Timber Supported Polycarbonate Roof Kit – 7.49m Coverage

Select the type and colour of polycarbonate required when ordering.

The 7.49m Timber Supported Polycarbonate Roof Kit provides the main components needed to create a secure polycarbonate roof on a timber structure. It is suitable for larger canopies, lean-to roofs, covered walkways, porches, pergolas and other timber-supported roofing projects.

This complete kit includes 7 polycarbonate sheets measuring 1050mm x 2.5m, together with the timber fixing bars and finishing components required to install the roof.

What's Included

• 7 x 1050mm x 2.5m polycarbonate roof sheets
• 8 x 2.5m bars for fixing to timber
• 2 x 3m edge fillets
• 7 x 1050mm sheet closures
• 1 x 150mm flash band
• Anti-dust tapes

Actual coverage: approximately 7.49m.

Installation Guide

Step 1 – Fit the Edge Bars

Fix your first edge bar as shown in diagram 1. Slide the edge fillet into the groove on the bar, then cut the bar to length, allowing for a 50mm overhang into the guttering. Cut the aluminium base 2mm longer than the intended length of the polycarbonate sheet to allow for the end cap.

Drill and fix the bar into position using No. 6 screws at approximately 300–400mm centres. Ensure the drip on the edge trim is correctly positioned and neat when viewed externally. Repeat at the opposite end.

Note: Where a bar butts against a wall, the edge trim is not required; fit the bar only.

Step 2 – Fit the Centre Bars

Decide whether you want to space the sheets evenly or work towards a sheet positioned in the centre. Once the layout has been established, position and fix the centre bars using screws at approximately 300–400mm centres.

IMPORTANT: Leave a clear 4mm expansion gap between the bars and the polycarbonate sheets.

Step 3 – Check the Gaskets

Ensure all rubber gaskets in the bars are flat and correctly positioned, with no bumps or raised sections.

Step 4 – Prepare and Fit the Polycarbonate

Cut the polycarbonate sheets to length if required and remove all swarf using a vacuum or condensation-free air line. Never try to wash swarf out of the sheet channels.

Fit the anti-dust tapes correctly, using the solid foil tape at the top of the sheet and the vented tape at the bottom. These tapes help reduce condensation and prevent insects and dust entering the sheet channels.

Peel approximately 50mm of protective film down both sides of the sheet and position it into place.

Step 5 – Fit the PVCU Caps

Position the PVCU caps so that the toothed legs locate inside the centre of the aluminium base. Press down firmly, then lightly tap the caps into position with a rubber mallet until they lock securely.

Complete the flashing as you work across the roof. Once the flashing and caps are fitted, remove the remaining protective covering.

Step 6 – Complete the Roof

Fit the end caps into position. Cut the sheet closures to the required length between the bars and push them securely into place.

Installation Tips

Polycarbonate cut to size: We recommend fitting your bars before ordering cut-to-size polycarbonate. We can cut, blow and tape the sheets to the required width and length. Remember to allow for expansion when ordering. Price on application.

Lead flashing: If using lead flashing, fit it before the sheets and dress it down as you install the roof panels. Fit lead in sections of approximately 2m and seal 100mm overlaps with Lead Mate.

Cleaning: Use mild soapy water only. Test a small area first to ensure there is no reaction and never use solvent-based cleaners.

Silicone: You should not normally need silicone. If required, use a good-quality low-modulus neutral clear silicone.

Sheet widths: For a good-quality roof designed to last, avoid excessively wide sheets. The recommended widths are 980mm or less for roofs up to 4m long and 700mm wide for roofs over 4m long.

Timber preparation: Fix wall plates at the top and bottom and install the joists as you fit the polycarbonate bars.

Finishing: For a low-maintenance finish, use 9mm economy fascia around the roof with square white guttering.

Timber Supported Polycarbonate Roofing

This 7.49m timber supported polycarbonate roof kit is designed to make ordering the main roofing components simple, providing the sheets, timber fixing bars and finishing accessories needed for a complete installation.

Not sure which polycarbonate or roofing kit you need? Email us and we'll be happy to help.