Timber Supported Polycarbonate Roof Kit

Our Timber Supported Polycarbonate Roof Kit provides everything you need to create a strong, practical and attractive polycarbonate roof on a timber structure. The kit is supplied with the main roofing components, including polycarbonate sheets, aluminium glazing bars, edge fillets, sheet closures, flashing and anti-dust tapes.

Available from our Bristol-based stock, these roofing kits are ideal for DIY projects, builders, roofers and installers working on canopies, lean-to roofs, carports, porches, covered walkways and other timber-supported structures.

What's Included

Price includes an actual coverage of 2,280mm:

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

Installation Guide

Step 1 – Fix the Edge Bars

Fix the first edge bar as shown in the diagram. Slide the edge fillet into the groove on the bar, then cut the bar to the required length, allowing for a 50mm overhang into the guttering.

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

Drill and fix the bar into position using No. 6 screws at approximately 300–400mm centres. Make sure 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 – Position the Centre Bars

Decide whether to cut the sheets so they are evenly spaced or work towards a cut sheet in the centre. Once you have established the layout, position and fix the centre bars using screws at approximately 300–400mm centres.

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

Step 3 – Check the Rubber Gaskets

Before fitting the polycarbonate, check that all rubber gaskets in the bars are flat and correctly positioned, with no bumps or raised sections.

Step 4 – Prepare and Fit the Polycarbonate Sheets

Cut the polycarbonate sheets to the required length if they have not already been cut. Remove all swarf using a vacuum or condensation-free air line. Do not try to wash swarf out of the sheet.

Fit the anti-dust tapes correctly. Use 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 the protective film down both sides of the sheet and carefully position the sheet into place.

Step 5 – Fit the PVCU Caps and Flashing

Position the PVCU caps so the toothed legs locate inside the aluminium base. Press down firmly, then lightly tap the caps into position using a rubber mallet or suitable equivalent until they lock securely.

Work across the roof, completing the flashing as you go. Once all the caps are securely fitted and the flashing is complete, remove the protective covering from the polycarbonate.

Step 6 – Fit End Caps and Sheet Closures

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

Installation Tips

Need Polycarbonate Cut to Size?

If you require polycarbonate cut to size, we recommend ordering your sheets after the glazing bars have been fitted. We can cut, blow and tape the sheets to the required width and length for you. Please allow for thermal expansion when ordering. Price on application.

Lead Flashing

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

Cleaning Polycarbonate

Use only mild soapy water when cleaning polycarbonate. Always test cleaning products on a small area first. Never use solvent-based cleaners.

Silicone

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

Recommended Sheet Widths

For a long-lasting roof, avoid using excessively wide sheets. As a guide, use widths of approximately 980mm or less for roofs up to 4m long and approximately 700mm wide for roofs over 4m long.

Timber Structure

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

Complete the Roof

For a low-maintenance finish, consider using 9mm economy fascia around the roof perimeter with square white guttering.

Polycarbonate Roofing Kits Bristol

We supply polycarbonate roofing kits from Bristol, with components available for DIY, trade and professional roofing projects. If you're unsure which kit, sheet thickness or accessories you need, contact us before ordering and we'll be happy to help.