PVC Roofing Sheets

What are PVC Roofing Sheets?

PVC roofing sheets are lightweight, durable panels made from Polyvinyl Chloride, a versatile plastic known for its excellent waterproofing, weather resistance, and cost-effectiveness. Widely used across both residential and commercial applications, PVC sheets are a practical choice for non-habitable structures such as sheds, garages, carports, greenhouses, and agricultural buildings. Their ease of handling, simple installation, and minimal maintenance requirements make them especially popular for DIY projects and functional cladding or roofing jobs.

Our range features Clear Heavy Duty Corrugated PVC roofing sheets, manufactured to a sturdy 1.1mm thickness and a standard 762mm width. Designed with a classic wavy corrugated profile, these transparent sheets strike the ideal balance between durability and light transmission. They're perfect for projects that demand added strength without sacrificing natural daylight - including workshops, reinforced carports, greenhouses, and agricultural or utility buildings. 

Available in standard lengths from 1830mm to 3660mm, our sheets provide a practical, long-lasting solution for a wide variety of roofing and cladding needs.

Applications

• Workshops & Sheds: Provides bright, weather-protected roofing for utility buildings. The heavy-duty nature withstands typical workshop environments better than lightweight sheets.
• Robust Carports & Canopies: Offers durable overhead protection for vehicles or entranceways while keeping the area bright.
• Greenhouses: A strong, clear option allowing maximum light for plant growth, offering better durability than very thin PVC or polythene films.
• Agricultural Buildings & Animal Shelters: Cost-effective roofing or cladding for barns, stables, or shelters where light is beneficial (ensure adequate ventilation).
• Log Stores & Covered Work Areas: Creates practical, protected outdoor storage or workspaces.

Benefits

• Maximum Natural Light: The 'Clear' finish allows daylight to infiltrate and brighten the space beneath - ideal for greenhouses or workshops where visibility is crucial.
• Enhanced Durability (Heavy Duty 1.1mm): Compared to thinner (e.g., 0.8mm) PVC sheets, this 1.1mm thickness provides noticeably better resistance to knocks, impacts from general weather (excluding severe hail), and physical handling during installation. 
• Cost-Effective Performance: Strikes an excellent balance, providing improved strength and expected lifespan over basic lightweight PVC, without the higher cost associated with premium materials like polycarbonate. 
• Lightweight Handling: Despite its 'Heavy Duty' specification, PVC remains significantly lighter than glass (approx. 1.4 kg/m²), making it easier and safer for one or two people to handle, transport, and install, often reducing the need for heavy lifting equipment or overly complex support structures.
• Simple Installation: The standard corrugated profile and sheet width (762mm) facilitate straightforward installation using traditional overlapping techniques (side and end laps). Sheets are easily cut and drilled with standard tools.
• Waterproof Reliability: When installed correctly according to guidelines - ensuring sufficient overlaps, crest fixings with sealing washers, and adequate roof pitch - it provides a reliable waterproof barrier against rain.
• Convenient Stock Lengths: Availability in standard lengths (1830mm/6ft, 2440mm/8ft, 3050mm/10ft, 3660mm/12ft) allows for efficient project planning, potentially reducing waste and the need for excessive joins.

Installation Guidelines for 1.1mm Corrugated PVC

Important Disclaimer & Safety Notice

• General Guide Only: The following steps provide general guidance based on standard UK practices. They are not exhaustive and do not cover every specific situation.
• Manufacturer Instructions are Paramount: Always obtain, read, and strictly follow the specific installation instructions provided by the manufacturer of the 1.1mm corrugated PVC sheets you are using. These instructions contain vital details specific to the product.
• Professional Advice: If you are unsure about any aspect of the installation, structural suitability, or compliance with regulations, consult a qualified building professional or roofing contractor.
• Safety First: Working at height is dangerous. Always use appropriate safety equipment (secure ladders/platforms, harnesses where necessary). Wear PPE: gloves, eye protection (especially when cutting), and a dust mask. Never walk directly on the roofing sheets – use crawl boards or ladders spanning across the supportive purlins.
• Responsibility: The installer is responsible for ensuring the installation is structurally sound, weatherproof, and complies with all relevant UK Building Regulations (including structural loads and fire safety).

