Timber Supported Polycarbonate Roof Kit – 9.61m Coverage

Select the type and colour of polycarbonate required when ordering.

This 9.61m Timber Supported Polycarbonate Roof Kit provides the main materials needed to construct a larger polycarbonate roof over a timber framework. The kit includes nine 1050mm wide polycarbonate sheets together with fixing bars, edge bars, sheet closures, flash band and anti-dust tape.

Ideal for larger lean-to roofs, canopies, porches and covered outdoor areas, the kit provides a straightforward way to order the principal roofing components together.

What's Included

• 9 x 1050mm x 3.5m polycarbonate roof sheets
• 10 x 4m bars to fix to timber
• 2 x 4m edge bars
• 9 x 1050mm sheet closures
• 1 x 150mm flash band
• Anti-dust tapes

Actual coverage: approximately 9.61m.

Installation Guide

Step 1 – Install 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 assembly 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 the end cap to be fitted later. 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 neat when viewed externally, then 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 – Fix the Intermediate Bars

Decide how you want the sheets positioned across the roof. You can space the sheets evenly or work towards having a sheet positioned centrally. Once the layout has been established, position and fix the intermediate bars 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 Gaskets

Before installing the polycarbonate, check that all rubber gaskets in the bars are sitting flat and have no bumps or raised sections.

Step 4 – Prepare and Install the Polycarbonate

Cut the polycarbonate sheets to the required length if they have not already been cut. Carefully 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 to each sheet. Use the solid foil tape at the top and the vented tape at the bottom. Correctly fitted tapes help reduce condensation while preventing insects and dust from entering the sheet channels.

Peel approximately 50mm of protective film down both sides of the sheet and position the sheet 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 and 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 caps and flashing are fitted, remove the remaining protective covering from the polycarbonate sheets.

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: For polycarbonate cut to size, we recommend ordering the sheets after the bars have been fitted. 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 installing the sheets and dress it down as the roof panels are fitted. Fit the lead in sections of approximately 2m and seal 100mm overlaps using Lead Mate.

Cleaning: Clean polycarbonate using mild soapy water. Test a small area first to make sure there is no reaction and never use solvent-based cleaners.

Silicone: Silicone should not normally be required. If silicone is necessary, use a good-quality low-modulus neutral clear silicone.

Recommended sheet widths: For a long-lasting roof, 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 you fit the polycarbonate bars.

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

9.61m Timber Polycarbonate Roofing Kit

This 9.61m timber supported polycarbonate roof kit is supplied as a complete set of the main roofing components, making it suitable for larger timber-framed roofing projects. Choose your preferred polycarbonate type and colour when ordering.

If you are unsure which polycarbonate or timber roofing kit is suitable for your project, email us and we will 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.