Replacing a Polycarbonate Plastic Roof

Posted: October 18, 2010 in Polycarbonate
Tags: , , ,

polycarbonate roofIf your polycarbonate plastic roofing has cracked or needs to be replaced for any reason, with a little help from a friend or two it is fairly easy to replace. Follow the steps below to learn how to complete this project.

Tools and Materials Needed:

  • Polycarbonate plastic sheets (available at Redwood Plastics)
  • Hammer
  • Nail Gun
  • Marker
  • Band saw
  • Measuring tape
  • Ladder
  • Nails
  • Prybar
  • Screws
  • Vise grip pliers
  • Powered screwdriver

Step 1 – Obtain Help

This job is nearly impossible to complete by yourself. Ideally, the help of two people. Two people on top of your roof to receive the plastic sheets and one person below to pass them up.

Step 2 – Remove Old Roof

Using your screwdriver, claw hammer and a prybar (if necessary) remove the old roofing material from its framing boards. Once you have removed the old roof and any nails and screws that were holding it down, you will be ready to install the new roof.

Step 3 – Cutting Polycarbonate Plastic

Polycarbonate plastic typically comes in 4’x8′ sheets, and you will most likely have to cut the sheets to the proper length before installing them. To do this, you can either use the old roofing sheets as a guide for your dimensions or you can use a measuring tape to determine the dimensions. Measure the correct dimensions on the sheet of polycarbonate plastic and use a marker to draw a line marking your cuts. Use your band saw to cut the polycarbonate to size.

Step 4 – Inspect Wood for Damage

Make sure that the wood you will be attaching the roof to is not damaged or rotting and replace or repair accordingly.

Step 5 – Install Polycarbonate Plastic Roofing

It’s up to you whether you want to use nails, screws, or a combination of the two to attach your polycarbonate to the roofing boards. Screws will typically be your best bet for stability, but a combination of the two will usually be best. Begin by using a nail gun to drive nails through the polycarbonate plastic into the ridges of the roof. When you reach the end of one sheet of plastic, simply overlap the pieces to achieve a seal. Once you have nailed the sheets in place, attach screws with watertight washers into the flat areas between the roof ridges.


For more information on polycarbonate please visit our website; email us at or call us at:

CDN: 1 800 667 0999
USA: 1 866 733 2684


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