total number to get your approximate required square footage of roofing. For instance, a roof with a width of 15 ft and a length of 10 ft has an area of 150 sq ft, which we then double for an A-frame roof. 15% of that number is 45 sq ft, which brings the total estimated material needed to 345 sq ft. The added 15% is to accommodate roofing overlap. You may want to add another 5-10% to be sure to buy enough.
Next, you will need to cut your panels to the desired length. Most PVC sheets come in a length of 32 feet. If you need to lap to complete the run, allow for a minimum of 18 inches. You can use a utility knife or a circular saw with a fine-toothed blade to cut the sheets. A circular saw is generally faster and suitable for larger projects, while a utility knife allows for more controlled and precise cuts. Before you begin cutting, secure the panel by placing the corrugated plastic roofing panel on a stable work surface. If possible, secure it in place using clamps or weights to prevent movement during cutting. This stability is crucial for achieving clean and straight cuts.
To cut the sheets, start by measuring the length you need for your corrugated plastic roofing panel. Mark the measurements and where you need to cut with a felt-tipped pen. Draw a straight line on your plastic roofing sheet with a straightedge ruler. Adjust the depth of the circular saw blade to match the thickness of the corrugated plastic panel. Align the saw blade with the marked cutting line and carefully make the cut, ensuring a steady and controlled motion. Use a straight edge or guide to help maintain a straight cutting line. If using a utility knife, score along the marked cutting line with the knife, applying firm and even pressure. Repeat the scoring process multiple times, gradually increasing the depth with each pass.
After cutting, inspect the edges for any rough or uneven areas. Use a fine-grit sandpaper or a utility knife to smooth out any imperfections.
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Remove old roof
Removing an old corrugated plastic roof is a challenging job that will likely require the assistance of one or two friends. Before you begin, gather the necessary tools, including a screwdriver, claw hammer, and pry bar. Since you are replacing an existing corrugated plastic roof, the first step is to remove the previous roof. Corrugated plastic roofing is typically held together with a combination of screws and nails, so you will need to use a combination of tools for removal. Use a screwdriver to unscrew any screws holding the roof in place, and a claw hammer to remove any nails. If necessary, use a pry bar for additional leverage to remove the roofing.
Once the old roof has been removed, inspect the underlying wood for any damage. If there is any rotting or other negative conditions, it is best to fix this now before installing the new roof. It is also important to ensure that the roof is square. To do this, measure an X across each side of the roof and compare the diagonal lengths. If the measurements are the same, your roof is square. If they are different, your roof is not square, and you may need to make adjustments before installing the new roof.
When removing the old roof, take care not to damage the underlying structure. Work carefully and methodically, and be sure to have a plan for disposing of the old roofing material. It is also important to take the necessary safety precautions, such as wearing protective gear and using a sturdy ladder to access the roof.
Additionally, consider the slope of your roof. The minimum slope for a corrugated plastic roof is typically recommended as 1-1/2″ for every 12″, or a 10-degree pitch. If your roof has a shallower pitch, you may need to consider additional weatherproofing measures to ensure proper drainage. This can include the use of gutters, which can be installed after the new roof is in place, particularly if you live in an area with a high level of rainfall.
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Prepare wood and purlins
When preparing the wood and purlins for a corrugated plastic roof, there are several important steps to follow. Firstly, ensure that the wood you will be attaching the roof to is not damaged by rotting or any other negative conditions. This is crucial, as an unstable base can compromise the integrity of the entire roof structure.
Purlins, the horizontal pieces of wood that span the top of the roof trusses, play a vital role in providing framing and support for the roofing material. They also offer a place to attach the roofing securely. When installing the purlins, it is essential to space them correctly. The recommended spacing for roof trusses should not exceed 24 inches, and purlins should not be more than 36 inches apart.
To ensure a snug fit for the corrugated plastic panels, the top purlin should be positioned about two inches down from the ridge. This spacing is ideal for winter installations, allowing for the expansion of the plastic material during warmer months. If installing in summer, remember to factor in temperature changes as the plastic roofing will shrink, so leave a slightly smaller expansion gap.
