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We offer an excellent range of different sizes of polycarbonate sheets, however, you will still need to join the sheets together to cover a wider area. We have all the fittings that you need to join your polycarbonate sheets together, and here, we will talk you through the steps needed to safely and securely fit your polycarbonate sheets. If you need any further advice, please contact our helpful and experienced team.

Tools and Materials Needed for Joining Polycarbonate Roofing

Preparation is key to making sure that your polycarbonate roofing does the job. Firstly make sure that the structure you are attaching your polycarbonate sheets to is strong enough. It should as polycarbonate is incredibly light making it an excellent choice as a roofing material. You will need the correct size polycarbonate sheets for your project, and suitable glazing bars to join them together. We have all the fittings that you will need to assemble for polycarbonate roofing. Polycarbonate is relatively easy to work with, so you won’t need any special equipment, only a hammer, drill, and safety glasses. If you wish to cut your polycarbonate sheets, then a circular saw is best.

How to Join Polycarbonate Sheets Step-by-Step Guide

It can seem a little daunting fitting your own polycarbonate structure, so make sure you plan your project, take your time, and follow each step. Here we will break down each step of the installation process for you.


Get everything you need before you begin. Ensure that you have a clear and usable space to work in so that you are not working around potential hazards. Gather your materials and your tools.

Cutting of Edges

If you are cutting your sheets to size then a circular saw is best, but you can use a jigsaw. Make sure your sheets are clamped before you begin cutting, and as ever – measure twice, and cut once!

Applying Adhesive on Roofing Sheets

Only certain types of adhesive work with polycarbonate. Some adhesives will cause the polycarbonate to “craze” as it reacts with the compounds so you must check on the suitability of the adhesive. Superglue works well as does epoxy for smaller areas, but consider what is the best choice for your requirements. The surfaces must be clean and free of debris before glueing. You can wash the polycarbonate in soapy water to ensure that the surface is as clean as possible, but make sure it is completely dry before you apply the adhesive.

Ensuring a Secure and Tight Fit

If you are creating a roof or a wall with your polycarbonate sheets, you want it to be weatherproof. Your sheets must be securely and tightly fitted together so that no weather can penetrate the joint. We have a range of glazing bars that are designed to join polycarbonate sheets together. We have both aluminium and plastic glazing bars. Choosing the best fit for your project will depend on the span between joins, and the thickness of the polycarbonate. We are always available to give you advice if you are unsure of the best glazing bars for your project.

Polycarbonate Sheets Maintenance and Cleaning

Polycarbonate sheet is a very resilient and long-lasting material, which is why it is so popular. To keep it in good condition simply clean it regularly with lukewarm water and mild soap, using a soft cloth or sponge, nothing abrasive.

Questions Answered About Joining Polycarbonate Sheets

1. How much do you overlap polycarbonate sheets?

Polycarbonate sheets should not overlap. If you are connecting the sheets using a glazing bar, then you slot a sheet into each side of the glazing bar and they will click into place.

2. Can you screw down polycarbonate?

It is best to pre-drill holes in your polycarbonate sheet before screwing your sheets onto your framework.

3. Can you nail polycarbonate sheets?

We recommend using screws to fix polycarbonate. Do not nail straight through the polycarbonate as you will damage the sheets.

4. What is the expansion gap for polycarbonate sheets?

You must leave an expansion gap for your sheets, as they will expand in higher temperatures. This is a variable as it depends on how warm the area is, where your sheets are, and the size of the sheet. Generally, it is advised to leave an expansion gap of between 3mm to 10mm per sheet, but this is only a guide.

5. What sealant can be used on polycarbonate?

Clear silicone adhesive is an excellent sealant to use on your polycarbonate sheets. Whichever sealant you choose, make sure that it is suitable for use on polycarbonate.

6. How do you finish polycarbonate edges?

How you finish the ends of your sheets is down to personal preference. We offer end caps that simply clip onto your sheets and give a tidy finish, but some people like to sand and polish the edges of their sheets to give a smart finish.

7. Can you sand the edge of the polycarbonate?

If you want to buff your sheets to give them a nice shine, then start by sanding them. Sanding the sheets with fine grit sandpaper, followed by buffing with a machine will give you a clean and smart finish to your edges.

8. Does polycarbonate crack easily?

Polycarbonate is a resilient and flexible material which is why it is commonly chosen over glass, which has a tendency to break. Polycarbonate sheets are a great choice for many constructions and projects partly because they don’t crack easily.


Here at Glazing Systems, we have an excellent range of polycarbonate sheets for your next project. Polycarbonate roofing is easy to assemble by a person who is competent at DIY and is extremely long-lasting and hard-wearing making it a popular choice for many people. We have all the associated accessories that you will need to join polycarbonate roofing sheets together, making us your go-to shop for polycarbonate supplies. If you need help or advice or want to enquire about our installation service, then simply get in touch with us today at 01942 871183.

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