Select the type and colour of polycarbonate required.

This 4-sheet timber supported polycarbonate roof kit is designed for timber-framed roofing projects using 5m long polycarbonate sheets. The kit includes four 700mm wide polycarbonate sheets, five 5m fixing bars, 3m edge fillets, sheet closures, 150mm flash band and anti-dust tapes.

Ideal for lean-to roofs, canopies, porches and other timber-framed roofing projects, this kit provides the main components required to install a polycarbonate roof onto a suitable timber framework.

What's Included

• 4 x 700mm wide polycarbonate sheets x 5m long
• 5 x 5m bars to fix to timber
• 4 x 3m edge fillets
• 2 x 2.1m sheet closures
• 1 x 150mm flash band
• Anti-dust tapes

Installation Guide

Step 1 – Install the Edge Bars

Fix your first edge bar as shown in Figure 1. Slide the edge fillet into the groove on the bar, then cut the bar to the required length, remembering to allow for a 50mm overhang into the guttering.

Cut the aluminium base 2mm longer than the intended length of the polycarbonate sheeting. This allows for the end cap to be fitted later.

Drill and fix the bar into position using No. 6 screws at approximately 300–400mm centres. Ensure the drip on the edge trim is correctly positioned and neat when viewed externally. Repeat at the opposite end.

Note: Where bars are butting against a wall, the edge trim is not required. Fit the bar only.

Step 2 – Position the Centre Bars

You can either cut all sheets to space them evenly or work towards positioning a sheet in the middle. Once you have decided on the layout, position the centre bars where required.

Drill and fix the bars using screws at approximately 300–400mm centres.

IMPORTANT: Remember to leave a clear 4mm expansion gap between the bar and the polycarbonate sheets.

Step 3 – Check the Rubber Gaskets

Ensure all the rubber gaskets in the bars are flat and free from bumps before fitting the polycarbonate sheets.

Step 4 – Prepare and Fit the Polycarbonate Sheets

Cut your polycarbonate sheets to length if they have not already been cut, ensuring that all swarf is removed. Use a vacuum or condensation-free airline to remove the swarf. Never try to wash swarf out of the sheet.

Fit the anti-dust tapes to the sheets. Use the solid foil tape at the top and the vented tape at the bottom. These tapes help reduce condensation and keep insects and dust out of the sheet channels, so ensure they are fitted correctly.

Peel approximately 50mm of the 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 that the toothed legs locate inside the centre of the aluminium base. Press down firmly, then lightly hammer the caps into position using a rubber mallet or equivalent until they lock down.

As you work across the roof, complete the flashing as you go. Once the flashing is complete and all caps are securely fitted, remove the protective covering.

Step 6 – Fit the End Caps and Sheet Closures

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

Installation Tips

Polycarbonate cut to size: For cut-to-size polycarbonate, order your sheets after you have fitted the bars. We can cut, blow and tape your sheets to the correct width and length. Price on application. Remember to allow for expansion when ordering.

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

Cleaning: Only use mild soapy water. Try a small panel first to ensure there is no reaction. Never use solvent-based cleaners.

Silicone: You should not normally need to use silicone. If required, only use a good-quality low-modulus neutral clear silicone.

Recommended sheet widths: For a good-quality roof that will last, avoid excessively wide sheets. Use recommended widths of 980mm or less for roofs up to 4m long and 700mm wide for roofs over 4m long.

Timber framework: Fix the wall plates at the top and bottom, and fix the joists as you install the polycarbonate bars.

Finishing the roof: Use 9mm economy fascia all around and square white guttering for a neat, maintenance-free finish.

4 Sheet 5m Timber Polycarbonate Roofing Kit

This 4-sheet timber supported polycarbonate roof kit provides the main roofing components required for a 5m long polycarbonate roof, including four 700mm wide sheets, five 5m fixing bars, four 3m edge fillets, two 2.1m sheet closures, 150mm flash band and anti-dust tapes.

Choose the required polycarbonate type and colour when ordering.

Not sure which polycarbonate or roofing kit is right for your project? Email us and we are here to help.

Delivery Service

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