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chillyinphilly 10-24-2011 10:20 PM

polycarbonate corrugated roofing question
I currently have a deck with a lean-to type of roof with plywood sheeting and shingles. I plan to tear off the plywood (leaving the rafters which are approx. 16 inches apart) and replace the roofing with polycarbonate corrugated roofing panels from one of the two major big box stores in my area. The panel mfrs install instruct one to attach horizontal 2x3 beams i.e. purlins, to the rafters, then attach their foam closure strips on those purlins, then use their fasteners (hex screw with foam washer) to attach the polycarbonate panels on the crest of the panelís curve.

My question is: Does anyone know of a way to avoid using the foam closure strips? For my 9x12 roof, the foam strips will cost about 120.00, nearly as much as the panels for the roof. I understand that the foam strip helps ensure that the crest of the panel doesnít get forced too far downward when using the fasteners, but I wonder if there is a cheaper way to achieve the same result.

I found a review comment on a big box website that suggested one could rip 2x4ís to the appropriate thickness and put those on top of the purlins, but I plan to use the panels with a curvy wave, as opposed to a panel with a square-type pattern, so I donít think that would prevent me from bowing the curve on the panel when I screw into it. Any thoughts or suggestions on this would be greatly appreciated!

shazapple 10-25-2011 10:35 AM

These things are just strips of foam, I assume to ensure you don't break the panel by tightening too much? Do they follow the profile of the panel?

Why not just use shingles or a metal roof? I don't think you'll get the longevity out of these panels you are looking for.

josall 10-25-2011 11:31 AM

Here are the two closure strips that you need, will cost about $20 one goes on top of the purlin and the other on top of the blocking on the 2 outsiide rafters. I attached the installation instructions.

chillyinphilly 11-15-2011 11:27 PM

Josall, thanks for the links. Those wood strips are not on the shelf at my big box so I'll need to order them, but never would've known they existed if you didn't point them out. MUCH more economical than the foam. Thank you!

I am a little concerned that they may not work with the tuftex panels I want to use, since the strips are for palruf, but I can order them and check them out. Here's the panels I'm planning to use:

If the strips don't fit my panel, perhaps I can compromise and find a Palruf panel that will be acceptable to me.

Shazapple, I hear what you're saying--I personally like the metal roofing panels better too (strength, ease of install and I think the rain would sound pretty fantastic on them.) However, I plan to sell next year so I'm going with opaque polycarb for aesthetic reasons.

And I believe that the foam strips are to ensure both that you don't break the panel by screwing too far and that you don't compress the crest of the wave on the panel when you drive the screws.

josall 11-16-2011 06:59 AM

The strips should work on either panel they are both a 2-1/2" corragated pattern.

bjohns2000 07-30-2013 05:25 PM

support for ridges of corrugated roofing
just came upon this site; I use 1/2" dowels cut about 2" long, drill a 3/8" hole for the screw & place them under the ridges for support; cheap but time consuming. Time I got.

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