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How to Install Corrugated Panels

With the wide variety of modern corrugated roofing panels such as those made with fiberglass, PVC and metal, this type of roofing product is once again gaining in popularity. Cheap compared to other roofing products, and extremely strong, the newer corrugated panel materials can be painted to match the existing décor and improvements in coatings now prevent rusting. Add to this the benefits of being lightweight, easy to handle and install, you can see why many homeowners are opting to make this their next "do-it-yourself" project for their home.

Difficulty: Moderate
Instructions

Things You'll Need:

  • Tape measure
  • Calculator
  • Underlayment
  • Nails or screws
  • Lap sealant
  • Caulking gun
  • Hammer
  • Drill
  • Circular or hand saw
  • Saw blade
  1. Step 1

    Estimate how many panels you will need for your project. Do this by using a tape measure to find the square footage of the surface to be covered and dividing that number by the square foot of one panel. For example, if you have a roof area of 12 feet by 20 feet, you will have 240 square feet. An average panel is roughly 4 feet by 8 foot and equals about 32 square feet. 240 divided by 32 equals 7.5, which means you'd need at least eight panels for the job. A calculator helps when computing square footage.

  2. Step 2

    Estimate the amount of ridge cap you need by measuring the linear feet (a straight line measurement) of all roof ridges. Also decide whether your project will require closure stripping underneath the panels and purchase the needed amount along with any fasteners, sealants, and equipment.

  3. Step 3

    Apply underlayment as required by the manufacturer. Different types of panels have varying requirements and not all installation will require underlayment. Also install any closure stripping if necessary.

  4. Step 4

    Lay the first full panel near a bottom corner of the roof structure. Adjust the piece to have at least 1 inch overhang at the gable and 2 inches along the eave. This overhang is to allow water to fall away from the fascia board and structure, not run down it. Secure as recommended by the manufacturer with either nails or screws.

  5. Step 5

    Place the next piece beside the first, overlapping the first by one or two ridges. Refer to the manufacturer's instruction on whether you will need to apply a vinyl lap sealant product. Overlapping and sealant use prevents water leakage and increases the roofing's strength. Secure the panel, then repeat until the first row is complete.

  6. Step 6

    Install the next course, overlapping the top of the previous by 4 to 8 inches depending on your product. Stagger the joints, being careful not to line up all seams upon the previous course, for it may cause leakage. Depending on the size of your roof, you may have to trim the panels to size on this course, or on subsequent courses. If trimming is needed, use a circular or hand saw equipped with the appropriate type of blade for your panel material.

  7. Step 7

    Repeat the installation of panels until the entire roof has been covered. Install the ridge cap as recommended by the manufacturer along the ridgeline. Add any necessary flashing along edges or in valleys. Double-check that all panels are secure.

Tips & Warnings
  • Store panels in a dry, shaded area.
  • Have help to make the job easier.
  • Consider hiring a pro for larger projects.
  • Wear protective eyewear when cutting or drilling panels.
  • Wear shoes with good traction on roof.
  • Refer to local code for special rules regarding the use of corrugated panels.
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