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How to install polycarbonate sheets

Updated February 21, 2017

Polycarbonate sheets are similar to sheets of plexiglass. They are as clear as glass and 250 times stronger. Polycarbonate sheets are also 30 times stronger than acrylic sheet plastic. These sheets have many different uses, including skylights, store fronts, covered walkways and displays. The main use of polycarbonate sheets is for installation on a roof. These sheets are available in various widths ranging from 1/16-inch to 15/16-inch and can be ordered to nearly any size dimension. Installing polycarbonate sheets is similar to installing plexiglass with a few extra steps involved.

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  1. Measure the length and width of the roof and multiply the two together for the total square footage. Divide that number by 32, which is the square footage of a standard roofing sheet of polycarbonate to get the number of sheets needed for installation.

  2. Line up the first sheet of polycarbonate at the bottom corner of the roof. Overhang the sheet 1/4 inch over the front edge of the roof and line it up evenly with the side of the roof. Position the sheet with the ribs running vertically.

  3. Drill 1/4-inch holes through the polycarbonate. Space out three holes equally across the polycarbonate 2-feet from the bottom between the ribs and drill three more holes across the sheet directly in the centre. Drill the final three holes 2 feet from the top.

  4. Insert 1-1/4-inch roofing screws through the holes and into the polycarbonate and sheathing underneath. Screw them in until the head is flush with the surface of the polycarbonate. Line up the second piece overlapping the first by one rib and drill holes into it. Install the second piece and all of the remaining pieces until reaching the end of the first side.

  5. Cut the piece at the end of the roof to size. Measure and mark the cut line. Line up a circular saw to the line and cut carefully along the line. Install the final sheet of the first row and all remaining sheets for the roof just like the previous sheets.

  6. Tip

    Polycarbonate roofing sheets comes in 4-by-8-foot sections.


    Always wear safety goggles when working with a circular saw.

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Things You'll Need

  • Tape measure
  • Power drill
  • Drill bit
  • Roofing screws
  • Circular saw
  • Safety goggles

About the Author

Alexander Callos began writing in 2005 for "The Lantern" at The Ohio State University and has written for various websites, including Bleacher Report, Top Ten Real Estate Deals and Columbus Sports. He has published articles for CBS Sports, and other websites. He graduated in 2007 from The Ohio State University with a bachelor's degree in public affairs journalism.

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