Ethan Clarke
Corrugated plastic roofing is a cost-effective and versatile roofing option. It is also easy to install, making it a popular choice for DIYers. When it comes to screwing corrugated plastic roofing, there are several things to keep in mind. Firstly, it is recommended to pre-drill holes for the screws to make the installation process easier. The spacing of these holes is important, with most guidelines recommending a distance of 6 to 8 inches between each hole. The diameter of the pre-drilled holes should be slightly larger than the screws, allowing for thermal expansion. When it comes to the placement of screws, opinions vary. Some sources recommend screwing through the crest or high position of the corrugation, especially in areas with high rainfall, as it prevents water from pooling and leaking through the screw holes. Others suggest screwing through the trough or bottom of the corrugation, which is a common practice in Australia, leaving room for thermal expansion. Ultimately, the placement of screws will depend on the manufacturer's instructions and the specific requirements of your roofing project.
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What You'll Learn
Use roofing screws with washers to prevent leaks
Corrugated plastic roofing is a cost-effective roofing option that's easy to install. However, dripping or leaking is a common issue with corrugated roof sheets, which can lead to moisture buildup, structural damage, and costly repairs. To prevent leaks, it is important to use the correct type of screws and washers and to place them in the proper locations.
When installing corrugated plastic roofing, it is recommended to use roofing screws with washers to prevent leaks. The washers help to create a tighter seal around the screws, reducing the risk of water infiltration. The washers also serve other purposes, such as distributing pressure to avoid metal fatigue and preventing electrolytic corrosion. They also help to protect the finish of the roofing and siding by preventing the screw head from scratching the surface.
It is important to note that the screws should not be over-tightened, as this can cause the corrugated plastic to crack or fracture. Instead, follow the manufacturer's instructions for tightening the screws and fasteners. Additionally, make sure to space the screws evenly apart, with rows of corrugated roofing panels overlapping by about four inches to create durable, weather-resistant protection.
When joining panels, use a generous amount of silicone sealant along their vertical length to ensure there are no gaps. You can also use vinyl lap seal and/or mastic to achieve an effective seal on side-laps and end-laps. For additional weather protection, you can use flashing to improve the seal, especially if your plastic roofing adjoins another building.
By using roofing screws with washers and following the proper installation techniques, you can effectively prevent leaks in your corrugated plastic roofing.
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Screw placement depends on the roofing material
When working with corrugated metal roofing, such as steel or tin, the screws are typically placed through the "bottom" or "trough" of the corrugation. This is to prevent water from pooling and leaking through the screws. However, some sources recommend screwing through the "top" or "crest" of the corrugation, especially in areas with extremely long and cold winters, as it is less likely that roof rakes will knock and displace the screws.
For polycarbonate corrugated roofing, specialized fasteners like Poly-Fast™ and PolyXpand™ are available to handle the material's high coefficient of thermal expansion and prevent over-tightening. These fasteners are designed to affix to the underlying structure, typically steel purlins and battens, rather than coming into direct contact with the polycarbonate sheets.
Aluminum panels are another option for roofing material. They are lightweight, durable, and affordable, but their lightweight nature makes them more susceptible to dents and divots. Aluminum nails with neoprene washers are typically used for fastening aluminum panels, along with mastic applied to the overlap of one corrugation.
The type of roofing material chosen will dictate the specific screw placement techniques and considerations to ensure a secure and long-lasting installation.
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Pre-drill holes for screws for corrugated plastic roofing
Corrugated plastic roofing is a cost-effective and easy-to-install roofing option. Before installing corrugated roofing, it is important to check local building codes for any restrictions on using this type of roofing.
To ensure a proper installation, it is recommended to pre-drill holes for the screws. This makes it easier to fasten the roofing panels securely and helps achieve a durable and weather-resistant roof. Here are some detailed instructions for pre-drilling holes when installing corrugated plastic roofing:
Spacing and Positioning of Holes:
Space the pre-drilled holes 6 to 8 inches apart on the end and side ridges of the panels. The fasteners should be placed at the high point of every fourth corrugation, or every second corrugation according to some sources. When joining panels, overlap the sheets by one corrugation and use silicone sealant along their vertical length.
Hole Diameter:
The diameter of the pre-drilled holes should be eight to ten millimeters, or slightly larger than the fastener diameter (by about 2 millimeters) to allow for thermal expansion. For non-metallic roofing, a 4.5mm diameter screw requires a 10mm hole.
