How to make a roof from cellular polycarbonate

Contemplating a roof renovation or construction project? Think about utilizing cellular polycarbonate, an adaptable, lightweight material that provides exceptional light transmission and durability. The practical procedures and factors to be taken into account when building a roof out of cellular polycarbonate are examined in this article.

Because of its strength and flexibility, cellular polycarbonate roofing is widely used. It’s a kind of plastic with several layers that form air pockets, or "cells," to improve insulation and lighten weight. Compared to conventional roofing materials, this makes it simpler to work with during installation.

Make sure the structure of your roof can support the weight of the polycarbonate panels before beginning any work. Polycarbonate is lightweight compared to heavier materials like metal or tiles, but it still needs a strong framework to keep its integrity over time.

Making a plan is essential. To start, measure your roof precisely to find out how many and what size polycarbonate panels you’ll need. Take into account elements like drainage and slope to avoid water accumulation, which can shorten the lifespan of your roof. Better outcomes and a more seamless installation process are guaranteed by careful planning.

Materials Needed: Cellular polycarbonate sheets, aluminum profiles, screws, washers, sealing tape.
Steps: 1. Measure and cut polycarbonate sheets to fit the roof dimensions.
2. Install aluminum profiles along the edges and at intervals across the structure.
3. Place the first polycarbonate sheet on one side, ensuring it aligns with the profiles.
4. Secure the sheet with screws and washers, avoiding over-tightening.
5. Repeat the process for subsequent sheets, overlapping edges slightly.
6. Seal the joints with sealing tape to prevent water leakage.
7. Ensure proper ventilation and drainage for optimal performance.

In this tutorial, we’ll look at a methodical process for constructing a sturdy and reasonably priced roof out of cellular polycarbonate. We cover everything you need to know to build a weather-resistant and aesthetically beautiful roof that improves the look and functionality of your house or building, from planning and material selection to installation advice. Whether your goal is to start a new construction project or replace an old roof, this article offers helpful tips and professional guidance to help you confidently and successfully finish your do-it-yourself roofing project."

Preparation of the frame for cellular polycarbonate

Assume that the walls and/or supporting structures have already been completed. The roof frame for the cellular polycarbonate just needs to be constructed, which includes installing the rafters, fixing the Mauerlat, and building the crate.

You can use aluminum profiles, wood, or round pipes made of steel profile as the material for the frame. Any material will do; just pick the one that makes the most sense in terms of both cost and appearance.

Mauerlat is constructed from an 80 × 80 mm or 100 × 100 mm profile pipe if the frame is made of steel. It is positioned horizontally and welded to the wall’s mortgage or to steel support pillars.

For a wooden rafter system, mauerlat is typically constructed from a single 100 x 100 mm piece of wood or two 50 x 100 mm boards stacked on top of one another. If there is a lot of snow in the area and on the roof, however, Mauerlat should use a beam measuring 150 x 150 mm or two to three boards measuring 50 x 150 mm.

Wooden Mauerlat is fastened to wooden pillars using brackets fastened with nails, reinforced corners, or perforated plates. The most common method of fixing them to brick and stone walls is with wire or embedded studs.

The aluminum frame is built using a maauerlat made of a 90 x 90 mm, 100 x 100 mm, or 120 x 120 mm square aluminum pipe. Use unique heads that are mounted on the wall with the aid of an armored vehicle for fastening. In the event that the pillars providing support are made of aluminum, concealed P-shaped mounts are employed, enabling you, the designer, to put the frame together.

The rafters and the crate are installed following the Mauerlat installation. The roof structure they choose from cellular polycarbonate determines their next step.

Name roof without a crate

Installing cellular polycarbonate on a roof without a crate and only using rafters is the simplest method. A multicarbonate sheet should be the next step in this situation. It is imperative that the edges of adjacent plates align with the central axis of the rafter legs; if not, an extra support must be positioned beneath each such joint.

The load on the roof and the thickness of the polycarbonate sheet determine the minimum step between the rafters. You can make your selection based on the table below, but it is preferable to use the information provided by the manufacturer of the cellular polycarbonate brand in question.

The 2.1 m maximum spacing between rafters was included in the table for a purpose: the cellular polycarbonate sheet’s standard width. However, typically, the distance between the rafter legs is taken in half, or roughly one meter.

Archite roof

Particularly for awnings, the Architea roof made of cellular polycarbonate is a highly popular type of roof. Because of the form, it appears airy and taller than it actually is. Furthermore, because of its small rounding radius, the arched roof hardly ever gets snow on it. Thus, in areas where there is a lot of snowfall, this roof shape is ideal.

One more aspect of the arched roof pertains specifically to cellular polycarbonate. The cells are always fastened to the rafters in a parallel fashion thanks to this material. Additionally, the cells start to function as a supporting element in addition to an air pocket when they bend. Thus, the greater the load that cellular polycarbonate can bear, the smaller the radius of its rounding.

