Installing Clear Roofing Panels
Mica Withington
To do this, we measured an X across each side of the roof to see if each diagonal length of the X was the same. On each side of the roof measure from the upper left (gable peak) to the bottom right (eaves) and then from the upper right (gable peak) to the bottom left (eaves). Repeat for the other side of the roof.
The top purlins should be about two inches down from the ridge so the edge of the roofing material will line up. This is great spacing for a winter installation since it leaves space for the plastic material to expand in the summer. If installing in summer, factor in temperature changes and remember the plastic roofing will later shrink so close the expansion gap a little more.
Alternatively, to save money since GRK screws can get expensive, a stapler (like Colby is using in the pic below) could also be used. Just make sure you use staples long enough to securely attach the drip edge.
Start by removing any protective films and stickers from the surface of the panels. While the protective film removal was simple, sticker removal was not. We successfully removed the stickers with some Goo Gone spray adhesive remover and a scrub brush.
Screw the panels into the purlins using the screws with sealing dome washers every other ridge. Be careful not to overtighten as that can dimple the material and have a detrimental effect on the efficacy of the panels.
You want to make sure that the ridge cap overlaps the panels plenty to keep water from seeping through. In the winter panels shrink and in the summer they expand. Be sure to accommodate for temperature changes when installing.
Angie is a former marketing professional turned stay-at-home mom and magical memory maker. She and her husband Colby are avid DIYers with more than 10 years of experience renovating and decorating old homes, blogging about projects along the way. Colby, a former builder, still works in the residential construction industry. Angie's work has been featured in This Old House magazine.
Suntuf is supported on the structure via Purlins, these are the bearers that run left to right along the width of the roof .The maximum purlin spacing for the corrugated profile is 800mm centres on the first and last purlins and 1 meter centres for the intermediate purlins. For the Greca profile 900mm first and last and 1200mm for the intermediates.
For a quiet roof - install the PSP noise reduction tape to all of the purlins, before installing the sheets. This will ensure that the expansion and contraction movement of the sheets has a minimal noise effect. Painting the tops of the purlins white is also recommended to prevent heat build-up.
If you need to alter the length or width of the Suntuf sheeting, it can be cut on site using various methods, a circular saw using an Irwin Marathon PVC blade or scoring with a sharp pointed Stanley knife and tear or simply with a pair of scissors.
When fixing the sheets to the purlins. The hole/fixing sequence is every second crest on the first and last purlin (top & bottom) and every third crest on the intermediate (middle) purlins.
It is also recommended that you fix every overlap.
For roofing applications fasten through the crests. Tighten your fixings until the rubber washer slightly pushes the crest downward with the washer sitting snug onto the sheet. Be sure not to overtighten and be sure that the fixings are perpendicular to the angle if the roof to allow sufficient expansion and contraction of the sheets.
For sealing (flashing) the area between the roof and the building, use the Suntuf apron flashing. If you have a hip type roof use the Suntuf ridge flashing. These are clear in colour and are designed to fit over the sheets.
We love our new patio pergola, but the only thing that could make it better was installing a clear pergola roof. Now even if it decides to rain for an entire month (like it did in September), we can still enjoy gatherings on the patio.
But my favorite part is that it lets the light in but blocks out the UV rays. Blocking UV rays on the patio means all our patio furniture will last longer. No more fading and sun bleaching! And we can enjoy the patio even if the weather decides to rain out another of our parties!
The biggest decision we had was whether to use the same Solar Gray color on the patio as we had on the playhouse roof. I love that the playhouse has the extra shading so the kids can play in it all summer long and it stays a bit cooler.
I seriously cannot wait for a rain storm so we can sit under the roof and watch the rain drops dance on it. Since it is later in the fall season now, we may have to be bundled up with a cup of hot cocoa, but you better believe we are not going to miss our first storm under the new clear pergola roof!
The best part of the SunTuf corrugated roofing panels is you can attach them to an existing structure. You only need to add purlins to the existing structure to attach the panels to. So if you have ever wanted to add a roof to an existing pergola, porch or even chicken coop, you are going to want to read on.
I think I went up and down the ladder a thousand times that afternoon (I know it was a lot because my bootie hurt so bad the next day). And I only completed 3 out of 7 purlins. The next day my husband helped me and the other 4 purlins were installed in no time.
