Timber Supported Polycarbonate Roof Kit – 7.49m Coverage

Select the type and colour of polycarbonate required when ordering.

The 7.49m Timber Supported Polycarbonate Roof Kit is a larger roofing package designed for timber-framed structures where a substantial area needs to be covered with polycarbonate. It includes the sheets, timber fixing bars and finishing components required for a secure and weather-resistant roof.

Suitable for larger lean-to roofs, canopies, porches, covered walkways and other timber-supported roofing applications.

What's Included

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

Actual coverage: approximately 7.49m.

Installation Guide

Step 1 – Install the Edge Bars

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

The aluminium base should be cut 2mm longer than the intended polycarbonate sheet length to allow for the end cap. Drill and secure the bar using No. 6 screws at approximately 300–400mm centres, ensuring the drip on the edge trim is correctly positioned and neat when viewed from outside. 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 Intermediate Bars

Plan the position of the polycarbonate sheets before fixing the remaining bars. The sheets can be evenly spaced or arranged with a sheet centred across the roof. Once the layout is established, position the bars and secure them to the timber 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

Make sure all rubber gaskets within the bars are flat and correctly positioned before fitting the sheets. There should be 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 attempt to wash swarf out of the sheet channels.

Apply the anti-dust tape correctly, using the solid foil tape at the top and the vented tape at the bottom of each sheet. These tapes help reduce condensation and keep dust and insects out of the channels.

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

Step 5 – Secure the PVCU Caps

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

Complete the flashing as you work across the roof. Once all the caps and flashing are in place, remove the remaining protective covering.

Step 6 – Finish 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

Cut-to-size polycarbonate: We recommend fitting the bars before ordering cut-to-size polycarbonate. We can cut, blow and tape your 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 polycarbonate sheets and dress it down as the roof panels are installed. Fit the lead in sections of approximately 2m and seal 100mm overlaps with Lead Mate.

Cleaning: Clean the polycarbonate using mild soapy water. Test 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.

Sheet widths: Avoid excessively wide sheets for the best long-term roof performance. Recommended widths are 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 you fit the polycarbonate bars.

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

Timber Supported Polycarbonate Roofing

This 7.49m timber supported polycarbonate roof kit provides the principal materials needed for a larger polycarbonate roof supported by a timber framework, helping simplify the ordering process and installation.

Not sure which polycarbonate or roofing kit is right 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.