How to Install Corrugated Polycarbonate Sheets

Corrugated polycarbonate sheeting keeps outside weather from coming in a building while still allowing natural light to flow into the building. The hard polycarbonate material cuts, drills and seals like other common building materials but its brittle nature requires more support and care when fastening the material to the structural supports of a building. A cracked piece of installed polycarbonate allows water to enter the interior of a building and damage materials that are not waterproof.

Install Corrugated Polycarbonate Sheets
  1. Set a piece of corrugated polycarbonate sheet on a firm work surface. Mark the location of the cut on the surface of the sheet by pulling a tape measure along the sheet and marking the cut location with a permanent marker. Make multiple marks on the polycarbonate sheet to provide you with a straight reference line.

  2. Cut the sheet on the marked line with a circular saw with a 10 TPI blade. Push the saw slowly to avoid cracking or splintering the edge of the sheet. Set a utility knife blade at a 45-degree angle to the cut edge. Drag the blade along the cut end to remove the burr from the cut.

  3. Mark mounting holes on the high ridges of the polycarbonate sheet. Drill a hole 1/16 inch larger than the mounting screws you will use to mount the sheet. Secure the drill bit in a drill motor. Drill a hole at each marked location.

  4. Place one spacer under each drilled hole. Run a rubber washer screw 1/2 its depth through the hole and into the center of the spacer. Set the sheet in position. Run the screws tight to the surface of the polycarbonate sheet and in the support structure of the building.

  5. Cut and prepare a second sheet. Set the second sheet in position with its lowest end sitting 3-4 inches over the installed sheet. Repeat the process until the entire area is covered with polycarbonate sheeting.