Timber Supported Polycarbonate Roof Kit – 3.26m Coverage

Select the type and colour of polycarbonate required when ordering.

This Timber Supported Polycarbonate Roof Kit provides an easy way to create a complete polycarbonate roof on a timber structure. The kit includes the main roofing components required for an installation with an actual coverage of approximately 3.26m.

Ideal for DIY projects, builders and installers, the kit can be used for timber-supported canopies, lean-to roofs, carports, porches, patio covers and other polycarbonate roofing applications.

What's Included

Price includes actual coverage of 3.26m:

• 3 x 1050mm x 3m polycarbonate roof sheets
• 4 x 3m bars for fixing to timber
• 2 x 3m edge fillets
• 3 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. Ensure the drip on the edge trim is correctly positioned and neat when viewed externally. Repeat at the opposite end.

Note: Where the 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 the layout has been decided, position the centre bars accordingly and fix them 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 Rubber 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 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. Never 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 that the toothed legs locate inside the aluminium base. Press down firmly, then lightly tap the caps into place using a rubber mallet or suitable equivalent until they lock securely.

Complete the flashing as you work across the roof. Once the flashing is complete and all caps are securely fitted, 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.

Installation Tips

Polycarbonate Cut to Size

If you require polycarbonate cut to size, order your sheets after fitting the bars. We can cut, blow and tape the sheets to the required width and length. Remember to 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 you fit the roof panels. Fit the lead in sections of approximately 2m and seal 100mm overlaps with Lead Mate.

Cleaning Polycarbonate

Only use mild soapy water when cleaning polycarbonate. Test on 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, use a good-quality low-modulus neutral clear silicone.

Recommended Sheet Widths

For a good-quality roof designed to provide long-lasting performance, avoid excessively wide sheets. Use recommended 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 bars.

Finishing the Roof

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

Polycarbonate Roofing Kits Bristol

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