Timber Supported Polycarbonate Roof Kit – 11.55m Coverage

Select the type and colour of polycarbonate required when ordering.

For larger timber roofing projects, our 11.55m Timber Supported Polycarbonate Roof Kit provides a convenient way to source the main roofing components together. With 11 polycarbonate sheets and 12 fixing bars, this kit is suitable for larger canopies, lean-to roofs, carports, pergolas, patio covers and other timber-supported structures.

Supplied from Bristol, the kit includes the polycarbonate sheets, timber fixing bars, edge fillets, sheet closures, flashing and anti-dust tapes required to complete the roof.

What's Included

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

Installation Guide

Step 1 – Install 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 the end cap to be fitted.

Secure 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 edge. Where a bar meets a wall, the edge fillet is not required.

Step 2 – Position the Remaining Bars

Plan the position of the polycarbonate sheets before fixing the centre bars. Sheets can be evenly spaced or arranged with a cut sheet in the centre. Once the layout has been decided, fix the remaining bars at approximately 300–400mm screw centres.

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

Step 3 – Check the Bar Gaskets

Before fitting the polycarbonate, make sure all rubber gaskets are flat and correctly positioned with no bumps or raised sections.

Step 4 – Prepare and Install the Sheets

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

Apply 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 insects and dust entering the channels.

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

Step 5 – Fit the PVCU Caps

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

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

Step 6 – Finish the Roof

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

Helpful Tips

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

Lead flashing: If using lead flashing, 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: Use mild soapy water to clean polycarbonate. Test a small area first and never use solvent-based cleaners.

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

Recommended sheet widths: Avoid excessively wide sheets for the best long-term performance. Use approximately 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 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 to DIY customers, builders and professional installers. With a range of kit sizes and polycarbonate options available, we can help you choose the right materials for your project.

Not sure which kit you need? Contact us before ordering and we'll be happy to help.