Westman Steel: PVC/Polycarbonate Installation Guide

Corrugated Roofing Panels

HANDLING & STORAGE:

Stack short sheets on top of longer ones. Store sheets in a cool and dry place out of direct sunlight. To prevent solar heat buildup, avoid covering the stack of sheets with a dark tarp or other heat absorbing material.

CUTTING:

Use a circular saw with a fine tooth blade at a high speed but a low advance rate to cut 3-4 sheets at a time. For curved cutting, use a jigsaw or metal cutting shears. During cutting, secure sheets to insure clean cuts. Clean sheets of any debris before installation.

DRILLING:

Pre-drill holes 3/32” larger than screw diameter to allow for expansion and contrac- tion. Start fastening sheets at bottom moving toward top of sheet. Do not fasten at both ends and move towards middle. Over tightening screws may cause sheet distortion leading to cracks & fractures. Sheets should be fastened at the peak of every third corrugation on plastic horizontal closure strips for roof applications. Fasten sheet every 3rd valley for wall applications.

THIS SIDE UP:

The UV-protected side of the sheet has a product label indicating the exterior side of sheets that must face towards the sun.

INSTALLATION:

Begin installation on side away from wind/rain direction. Continue to work to left or right accordingly. Never start from both sides and work to middle. Minimum recommended roof pitch of 2/12. Only one corrugation overlap is required on sides of sheets. Do not stretch or force sheet to overlap. Cover long spans by overlapping sheets a min. of 4”.

CLOSURE STRIPS:

Plastic or foam closure strips can be used horizontally under the panels as fastener supports. Plastic vertical closures are recommended for finishing the outside edges. Foam closures can be stretched slightly to align with the panels to form a compression fit. Foam closure strips can be used under top and bottom of sheets to prevent leaks.

CLEANING:

Normal dirt and dust accumulation is washed off by periodical rains. Regular rinsing of the sheets with clean lukewarm water is sufficient in dry areas. Mild household detergent may be used with a soft rag. Never use aggressive or abrasive cleaning agents or glass window cleaners; they can chemically attack the sheets.

PURLINS:

Max distance between purlins is listed below for a 25 lb load:

PVCLite – 24” / FiberLite – 36”
PVCLite Plus – 24” / CoverLite – 48”

FASTENERS:

Wood – #10 Woodgrip
– 1/2” Neoprene bonded washer
Metal – #12 Self-Drilling/Tapping
– 1/2” Neoprene bonded washer
Roof Application – 2” or 2 1/2” screw
Wall Applicaton – 1” or 1 1/2” screw

SILICON SEALANTS:

Use silicon as a sealant. Other caulking or sealants may attack sheets. Check silicon product label to insure compatability. 100% silicone is compatible with polycarbonate.

Multiwall Polycarbonate Panels

HANDLING & STORAGE:

Stack short sheets on top of longer ones. Store sheets in a cool and dry place out of direct sunlight. To prevent solar heat buildup, avoid covering the stack of sheets with a dark tarp or other heat absorbing material.

REMOVING FILM:

Remove approximately 2 inches of film from sheet edges before installing. Remove all film immediately after sheet installation is complete.

INSTALLATION:

Use H-Channel to connect two sheets. Fasten supports at all four corners 1 1/2” from edges. At purlin supports, fasten 6” from edge. When cold bending, min. radius is 41” for 6mm /110” for 16mm. Bend sheet longitudinally, never across sheet width. Flutes must run on at least a 2/12 pitch. Maximum purlin spacing is 24” for 6mm / 36” for 16mm. Do not walk on sheets at any time.

THIS SIDE UP:

The UV-protected side of the sheet is covered with printed film and must face towards the sun.

DRILLING:

Use only new or sharply ground steel or carbide tipped drills. The diameter of drilled holes must be 50% larger than the screws diameter to allow for thermal expansion, providing enough space to allow for seasonal temperature fluctuation.

END CLOSURE:

Structured polycarbonate sheets must always be installed with ribs positioned vertically. Seal ends with anti-dust tape and a U channel. Drill weep holes every 12” with a 1/8” drill bit to allow condensation to drain out the bottom of the U channel.

CLEANING:

Normal dirt and dust accumulation is washed off by periodical rains. Regular rinsing of the sheets with clean lukewarm water is sufficient in dry areas. Mild household detergent may be used with a soft rag. Never use aggressive or abrasive cleaning agents or glass window cleaners; they can chemically attack the sheets.

CUTTING:

Masking film should remain on the sheet to prevent scratching. Utility knives can be used to cut. Sheets should be clamped for hand saw cutting to prevent vibration. Sheets can be cut with a circular saw using carbide triple-chip fine tooth panel blades. Remove dust from the surface with compressed air or a vacuum.

SILICON SEALANTS:
Use silicon as a sealant. Other caulking or sealants may attack sheets. Check silicon product label to insure compatability. 100% silicone is compatible with polycarbonate.

FASTENERS:
Wood – MultiLite 1” Screw for 6mm / 2” Screw for use with 16mm
– 1/4” Hex head w/neoprene washer
Metal – #12 Self-Drilling/Tapping
– 1/2” Neoprene bonded washer

Tough Rib PVC Liner Panels

STORAGE AND HANDLING:

1. Panels should be transported and stored horizontally on a flat, sturdy
   • Cover panels stored outside with a white opaque polyethylene sheet
2. Panels should be stored inside interior space in which they will be
   • Install panels after they have acclimated to the inside structure temperature
   • This will prevent warping through changes of thermal expansion/contraction

BASIC INSTALLATION:

1. Panels may be installed vertically on walls or horizontally sloped on
   • Maximum recommended panel length is 20′ 4”
   • In lieu of longer panels, lap panels to achieve desired length
   • Place a plumb line to mark starting panel starting postion and direction
2. It is possible to cut panels with a circular saw, using a blade intended for hardwood or a special one for plastics, rotating at a high
   • Advance the saw at a slow feed rate
3. Predrill holes 1/16” larger in diameter than the fastening
   • Drilling should be carried out with a metal drill bit
   • Drill holes perpendicular to the face of the panel
4. Start installation at panel bottom and work towards wall eave or ceiling
   • Start at bottom edge, at right or left side, and proceed to left or right and up
   • Never fasten both edges first and then work towards the middle
   • It is possible to begin installation in middle of panel and proceed to both sides
   • Maintain correct fastening sequence
   • Keep panel flush and taut during positioning and fastening to avoid deformation and a wavy appearance
   • Installations with purlin spacing greater than 24” may result in increased

** Do not leave partly installed panels unattended until all the required fasteners have been placed and properly tightened.

OVERLAP:

1. Minimal recommended end lap is 4”
   • Install lower panels first
   • Lap with upper panels to avoid drip into ceiling or wall
   • Maximum overlap 8”
2. Side lap is one corrugation
3. Panel’s edge overhang shouldn’t extend more than 4”
4. Overlap should be sealed with silicone in wash areas or extremely wet
   • Install butyl-rubber sealing strip along length of side or end lap corrugations