Timber Supported Polycarbonate Roof Kit – 8.55m Coverage

Select the type and colour of polycarbonate required when ordering.

The 8.55m Timber Supported Polycarbonate Roof Kit is designed for larger timber-framed roofing projects, supplying the main materials needed to create a secure and weather-resistant polycarbonate roof. With eight 1050mm wide sheets and nine timber fixing bars, this kit is suitable for substantial lean-to roofs, canopies, porches and covered outdoor areas.

What's Included

• 8 x 1050mm x 3.5m polycarbonate roof sheets
• 9 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 8.55m.

Installation Guide

Step 1 – Fit 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 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 secure the bar using No. 6 screws at approximately 300–400mm centres. Make sure the drip on the edge trim is correctly positioned and neat from the outside, then repeat the process at the opposite end.

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

Step 2 – Position the Remaining Bars

Plan the position of the sheets before fixing the intermediate bars. The sheets can be evenly spaced or arranged with a sheet centred across the roof. Once the layout has been decided, position the remaining bars and fix 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

Ensure all rubber gaskets within the bars are sitting flat and correctly positioned before installing the polycarbonate sheets.

Step 4 – Prepare the Polycarbonate

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 tapes 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 prevent insects and dust entering 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 the caps and flashing are fully installed, remove the remaining protective covering from the sheets.

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

Cut-to-size polycarbonate: 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 polycarbonate sheets and dress it down as the roof panels are installed. Fit lead in sections of approximately 2m and seal 100mm overlaps using Lead Mate.

Cleaning: Use mild soapy water to clean the polycarbonate. 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.

Recommended sheet widths: Avoid 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 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 8.55m timber supported polycarbonate roof kit provides the main materials required for a larger timber-framed polycarbonate roof, making it easier to order the sheets, fixing bars and finishing components together.

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.