Preparation & Support Structure

• Check Purlin Supports: Ensure you have adequate timber or metal purlins (horizontal supports) correctly spaced across the roof slope.
• Verify Purlin Spacing: The maximum distance between purlins MUST be based on the manufacturer's load/span data specifically for 1.1mm thick corrugated PVC sheets. This calculation depends on your roof pitch and geographical location (for wind/snow load). Insufficient support will cause sagging, water pooling, and potential roof failure. Do not guess or assume standard spacing.
• Gather Tools & Materials: Ensure you have all necessary sheets, fixings, accessories (fillers, flashings), sealants, cutting tools, drill, safety equipment, and access equipment ready.

Laying the Sheets

• Starting Point: Begin laying the first row of sheets at the eaves (bottom edge of the roof), working upwards towards the ridge. Ensure the correct overhang into the gutter (typically 50-60mm).
• Orientation: Position sheets so the side laps will face away from the prevailing wind direction. This helps prevent wind-driven rain from being forced into the overlap.
• Side Overlaps: Overlap adjacent sheets along their length by a minimum of one full corrugation. For low-pitched roofs or in very exposed locations, overlapping by two corrugations provides significantly better weather protection.
• End Overlaps (If Required): If the roof slope is longer than a single sheet length, sheets must overlap vertically. 
  • Ensure a minimum end lap of 150mm (6 inches).
  • For roof pitches below 10 degrees, increase the end lap to at least 250-300mm and apply a suitable butyl sealing strip or compatible mastic within the overlap for a watertight seal.
  • Crucially, ensure the entire end lap area is fully supported by a purlin positioned directly underneath it.

Fixing the Sheets Correctly

• Pre-Drill Fixing Holes: This is essential. Before inserting any screws, you must pre-drill fixing holes through the PVC sheet. 
  • Drill at the crest (top) of the corrugation where the fixing will be placed.
  • The hole diameter must be 2-3mm larger than the fixing screw's shank. This allows for thermal expansion and contraction of the PVC sheet, preventing stress cracks and buckling.
• Use Correct Fixings: Use only specialised corrugated roofing fixings. These typically consist of a screw (suitable type/length for your purlin material – timber or steel) combined with a sealing washer (often bonded) and ideally a plastic cap shaped to fit the corrugation profile.
• Fixing Location: Always fix through the CREST (peak/top) of the corrugation. Never fix in the valley (trough), as this is the water channel and will inevitably lead to leaks.
• Fixing Density: Fixings should typically be placed on every second or third crest across the sheet's width along each purlin line. Consult manufacturer guidelines or structural calculations for specific density required based on wind uplift risk in your area. Ensure sheet edges and overlaps are securely fixed on each purlin they cross.
• Tightening Fixings: Tighten fixings carefully using appropriate tools (e.g., drill driver with torque setting). Tighten just enough so the sealing washer forms a gentle, positive seal against the sheet surface. 
  • CRITICAL: Do not overtighten! Overtightening will compress or distort the corrugation profile, prevent the necessary thermal movement, potentially crack the sheet immediately or later, and can damage the sealing washer leading to leaks. The sheet needs to be held securely but still able to move slightly beneath the washer as temperatures change.

Cutting the Sheets (If Necessary)

• Recommended Tools: Use a fine-toothed panel saw, a jigsaw equipped with a fine blade suitable for plastics, or potentially an angle grinder with a thin abrasive disc (use angle grinders with extreme caution and full PPE due to dust and potential melting/rough edges).
• Technique: Support the sheet firmly on a flat surface (like timber battens) on both sides, very close to the intended cut line, to minimise vibration and prevent cracking or shattering, especially in cold weather. Mark the cut line clearly. Cut smoothly and steadily.
• Finishing: Carefully smooth any rough or sharp edges after cutting using fine sandpaper or a deburring tool if necessary.

Finishing Details: Eaves, Ridge & Abutments

• Eaves Detailing: Insert profiled foam eaves fillers into the corrugations along the eaves line (underneath the sheet edge). These block drafts, dust, and pests from entering the roof space via the corrugation gaps. Ensure they don't completely block essential ventilation pathways if required by the building's design.
• Ridge Detailing: Use appropriate profiled ridge fillers and/or a purpose-made ridge flashing (metal or plastic) correctly installed and sealed over the top edge of the sheets at the roof apex to ensure weather tightness.
• Wall Flashings: Where sheets meet (abut) a vertical wall, install suitable flashing (e.g., lead, GRP flashing roll, purpose-made PVC/metal flashing). The flashing should be dressed down over the corrugation crests and securely fixed and sealed into the wall above to create a waterproof junction.