Drilling Technique:
Use a drill with normal drill bits and start with a pilot hole, gradually increasing the size until you reach the desired hole diameter. Drilling from the underside of the roof, use a stick with a hole as a guide to ensure straight drilling. Avoid drilling in the valley of the ridges to prevent leaks, and be careful when the sheets are cold as they are more brittle.
Screw Selection:
Use roofing fasteners with a waterproof seal, such as Poly-Fast™ or PolyXpand™ screws, rather than standard screws. For corrugated polycarbonate sheets attached to wood bases, #9 x 1-1/4″ screws with EPDM sealing washers are suitable.
By following these instructions for pre-drilling holes and selecting the appropriate screws, you can achieve a secure and long-lasting corrugated plastic roof installation.
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Use flashing to improve the seal and finish
Corrugated plastic roofing is a cost-effective, long-lasting, and low-maintenance roofing option. It is also easy to install, but there are still some challenges to achieving a neat finish. One of the most critical steps to ensuring your roofing sheets last is sealing your roof against any back, top, or side walls.
If your roof abuts a rising wall, you will need a wall flashing. One of the hardest areas to seal on a corrugated lean-to roof is where the corrugated roof meets the back wall, as there is no flat surface for lead flashing to seal onto. Top wall flashing makes corrugated roof flashing 75% easier to waterproof.
To install a top wall flashing, first secure the flashing with screws. Then, seal the top lip with flashing tape or silicone to create a weather-tight seal. You can also use a top wall flashing foam gasket to seal the roof. The foam gasket can be compressed or notched out to fit your roof exactly.
When installing corrugated roofing, it is important to use special roofing fasteners rather than standard screws to secure the corrugated sheets. These fasteners have a waterproof seal underneath the head that prevents leaks. Additionally, when joining panels, use silicone sealant along their vertical length and overlap the sheets by one corrugation. Be sure to use a generous amount of sealant to fill any gaps and achieve the best performance.
For an attractive finish and additional weather protection, especially if your plastic roofing adjoins another building, you can use flashing to improve the seal.
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Choose the right screw type for polycarbonate roofing
Polycarbonate roofing requires specific types of screws to ensure a secure and long-lasting installation. The right screws will also help to prevent damage caused by thermal expansion and over-tightening.
One recommended screw type for polycarbonate roofing is the Poly-Fast™ fastener. This screw is designed for roofing profiles made from non-metallic materials, such as polycarbonate, PVC, and fiberglass-reinforced polyester resin. Poly-Fast™ screws feature a Thermal Expansion Hole Cutter, which creates an 11mm diameter hole to allow for the expansion and contraction of the polycarbonate sheets due to temperature changes. This screw also comes with a Domed Weatherseal EPDM washer, which provides a perfect seal against the elements and prevents leaks.
Another option is the PolyXpand™ fastener, which is also designed for non-metallic roofing profiles. The PolyXpand™ screw features drilling-tip wings that create an 11mm diameter thermal expansion hole. Like the Poly-Fast™, the PolyXpand™ also has a Domed Weatherseal EPDM washer to create a seal against the elements.
One Shot Polycarbonate fixing screws and Laserlite Vortex Polycut screws are also suitable for polycarbonate roofing. These screws have a unique design that eliminates the need for pre-drilling, as they can be driven directly through the roofing material. They feature a 10mm hole cutter on the screw thread, creating the necessary clearance hole. These screws also come with a domed sealing washer for a watertight seal.
When choosing screws for polycarbonate roofing, it is important to select those with sealing dome washers. These washers create a waterproof seal around the screw head, preventing leaks and potential damage caused by water infiltration.
Additionally, it is recommended to use screws with a lower RPM when fixing polycarbonate sheets. This helps to prevent cracking and splitting and improves the overall aesthetics of the roofing.
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Frequently asked questions
It is recommended that you place screws near the edges of the roof panels, both vertically and horizontally, with even spacing. The ideal spacing for screws is six to eight inches apart.
It is recommended to use special roofing fasteners, rather than standard screws, as they have a waterproof seal underneath the head that prevents leaks. Zinc-plated screws, also known as galvanised screws, are also used for corrugated roofs. Poly-Fast™ and PolyXpand™ fasteners are designed to handle thermal expansion and prevent damage.
It is recommended to pre-drill holes for the screws. The pre-drilled holes should be eight to ten millimetres in diameter and two millimetres wider than the fasteners. When screwing, do not over-tighten as this leaves room for expansion in the heat.