In order to attach the purlin on top of the header, we had to screw up from the header of the pergola into the purlin. We did this by pre-drilling a pilot hole at an angle then securing the purlin with a screw. I added a screw on each side of every cross beam.
Now we were finally ready for the roof! All that prep took way more time that actually adding the roof, but I know proper prep is important (but I definitely prefer being able to see the instant results).
To cut the panels, we clamped a level to create our cut line and used a circular saw to run right down the edge of it. It was super quick to measure and cut each one. The sound of the saw hitting each corrugation is a little scary at first, but it cuts so clean that there is no need to worry.
You have to be careful when fastening the screws so they do not sink into the roofing material causing a dimple. After a few screws though, we figured out the groove and were able to quickly insert each screw perfectly. We installed screws in every other corrugation except the last one where the next panel would be overlapping it.
To install the next panel, we measured and cut to the correct length. Then overlapped it one corrugation with the first panel and started pre drilling and screwing in the screws. We found it was easiest to add the screws all the way down the top of the overlap first, then go back in and fill in the rest of the panel.
The rest of the day was all about measuring for the next panel, cutting, then securing it to the roof. Luckily it was a beautifully sunny day, with temperatures in the low 70s. A perfect day to install a clear pergola roof!
It was not hard work, but there are a LOT of screws on the top of our pergola so it did take the better part of the day to complete. But when that last screw was finally attached, we cheered a little bit and then had a few minutes to admire our work before the kids needed us.
Next I will be sharing the build plans for our outdoor kitchen island. It is going to be the perfect place to store all our outdoor eating and cooking supplies. And even has a bar area for stools so the kids can sit up to it and help cook. Stay tuned for lots more patio fun!
Our roof ends 6" before the fence line. There is a gap between the fence and the cement patio for the water to run to. But it also prevents the berries from our neighbors trees from dropping all over our patio ;)
Hi Kati... And here I thought this was my own original idea! ? When I told a deck contractor what I wanted, he looked at me like I was nuts. I love brightness and the outdoors. When I decided to cover my new deck I dreaded the shade darkening the interior of my house. Clear panels,was the obvious choice. It was completed 2 weeks ago and I'm still trying to get used to such brightness when I step out. It feels like there's no roof. It's raining and it feels odd. I absolutely love my choice. My contractor didn't know how to cut the panels so 2 pieces are longer by a few inches. Not happy about that. He chose foam strips supporting the panels but I highly doubt their longevity. I need to add an eaves trough because the water drops right onto my garden bed. I love seeing the sky and trees through it, and rain falling and watching it run off the roof. I'm in Ontario Canada where we can get significant snow some years so I'm waiting with bated breath to see if it will hold under the weight. I'm thinking I might have to heat underneath to melt it off if it gets too bad... Cautiously, of course. The slope isn't what I wanted but the contractor insisted on sticking with building codes ... 1" per foot. At 10 feet, it's only sloped about 9-10 inches. So we'll see. I hope others see your article as this roof type solves more issues than rain, wind and snow... Except from the sides, alas. Need curtains and planning to add a retractable awning as I get a lot of sun which is too much on hot days but great on cooler days. The best of all worlds!
I have never seen wood used to build your pergola that had slotted holes every where. Never. I live in a hurricane state and believe that might weaken the wood, making it go up in the sir a lot quicker.
Kati I enjoyed your post on covering your pergola. I do have a question regarding the SunTuf clear panels. Have they yellowed or discolored any over the time you have had them up? The summer sun is quite intense in southern Alabama and it also shines brightly year round. I have seen corrugated plexi-panels, both clear and colored, that discolor or become cloudy with time.
@Rick,This is something I was wondering about, too. About 10+ years ago I put a clear panel from Home Depot (I think probably SunTuf) along my fence sideways to prevent my neighbours plants from drifting onto my garden. Over the years it has maintained its clarity on the upper side but the side sitting on the ground has developed a green algae/mildew that looks like it will wash off. It would be more difficult on a roof. I've seen tv ads for a spray window cleaner you can apply from the ground using your garden hose. It might work on these panels. But that green is because it's sitting on the ground surrounded by plants. Unless your roof is buried under a bushy area and very damp, this should not be a problem. The top edge is perfectly clear even after 10+ years. I can see absolutely no discoloration - and it gets lots of sun exposure.
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