Polycarbonate Roofing

About Polycarbonate Roofing

Polycarbonate is a rigid thermoplastic used in a variety of ways. This plastic can consume heat, which makes it a fantastic insulator and incredibly energy efficient. In addition, polycarbonate is lightweight, which makes it easy to work on-site. 

Polycarbonate can be melted down, chilled, and reused as a highly sustainable material, restricting unnecessary residue in landfills. Moreover, polycarbonate is highly resilient to UV light and high temperatures, preventing discolouration or warping in the sun. All these advantages of using the polycarbonate material have countless applications.

Essentially, there are two types of polycarbonate roofing – both are thermoplastic, extremely moldable, shatterproof, lightweight, durable, and can survive in a wide range of temperatures. The main difference lies in their installation types and appearance.

Polycarbonate roofing can be installed on the following:

• Carports
• Conservatories
• Greenhouses
• Lean-tos
• Sheds
• Canopies
• Cloches

Polycarbonate sheeting can also be used for various glazing applications. This includes bike racks, sports shelters, security barriers, etc. 

Polycarbonate Vs. Glass

Glass and polycarbonate have both established themselves and are considered dependable glazing solutions. However, each of them has its pros and cons. 

From a utility and roofing-based outlook, glass can't come close to the polycarbonate material. However, it is lighter, cheaper, simpler to maintain, and more robust. The only reason people might prefer glass roofing would be the high light transmission and the aesthetics. 

While polycarbonate doesn't offer the same crisp, clean finish of glass, there is a broad range and variety of finishes to opt from to make an aesthetically pleasing and sustainable roof. 

Advantages of Polycarbonate Roofing

Most polycarbonate roofing sheets provide homeowners with a myriad of benefits, including their durability, insulation properties, safety, and lightweight. When assimilated, these advantages make polycarbonate roofing a brilliant solution and a fantastic glazing option for multiple projects.

Here are some advantages of polycarbonate roofing.

Lightweight

Weight is always a key consideration for homeowners when choosing an appropriate roofing system. While the weight of the polycarbonate material per square meter depends on the preferred thickness, it is considerably lighter than glass and other roofing systems. 

For instance, 10mm polycarbonate weighs up to about 4.5kg per square meter. This indicates that polycarbonate is easier to install, work with and maintain. Still, it is also implausible that any substantial changes are needed to the support and structure of the building. 

Safety

Lots of homeowners have chosen or wish to opt for polycarbonate roofing because of its augmented safety compared to glass roofing options. Polycarbonate is immune to shattering or breaking, making it safer where glazing is installed at a lower height or for children. 

And since it's also lightweight, it's easier to install and work with at height, like for a conservatory roof or lean-to roof.

Durability

Few materials boost the excellent impact resistance of the polycarbonate material. So there is no need to fret about cracks or chips caused by falling debris or hailstorms. Additionally, unlike PVC, polycarbonate roofing is highly resilient to UV light and won't be warped or discoloured by sun exposure. 

Most polycarbonate roof sheets also have incredibly high thermal resistance where they can endure temperatures of up to 135 degrees centigrade. Additionally, the polycarbonate material is so durable that the leading suppliers offer a 10-year guarantee.

Insulation Properties

Multiwall polycarbonate sheeting specifically offers thermal insulations of exceptional levels, which boosts lower u-values as compared to many other alternatives. In addition, a polycarbonate roof keeps the heat in winters while keeping spaces a lot cooler in summer. This makes for a comfortable and temperature-regulated home all year round.

Types Of Polycarbonate Sheets

There are various types of polycarbonate sheeting available to buy, including solid, corrugated, and multiwall sheets. Each of them is manufactured for different applications and offers unique benefits. 

When used correctly with proper fitting and according to manufacturers' guidelines, they offer fantastic reliability and strength.

Multiwall Polycarbonate

Multiwall polycarbonate is one of the most famous types that are ideal for lean-tos and conservatories. As the name indicates, multiwall is created with numerous layers, which offer excellent acoustic and thermal insulation when combined. 

Available in bronze, clear, and opal finishes, thicknesses from 4mm to 35mm, these sheeting can be ordered in a range of standard sizes or cut to size.

Corrugated Polycarbonate

Ideal for budget constricted projects, corrugated sheets offer various benefits of resilient polycarbonate at an affordable rate. Thanks to the corrugated system factor, this sheeting also provides excellent resistance to impact and durability. 

There are also corrugated plastic roofing sheets that someone with the necessary DIY skills can efficiently work with. It's possible to use these plastic roof sheets for a multitude of purposes.

Unlike solid or multiwall polycarbonate, corrugated polycarbonate sheets are usually only available in clear roofing materials. However, because their thinner profile ranges between 0.8 to 1mm, it is good to use corrugated polycarbonate for smaller projects.

When opting for polycarbonate for the next project, it is critical to note that 4mm twin-wall polycarbonate roofing isn't recommended for sealing-related applications.

Solid Polycarbonate

Solid polycarbonate sheets are made up of a single layer that is pretty lightweight and can match the glass's light transmission, which allows up to 90 per cent of sun rays to pass through. This makes strong polycarbonate a brilliant option for projects where the fairway is paramount.

Available in various colours, including black, clear, bronze, and opal, these sheets range from 2mm - 12mm in thickness. Unfortunately, solid polycarbonate isn't available cut-to-size even though there are multiple standard sizes to opt from.

Installing Polycarbonate Roofing

Here are the steps involved in the installation of polycarbonate roofing.

Lay The Sheets And Bars Glazing

Ensure that the sheets fit the structure properly without any unevenness or gaps, as it is a crucial aspect of polycarbonate roofing installation. Unfortunately, many miss this step since they have already measured the sheets and the area required to place them. But it is better to do this instead of fixing the sheets halfway through the installation process. 

This process can also determine whether the sheets are as durable as they should be. The reason many choose polycarbonate sheeting is due to its high impact resistance; however, they are only effective when the panels fit the roof correctly. This also proves the effectiveness of the roof to resist the accumulation of water during showers and storms. 

Fit The Sheets

Before fixing sheets properly on the roof, start with glazing the bars first.

• Place the glazing bars on the roof’s edge with the holes drilled approximately 500mm apart. These holes can be used to fix and secure the bars effectively for the sheets
• Most roofs need eaves fillers; therefore, it is better to add them during the process. Once that is done, start adding the sheets by attaching one to the glazing bar at one end of the roof. The sheets can then be lined up on the roof so they can be prepared for fixing
• A glazing bar must be attached between every sheet since it will help in sealing any gaps properly between them. Once the alignment of the sheets is done and they are attached with the bars, finish off by adding screws and screw caps for a secure fit
• At this point, the protective film on the sheets can also be removed. Once done, start drilling holes in the sheets and add fixing buttons or screws to strengthen the polycarbonate roof further
• Multiple other things can be done to increase the roof's effectiveness, like the addition of flashing if the roof attaches to some other wall. 

Final Touches

Once the process is complete and installation is done, it is time to start with the final adjustment of the roof. It is recommended to clear the sheets of any residual dust that settle due to drilling. Furthermore, make sure that any buttons or screw caps have been applied correctly and uniform throughout the roof.