Timber Supported Polycarbonate Roof Kit – 10.55m Coverage

Select the type and colour of polycarbonate required when ordering.

Our Timber Supported Polycarbonate Roof Kit provides the main components needed to create a secure and professional polycarbonate roof on a timber structure. With approximately 10.55m of actual coverage, this larger kit is ideal for extended canopies, lean-to roofs, carports, pergolas, patio covers, porches and other timber-supported roofing projects.

Supplied from Bristol, the kit brings together the polycarbonate sheets, timber fixing bars, edge fillets, flashing and anti-dust tapes needed for a straightforward roofing installation.

What's Included

• 10 x 1050mm x 3.0m polycarbonate roof sheets
• 11 x 3m bars for fixing to timber
• 2 x 3m edge fillets
• 1 x 150mm flash band
• Anti-dust tapes

Installation Guide

Step 1 – Fit the Edge Bars

Fix the first edge bar into position and slide the edge fillet into the groove. Cut the bar to length, allowing for a 50mm overhang into the guttering. Cut the aluminium base approximately 2mm longer than the polycarbonate sheet to allow for the end cap.

Fix the bar using No. 6 screws at approximately 300–400mm centres, ensuring the drip on the edge trim is correctly positioned. Repeat at the opposite end. Where a bar meets a wall, the edge fillet is not required.

Step 2 – Position the Centre Bars

Plan the sheet layout before fixing the remaining bars. Sheets can be evenly spaced or arranged with a cut sheet in the centre. Position and secure the centre bars at approximately 300–400mm screw centres.

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

Step 3 – Check the Gaskets

Before installing the sheets, check that all rubber gaskets are flat and correctly positioned with no bumps or raised sections.

Step 4 – Prepare and Fit the Polycarbonate

Cut the sheets to length if required and remove all swarf using a vacuum or condensation-free air line. Do not wash swarf out of the sheet channels.

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

Peel approximately 50mm of protective film from each side and carefully position the sheet into the roof.

Step 5 – Secure the PVCU Caps

Locate the toothed legs of the PVCU cap inside the aluminium base. Press down firmly and lightly tap into position with a rubber mallet until the cap locks securely.

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

Step 6 – Fit the End Caps

Fit the end caps into position and check that all sections of the roof are securely finished.

Polycarbonate Roof Kit Tips

Cut-to-size polycarbonate: If you require sheets cut to size, fit your bars first and then order the polycarbonate. We can cut, blow and tape sheets to the required width and length. Remember to allow for expansion. Price on application.

Lead flashing: Where lead flashing is being used, fit it before the sheets and dress it down as the roof panels are installed. Fit lead in sections of approximately 2m and seal 100mm overlaps with Lead Mate.

Cleaning: Clean polycarbonate using mild soapy water. Always test a small area first and never use solvent-based cleaners.

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

Sheet widths: For a long-lasting roof, avoid excessively wide sheets. Recommended widths are approximately 980mm or less for roofs up to 4m long and 700mm wide for roofs over 4m long.

Timber structure: Fix wall plates at the top and bottom and install the joists as the polycarbonate bars are fitted.

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

Polycarbonate Roofing Kits Bristol

We supply timber supported polycarbonate roofing kits from Bristol for DIY customers, builders and professional installers. If you're unsure which polycarbonate, roofing kit or accessories you need, contact us before ordering and we'll be happy to help.