Timber Supported Polycarbonate Roof Kit – 5.37m Coverage

Select the type and colour of polycarbonate required when ordering.

The 5.37m Timber Supported Polycarbonate Roof Kit contains the main components required to construct a secure polycarbonate roof over a timber framework. Supplied with five polycarbonate sheets, timber fixing bars and the necessary finishing components, it provides a practical solution for lean-to roofs, canopies, porches and other timber-supported structures.

What's Included

• 5 x 1050mm x 3.5m polycarbonate roof sheets
• 6 x 4m bars for fixing to timber
• 2 x 4m edge fillets
• 1 x 150mm flash band
• 3 x 2.1m sheet closures
• Anti-dust tape

Actual coverage: approximately 5.37m.

Installation Guide

Step 1 – Fit the Edge Bars

Fix the first edge bar as shown in diagram 1. Slide the edge fillet into the groove on the bar and cut the bar to length, allowing for a 50mm overhang into the guttering. Cut the aluminium base 2mm longer than the intended polycarbonate sheet length to allow for the end cap.

Drill and fix the bar 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

Plan the sheet layout before fixing the remaining bars. You can space the sheets evenly or arrange the layout with a sheet centred across the roof. Once the layout has been decided, position and fix the centre bars 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 Gaskets

Before fitting the sheets, 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

Cut the polycarbonate sheets to length if required and remove all swarf using a vacuum or condensation-free air line. Never try to 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 of each sheet. The tapes help reduce condensation and prevent insects and dust entering the channels.

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

Step 5 – Fit the PVCU Caps

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

Complete the flashing as you work across the roof. Once the flashing and caps are fully installed, remove the remaining protective covering.

Step 6 – Complete the Roof

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

Installation Tips

Polycarbonate cut to size: We recommend fitting the bars before ordering cut-to-size polycarbonate. We can cut, blow and tape the sheets to the required width and length. Remember to allow for expansion when ordering. Price on application.

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

Cleaning: Use mild soapy water only. 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.

Sheet widths: For a good-quality roof, avoid excessively wide sheets. Recommended widths are 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 you fit the polycarbonate bars.

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

Timber Supported Polycarbonate Roofing

This 5.37m timber supported polycarbonate roof kit combines the main roofing materials into one package, making it straightforward to order the components needed for a timber-framed polycarbonate roof.

Not sure which polycarbonate or roofing kit you need? Email us and we'll be happy to help.

Delivery Service

If you do not have personnel available to unload the lorry, please select 2-man delivery in the delivery options. This is a surcharge in addition to the normal delivery charge.