For added stability, it is recommended to use blocking on the gable rafters to create an even surface to attach the drip edge. Cut the rough-cut lumber to the appropriate length to fit the gap between the purlins, and screw it into the rafters using multi-purpose construction screws. The drip edge will help protect the roof's edges from water damage by guiding water away from the structure.
Finally, you can attach the wood closure strips to the purlins. These strips provide support for the corrugated sheets and ensure a secure fit. Staple or screw the closure strips in place, and then apply universal seal tape to fill any remaining gaps. This tape expands after installation, creating a tight seal.
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Fasten sheets with screws and nails
When fastening sheets with screws and nails, it is important to plan out the screw locations and pre-drill the panels on the ground with a 1/8" bit. Pre-drilling holes on the end and side ridges of the panels, spacing them 6 to 8 inches apart, is also crucial. The screws should then be driven so that their heads just meet the corrugated panel, securing it in place without causing any dents or dimples. It is recommended to leave a gap underneath to allow for movement as the panels heat and cool, as tightening them too much can cause the screws to pull out.
For corrugated plastic roofing, nails can be driven through the ridges of the roof using a nail gun. Overlapping the sheets at the end of each plastic sheet will create a seal. Following this, screws with watertight washers should be attached to the flat areas between the roof ridges. It is important to note that the washers should be as flat as possible to create a watertight seal.
When installing corrugated roofing sheets, the use of screws is generally recommended for stability. However, a combination of screws and nails can also be used. For instance, screws can be used in the hills (crests) of the sheets, while nails can be used in the valleys (gullies). This combination provides stability and helps prevent leaks.
Additionally, when installing screws, it is important to ensure that the panels are square with the roof to avoid crooked placement. Using a chalk line to snap down a grid that is perpendicular to the roof's edges can help achieve this. Furthermore, the use of polyeurathane sealant on top of the screws can provide added protection.
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Seal and weatherproof
When sealing and weatherproofing a corrugated plastic roof, there are a few key steps to follow. Firstly, it is important to ensure that the roof is installed correctly and securely. This includes checking that the purlins are installed correctly and that the roofing sheets are properly attached to the rafters with nails, screws, or a combination of both.
Next, you should carefully inspect the roof and tighten any loose fasteners with a power screwdriver. It is also recommended to power wash the roof to remove any dirt, debris, or residue that may interfere with the sealing process.
To achieve a proper seal, you can use a combination of methods. One option is to use a clear silicone sealant to waterproof the seams of the roofing sheets. This will help to prevent leaks where the panels overlap. You can also use a product like Flex Seal spray, which is designed to create a watertight barrier.
Additionally, when attaching the roofing sheets, you can use special screws with rubber washers that are designed to create a watertight seal. These screws should be attached to the flat areas between the roof ridges.
Another important component of weatherproofing is the installation of a drip edge. This helps to protect the roof's edges from water damage by guiding water away from the structure.
By following these steps and paying attention to the details, you can effectively seal and weatherproof your corrugated plastic roof, ensuring that it stands up against the elements.
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Frequently asked questions
You will need a screwdriver, claw hammer, and a prybar to remove the existing roof. To install the new roof, you will need corrugated plastic sheets, a measuring tape, a marker, a band saw, a drill, fasteners, a nail gun, nails, and screws.
First, gather the necessary tools and materials. Remove the existing roof using a screwdriver, claw hammer, and prybar. Cut the new corrugated plastic sheets to the proper length using a measuring tape, marker, and band saw. Drill holes in the sheets and use fasteners, nails, and screws to attach the sheets to the rafters.
Ensure that the wood you are attaching the roof to is not damaged. The roof should have a pitch of at least one inch per foot to allow for proper water drainage. The fasteners should be placed at the high point of every fourth corrugation, and the sheets should overlap by about four inches for weather protection.
