2.5 m long x 4 m Wide Polycarbonate Kit Roof

The lean to roofing kit measuring 2.5 metres long by 4 metres wide provides excellent medium-scale coverage for homeowners and businesses throughout Bristol and Bath, delivering a generous 10 square metre roofing solution with customizable sheet thickness options of 10mm, 16mm, or 25mm to meet specific structural, thermal, and budget requirements for diverse residential and commercial applications. This well-balanced system is ideally suited for substantial residential projects, compact commercial spaces, or functional outbuildings where quality weather protection and enhanced structural performance are essential for maximizing property value and year-round usability. The choice of sheet thicknesses allows for precise specification based on application demands: 10mm sheets for standard weather protection in residential settings, 16mm for improved thermal performance and structural strength in demanding conditions, or 25mm for maximum insulation and commercial-grade performance in exposed locations common throughout Bristol and Bath's varied topography. The practical dimensions create substantial covered space while maintaining appropriate scale for typical residential gardens and commercial areas, making it ideal for covering large patios, creating spacious carports, building workshop facilities, or providing extensive shelter for outdoor dining and entertainment areas that enhance both residential living and business operations. The lean-to design ensures optimal water drainage across the full span while maintaining generous headroom, making it particularly suitable for applications where reliable weather protection is crucial for multi-season functionality and user comfort. This roofing system is engineered to handle Bristol and Bath's challenging weather conditions, from strong winds affecting elevated locations to heavy rainfall requiring effective drainage management, ensuring dependable long-term performance that meets the quality standards expected by discerning property owners throughout the region.

Select the type of polycarbonate and colour required.

1. Price includes(Actual coverage 4.310mm)
2. 4no 1050mm x 2.5m polycarbonate roof sheets
3. 5no x 2.5m bars to fix to timber
4. 2no x 3m edge fillets
5. 4no x 1050mm sheet closures
6. 1no x 150mm flash band
7. Anti-dust tapes 

Installation Guide

Step one 

Fix your first edge bar as shown in Dia. 1. Slide the edge fillet up the groove on the bar as shown, then cut the bar to length, remembering to allow for a 50 mm overhang into the guttering. Cut the aluminium base 2 mm longer than the predetermined length of the polycarbonate sheeting, allowing for the end cap to fit later.
Drill and fix the bar into position,n screw with no less than six screws at 3- 400 mm centres, ensuring the drip on the edge trim is in the required place and neat from the external view. Repeat on opposite end Dia 1.
NNB Where bars are butting against a wall, the edge trim is not required; fit the bar only.

Step two 

You can choose to cut all sheets and then evenly space them out, or you can work towards cutting a sheet in half. Once you have decided, start fixing centre bars in your required position. Drill and fix the bars with screws at 3-400 mm centres

IMPORTANT REMEMBER TO LEAVE A CLEAR EXPANSION GAP OF 4MM BETWEEN THE BAR AND THE POLYCARBONATE SHEETS.

Step three 
Ensure all the rubber gaskets in the bars are flat with no bumps.

Step four
Cut your polycarbonate sheets to the length if not already done, ensuring that all swarf is removed. Use a vacuum or a condensation-free airline to remove swarf (never try to wash it out). Now fit anti-dust tapes to the sheet. Use the solid foil tape on the top of the sheet and the vented tape on the bottom of the sheet. Peel off the backing tape and stick in place as shown. These tapes reduce condensation and keep out insects and dust, so ensure they fit correctly. No, we peel about 50 mm of the protective film down both sides and place the sheet in position.

Step Five
Position the PVCU caps so that the toothed legs locate inside the centre of the aluminium base. Press down firmly, then lightly hammer down with a rubber mallet or equivalent until the caps lock into place. As you work across the roof, complete flashing as you go (see tips).
When the flashing is complete and all caps are in place, remove the protective covering.g

Step Six
Fit the end caps into place. Now, cut the sheet closures to the length between the bars and push them in place as shown.

Tips

For polycarbonate cut-to-size orders, please order your polycarbonate sheets after you have fitted your bars. We can then cut, blow, and tape your sheets to the correct size (width and length). NB: Please allow for expansion when ordering. (P.O.A)
If using lead flashing, ensure the lead (recommended) is fitted before the sheets and dress down as you install the roof panels. Fit your lead in sections of 2m and seal the overlap with a lead mate, 100 mm.

For cleaning, use mild soapy water. Try a small panel first to ensure there is no reaction. Never use solvent-based cleaners.
You should not need to use silicone; however, if you do, use only high-quality, low-modulus, neutral-clear silicone.
For a good-quality roof that will last the test of time, avoid wide sheets. Try to use the recommended widths: 980 mm or less for roofs up to 4m long and 700mm wide for roofs 4m or longer.
Fix wall plates, top and bottom, and fix joists as you fix polycarbonate bars
Use 9mm economy fascias all round and square white gutters for a maintenance-free finish.
Not Sure? Please email us; we are here to help.