Timber Supported Polycarbonate Roof Kit – 3 Sheets x 2m

Select the type and colour of polycarbonate required when ordering.

This 3-sheet timber supported polycarbonate roof kit is designed for smaller timber-framed roofing projects. It includes three 1050mm wide polycarbonate sheets at 2m long, together with two 4m fixing bars cut to 2m, four end caps, an edge fillet, sheet closures, flash band and anti-dust tapes.

Ideal for small lean-to roofs, canopies, porches and covered outdoor areas, the kit provides the main roofing components needed to create a neat polycarbonate roof over a timber framework.

What's Included

• 3 x 1050mm wide x 2m long polycarbonate sheets
• 2 x 4m bars to fix to timber, supplied cut to 2m
• 4 x end caps included with the fixing bars
• 1 x 4m edge fillet
• 3 x 1050mm sheet closures
• 1 x 150mm flash band
• Anti-dust tapes

Actual coverage: approximately 3.26m.

Installation Guide

Step 1 – Install the Edge Bar

Fix your first edge bar as shown in diagram 1. Slide the edge fillet into the groove on the bar and cut the bar to the required length, remembering to allow for a 50mm overhang into the guttering.

Cut the aluminium base 2mm longer than the intended length of the polycarbonate sheeting. This allows for the end cap to be fitted later.

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 bars are butting against a wall, the edge trim is not required. Fit the bar only.

Step 2 – Position the Centre Bar

You can either cut the sheets to evenly space them across the roof or work towards positioning a sheet centrally. Once you have decided on the layout, position the centre bar in the required position.

Drill and fix the bar using screws at approximately 300–400mm centres.

IMPORTANT: Remember to leave a clear 4mm expansion gap between the bar and the polycarbonate sheets.

Step 3 – Check the Rubber Gaskets

Ensure all the rubber gaskets in the bars are flat with no bumps or raised sections before fitting the polycarbonate.

Step 4 – Prepare and Fit the Polycarbonate

Cut your polycarbonate sheets to length if they have not already been cut, ensuring that all swarf is removed. Use a vacuum or condensation-free air line to remove swarf. Never try to wash swarf out of the sheet.

Fit the anti-dust tapes to the sheet. Use the solid foil tape at the top and the vented tape at the bottom. These tapes help reduce condensation and prevent insects and dust from entering the sheet channels, so ensure they are fitted correctly.

Peel approximately 50mm of the protective film down both sides of the sheet and position the sheet 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 hammer the caps into position using a rubber mallet or equivalent until they lock down.

As you work across the roof, complete the flashing as you go. When the flashing is complete and all caps are in place, remove the protective covering.

Step 6 – Fit the End Caps and Sheet Closures

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

Installation Tips

Polycarbonate cut to size: Order your polycarbonate sheets after you have fitted the bars. We can cut, blow and tape your sheets to the correct width and length. Price on application. Remember to allow for expansion when ordering.

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

Cleaning: Only use mild soapy water. Try a small panel first to ensure there is no reaction. Never use solvent-based cleaners.

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

Recommended sheet widths: For a good-quality roof that will last, avoid excessively wide sheets. Use recommended widths of 980mm or less for roofs up to 4m long and 700mm wide for roofs over 4m long.

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

Finishing the roof: Use 9mm economy fascia around the roof and square white guttering for a neat, maintenance-free finish.

3 Sheet Timber Polycarbonate Roofing Kit

This 3-sheet timber supported polycarbonate roof kit provides the main roofing components required for a smaller 2m long polycarbonate roof. The fixing bars are supplied as 4m lengths and cut to 2m, with four end caps included.

Choose the required polycarbonate type and colour when ordering.

Not sure which polycarbonate or roofing kit is right for your project? Email us and we are here to help.