The step of the crate beneath the cellular polycarbonate arched roof is directly impacted by this feature. It is displayed in the table that follows.

No matter the shape of the roof, the rafters for it are composed of 150 x 50 mm boards, 60 x 40 mm steel profiles, or 90 x 50 mm, 100 x 50 mm, or 120 x 50 mm profile aluminum pipes, depending on the Mauerlat section. Rafting legs operate on a bend, so they always install a narrow side to the ground.

As directed by the manufacturer, the cross section of the crate used to install a cellular polycarbonate roof is chosen. The standard measurements are 60 x 40 mm, 60 x 30 mm, or 40 x 20 mm for steel profiles, 60 x 60 mm for wood, and 50 x 50 mm for aluminum.

Installation of polycarbonate on the roof: Instruction

Installing the lower portion of the detachable N-shaped connecting profile is the first step in installing cellular polycarbonate. It is placed at the intersection of the two coating sheets, and the seal is adhered to in the designated areas along the lower H-profile’sedges.

Next, the cellular polycarbonate plates are placed. a side that is unavoidably protected from UV radiation. Typically, this side launches onto a marking. Parallel to the rafters, ribs support the sheets.

The upper portion of the H-profile is then used to secure the sheets. The upper bar is positioned above the lower bar and fixed after the seals are affixed. Self-tapping wood or metal screws are used to fasten the H-Profil. They are screwed into each profile or bar of the crate. To avoid deforming the bar in this situation, you must watch how hard you press it.

In the event that a decorative cover is present, the connecting profile is closed from above after installation.

When putting cellular polycarbonate on the roof, self-tapping screws with thermo-haired are also used in addition to N-profile. They are fastened by screws into the center crossbone of the crate as well as through its two edges. Avoiding direct contact with the frame material is advised, so you must place the substrate beneath polycarbonate-rubber gaskets that have the same diameter and thickness at the locations where the slab fasteners to the crate.

Prior to driving the screws into the polycarbonate sheet, holes must be made to account for the material’s temperature expansion. They ought to be 1-2 mm larger than the fasteners’ diameter. If not, the cellular polycarbonate plate may break.

Cellular polycarbonate sheets are sealed with phony end-shaped profiles after installation. This is required to keep dust, trash, and insects out of the cells.

Furthermore, when installing a polycarbonate roof, there are a few more details that need to be considered:

  1. The film must be removed immediately after installation. Then it will be much more difficult.
  2. Care with caution to combine cellular polycarbonate with other materials – even ordinary PVC in some conditions can distinguish chlorine, which destroys polycarbonate. Therefore, it is advisable to use complete fasteners and other consumables that the manufacturer recommends.
  3. Rafters and crate must be painted white or covered with foil material, for example, reflecting adhesive tape. This will prevent overheating of cellular polycarbonate.
  4. You can’t walk on the slabs of cellular polycarbonate, so you need to carefully think over the order of its installation on the roof. If you move along the already laid coating, it is still necessary, for this you use a board 40 cm wide or more.

The fasteners are sealed with silicone, and the polycarbonate roof has a slight slope for increased dependability. Furthermore, the silicone needs to be unique and free of contaminants that harm polycarbonate. It is forbidden to use other sealants for this purpose.

Cellular polycarbonate roofing has various benefits for homeowners wishing to improve their living areas. In comparison to more conventional roofing materials like tiles or shingles, installation is made simpler by its lightweight nature. This kind of roof is renowned for its resilience to different weather conditions, such as intense rain and hail.

Excellent light transmission is one of the main advantages of using cellular polycarbonate for roofing. It makes the covered area more light-filled and airy inside by letting in natural light. This can be especially helpful for buildings that need natural light, such as carports, patio covers, and greenhouses.

The ability to customize and design cellular polycarbonate to one’s liking is another benefit. It is available in a variety of colors, thicknesses, and profiles so that homeowners can select the one that best meets their functional requirements and design tastes. There are options to fit your needs, whether you want a clear roof to maximize light or a tinted one for shading.

In addition, compared to other materials, polycarbonate roof maintenance is comparatively easy. Its lifespan can be extended and its appearance preserved with regular cleaning using mild soap and water. It is a sensible option for time-pressed homeowners searching for a low-maintenance roofing solution because of its ease of maintenance.

In conclusion, cellular polycarbonate roofing offers easy maintenance, light transmission, durability, and design flexibility while combining practicality and aesthetic appeal. Cellular polycarbonate shows itself as a contemporary and dependable alternative that is worth taking into consideration when thinking about replacing the roof on a patio, greenhouse, or any other building.

Video on the topic

What you need to know when choosing cellular polycarbonate?

What do you think, which element is the most important for a reliable and durable roof?
Share to friends
Alexandra Fedorova

Journalist, author of articles on construction and repair. I will help you understand the complex issues related to the choice and installation of the roof.

Rate author
Add a comment