Polycarbonate Handling Information

Dimensional Lumber

The most popular building material for greenhouses, garages, sheds, out buildings, sunrooms and patio deck covers is dimensional lumber. This is a popular choice when a design calls for transparent sunlight to provide shelter and interior warm light.
The design transition to frame for joining polycarbonate panels together does require structural rafters and wall studs to have 3-inch surface to attach to.

Panels are available in 4-foot and 6-foot widths. Framing a double stud every 4-foot or 6-foot on center, using a double 2×4 or 2×6 for a 3-inch surface to attach to.

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Single 2 x 4 structural framing member should be every 24 inches on center.

Double up for a 3-inch stud, at 4 feet and 6 feet, to fasten in place a 3-inch wide polycarbonate H channel or a 2 3/4-inch wide aluminum glazing system, and join two panels together. Structural framing members for walls can also be framed horizontally, in much the same way a steel building is structurally framed. With horizontal framing, the exterior steel siding panel overlaps at the edges and runs vertically from top to bottom. For best results, all polycarbonate panel joints / seams should be joined with an H-channel, running horizontal or vertical, and should be on the same plane.

Join all polycarbonate panel seams with H-channels and seal the top and bottom fluted ends of the panels with U-channels.

The top fluted end of the panel should always be taped and sealed with aluminum foil tape. This helps to keep the fluted air space channels clear and clean. Polycarbonate panels have a tendency to collect a variety of tiny bug species, along with particulates and dust, which over time will build up and darken the transmittance of light. This condition will eventually get worse over time if the ends of the panels are not properly sealed.

Once the aluminum or solid woven tape is applied, then apply the U-channel over the tape. Custom bent aluminum flashing can also be used in certain locations. The idea is to protect and seal the open fluted ends of each polycarbonate panel.

The bottom fluted end of Colorado polycarbonate multiwall panels, and Colorado polycarbonate sheets, should also be taped with breather vented tape, as shown in the picture below. Breather vented tape not only helps to keep the lower portion of the panel clean but also helps to provide fresh air inside the air fluted channels to dry up built-up condensation. Condensation is invariably a condition that exists in all polycarbonate structural applications. The best way to alleviate this condition is to use polycarbonate breather vented tape, which is designed for this application.

The bottom end of panels is usually located at the bottom roof eave of your structure and at the bottom end of your base wall. These are critical and vulnerable areas. Be sure to apply U-channels and/or aluminum flashing over both ends of each panel after each end has been sealed and taped.

Caulking is a primary ingredient when building with Colorado polycarbonate panels. It’s best to use a quality clear or colored pure silicone caulk in key areas of your application, including roof eave locations, ridge vent locations, operable windows, door locations, and base wall locations. If you elect to forego the tape, then U-channels by themselves will help somewhat, but they won’t seal as well as the tape can. It’s best to use both tape and U-channels. Remember to provide weeping and breathing holes through the U-channel every 6 inches along the bottom edge of the polycarbonate panel.