Timber Supported Polycarbonate Roof Kit – 6.43m Coverage

Select the type and colour of polycarbonate required when ordering.

The 6.43m Timber Supported Polycarbonate Roof Kit is designed for larger timber-framed roofing projects where a wider covered area is required. The kit brings together the polycarbonate sheets, timber fixing bars and finishing components needed to create a secure and weather-resistant roof.

Ideal for lean-to roofs, canopies, porches, covered outdoor areas and other timber-supported structures.

What's Included

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

Actual coverage: approximately 6.43m.

Installation Guide

Step 1 – Install the Edge Bars

Start by fixing the first edge bar as shown in diagram 1. Slide the edge fillet into the groove on the bar and cut it to the required length, allowing approximately 50mm of overhang into the guttering.

Cut the aluminium base 2mm longer than the intended polycarbonate sheet length to allow the end cap to be fitted. Drill and secure the bar using No. 6 screws at approximately 300–400mm centres. Check that the drip on the edge trim is correctly positioned and looks neat from the outside, then repeat at the opposite end.

Note: Where a bar finishes against a wall, the edge trim is not required; fit the bar only.

Step 2 – Fix the Remaining Bars

Decide how the sheets will be positioned across the roof. They can be evenly spaced or arranged with a sheet centred across the roof. Once the layout has been established, position the remaining bars and secure them to the timber at approximately 300–400mm centres.

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

Step 3 – Check the Bar Gaskets

Before installing the sheets, check that every rubber gasket is sitting flat inside the bars and is free from bumps or raised sections.

Step 4 – Prepare the Polycarbonate Sheets

Cut the polycarbonate sheets to the required length if necessary and make sure all swarf is removed. Use a vacuum or condensation-free air line to clean the sheet channels. Do not attempt to wash swarf out of the channels.

Apply 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 dust and insects entering the channels.

Peel approximately 50mm of protective film from both sides of the sheet before positioning it on the roof.

Step 5 – Secure the PVCU Caps

Position each PVCU cap so that the toothed legs locate inside the centre of the aluminium base. Press down firmly, then use a rubber mallet to lightly tap the cap until it locks into position.

Work across the roof, completing the flashing as you go. Once all the caps and flashing are installed, remove the remaining protective covering from the sheets.

Step 6 – Finish the Roof

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

Installation Tips

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

Lead flashing: Where lead flashing is being used, fit it before installing the polycarbonate and dress it down as the roof panels are fitted. Install lead in sections of approximately 2m and seal 100mm overlaps using Lead Mate.

Cleaning: Clean polycarbonate using mild soapy water. Test any cleaning method on 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.

Recommended sheet widths: Avoid using excessively wide sheets. We recommend widths of 980mm or less for roofs up to 4m long and 700mm wide for roofs over 4m long.

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

Low-maintenance finish: Use 9mm economy fascia around the roof with square white guttering for a neat, practical finish.

Timber Supported Polycarbonate Roofing

This 6.43m timber supported polycarbonate roof kit provides the principal materials needed for a larger timber-framed polycarbonate roof in one convenient package.

Not sure which kit or polycarbonate option is suitable for your project? 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.