How to install corrugated polycarbonate sheets

Updated February 21, 2017

Corrugated polycarbonate sheets keep the weather outside while still allowing natural light to flow into the building. The hard polycarbonate material cuts, drills and seals like other common building materials but its brittle nature requires more support and care when fastening the material to the structural supports of a building. A cracked piece of installed polycarbonate allows water to seep in and damage other materials that aren't waterproof.

Place a piece of corrugated polycarbonate sheet on a firm work surface. Mark the location of the cut on the surface of the sheet by pulling a tape measure along the sheet and marking the cut location with a permanent marker. Make multiple marks on the polycarbonate sheet to provide you with a straight reference line.

Cut the sheet on the marked line with a circular saw with a 10 TPI blade. Push the saw slowly to avoid cracking or splintering the edge of the sheet. Set a utility knife blade at a 45-degree angle to the cut edge. Drag the blade along the cut end to remove the burr from the cut.

Mark mounting holes on the high ridges of the polycarbonate sheet. Drill a hole 1.5 mm (1/16 inch) larger than the mounting screws you will use to mount the sheet. Secure the drill bit in a drill motor. Drill a hole at each marked location.

Place one spacer under each drilled hole. Run a rubber washer screw half its depth through the hole and into the centre of the spacer. Move the sheet in position. Run the screws tight to the surface of the polycarbonate sheet and in the support structure of the building.

Cut and prepare a second sheet. Set the second sheet in position with its lowest end sitting around 10 cm (4 inches) over the installed sheet. Repeat the process until the entire area is covered with polycarbonate sheeting.


Wear goggles to protect your eyes when cutting corrugated polycarbonate sheeting.

Use proper ladder safety if installing the sheeting on a roof or other high structure.

Things You'll Need

  • Stable work surface
  • Tape measure
  • Permanent marker
  • Circular saw
  • Utility knife
  • Drill bit set
  • Drill motor
  • Spacers
  • Screw gun
  • Rubber washer screws
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