Install Corrugated Roofing

Corrugated roofing is a great way to top a garden shed, shop, or patio. It's quick, easy, and you can do it yourself. You only need basic tools and materials, and to follow the steps below.

Steps

Install Corrugated Roofing

  1. Cut the panels to the length. Most panels come up to 32 feet (9.8 m) in length. Allow for a minimum of 18 inches (45.7 cm) if you need to lap to complete the run.
    Cutting tools:
    Angle grinder: The fastest option. Wear hearing and eye protection. Paint or prime cut edges to prevent rust.
    Circular saw: Slower than angle grinder, but follow same instructions. Use a metal blade and expect it to wear quickly.
    Nibbler: Effective if rated for the right metal and gauge.
    Tin snips: Slow but safe. Wear work gloves and find the longest pair you can.
  2. Pre-drill holes on the ridges. Use a 3/16-inch (4.76 ml) drill bit.
    • Spacing for the holes on the ends and sides of the panels should be 6 to 8 inches (15.3 to 20.4 cm).
  3. Install the panels. Place them directly onto purlins that are attached to the roof trusses, beginning on the outside edge.
    • Close or seal off the ends with a wood or plastic strip under the panel at each end. These will stop the entry of rain, wind and pests.
  4. Screw down the panels. Pre-drill the holes, and use #10X2-inch (#10X5.2 cm) screws with polycarbonate washers.
    • Continue across the roof until it is completely covered, lapping over the previous panel by at least 2.5 inches (5.5 cm) minimum.
    • Adjust the lap so that the last panel completes the coverage without making a cut lengthwise.
  5. Complete the opposite side. If your roof is two-sided (and not just a single slope), repeat the installation on the other side of the roof, and install a corrugated ridge cap as you proceed across with the panels.

Choose Roofing

  1. Choose the type of corrugated roofing you want to use: PVC/fiberglass, or metal. These come in various lengths, but with a nominal 26-inch (66.04 cm) width. They each have advantages and disadvantages:
  2. PVC roofing. The advantage of the PVC/polycarbonate roofing is the translucency of the panels.They allow daylight to enter through them.
    • If cost is a factor, PVC is a cheaper alternative to sheet metal.
    • PVC will block out the heat from the sun much more effectively than sheet metal, which will act like a radiator.
    • Some PVC is translucent, but filters ultraviolet rays, and comes in a variety of colors.
    • The disadvantages of PVC are that it's not as durable as sheet metal, is noisy in the rain, and can easily break off during high winds.

  3. Metal roofing. One of the strongest features of corrugated metal is its durability. Modern galvanized steel or aluminum is resistant to rust, and can easily last up to 100 years.
    • Metal roofing is quieter than PVC when it rains.
    • Metal roofing resists rot, is not susceptible to insect damage, and is non-combustible (a boon in fire-prone areas).
    • The downsides include a susceptibility to denting, both in installation and in the case of an during hailstorms. It can also be significantly more expensive.



Tips

  • When framing the roof, the spacing for roof trusses should not exceed 24 inches (61 cm) and purloins should not exceed 36 inches (92 cm) apart.
  • Lay the panels on the ground the way you want them to be on the roof. This helps in setting up the lap of the panels.
  • Install a corrugated roofing wall connector panel to a wall with roofing sealant when installing panels for a patio cover. Follow manufacturer's instructions for the sealant application.
  • You can use both types of corrugated roofing together, creating panels that will allow light to come through as with a clear or white fiberglass corrugated panel known as a skylight.

Warnings

  • Work from the sides, using ladders or movable scaffolding, to avoid standing or walking on the panels.
  • Do not drill holes for the screws in the valley of the ridges to prevent leaks.

Things You'll Need

  • Corded or cordless electric drill
  • Straight edge
  • 3/16 inch (4.76 ml) drill bit
  • Circular saw or jigsaw with metal cutting blade
  • Tin or heavy-duty garden snips
  • Polycarbonate or galvanize metal corrugated roofing panels
  • End stops
  • Corrugated wall connectors
  • Corrugated ridge connectors
    1. 10x2-inch (10x5.2 cm) corrugated fasteners with polycarbonate washers
  • Roofing sealant (only if manufacturer of corrugated polycarbonate recommends using)

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Sources and Citations

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