7 Steps to Properly Attach Corrugated Roofing

Corrugated Roofing Sheets

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Learning how to attach corrugated roofing is a crucial step in constructing a robust and weather-resistant roof. This type of roofing material, characterized by its distinctive wavy pattern, offers several advantages, including durability, ease of installation, and versatility. Whether you’re a seasoned roofer or a DIY enthusiast, mastering the techniques of corrugated roofing installation is essential for ensuring a secure and long-lasting roof.

Before embarking on the installation process, it’s important to gather the necessary tools and materials. These include corrugated roofing panels, roofing screws, a drill with a driver bit, a measuring tape, a chalk line, and safety gear such as gloves and eye protection. Additionally, selecting high-quality roofing panels and accessories from reputable manufacturers is crucial for ensuring the longevity and performance of your roof.

The installation process begins with preparing the roof deck. This involves ensuring that the deck is level, square, and free of any debris or imperfections. Proper preparation of the deck is critical for the overall stability and integrity of the roof. Once the deck is ready, the corrugated roofing panels can be laid out and secured with roofing screws. The panels should be overlapped by a minimum of one corrugation, and the screws should be driven into the peaks of the corrugations. By following these steps carefully and paying attention to details, you can achieve a professional-looking and weather-resistant corrugated roof that will provide years of protection and curb appeal.

Selecting the Right Corrugated Roofing Panels

The selection of corrugated roofing panels is a crucial step in ensuring the durability and performance of your roofing system. Consider the following factors to make an informed decision:

Material:

Galvanized Steel: Durable, resistant to corrosion, and available in a variety of finishes.

Aluminum: Lightweight, corrosion-resistant, and fire-resistant, but more expensive than galvanized steel.

Polycarbonate: Translucent or opaque panels that allow natural light to pass through, suitable for greenhouses or covered walkways.

PVC: Lightweight, weather-resistant, and available in various colors and profiles.

Thickness:

The thickness of the panels, measured in gauges, affects their strength and durability. Higher gauges indicate thicker panels, which are more resistant to impact and deformation.

Profile:

The profile refers to the shape of the corrugations. Common profiles include:

Profile	Characteristics
Sinusoidal	Semi-rounded waves, providing a classic and aesthetically pleasing look.
Trapezoidal	Straight ribs and a flat surface, offering high strength and wind resistance.
Corrugated	Parallel ridges and valleys, providing good water runoff and durability.

Color and Finish:

Corrugated roofing panels come in various colors and finishes. Consider the aesthetic appeal, heat reflectivity, and durability when selecting the appropriate option.

Accessories:

Accessories such as ridge caps, flashings, and fasteners play a vital role in the functionality and integrity of the roofing system. Ensure that the selected panels are compatible with the available accessories.

Preparing the Roofing Surface

1. Inspection and Cleaning

Before installing corrugated roofing, ensure that the underlying surface is structurally sound and free from any defects. Thoroughly inspect the area for any damaged or rotten roofing materials, as these will need to be replaced before proceeding. Additionally, remove any dirt, debris, or algae that may have accumulated on the surface using a broom or power washer.

2. Laying Roofing Felt

Laying roofing felt as an underlayment provides an additional layer of protection for your roof and helps prevent moisture penetration. Choose a roofing felt with sufficient weight (15-30 pounds per square) and that is compatible with your type of roofing material. Start by rolling out the roofing felt parallel to the eaves, ensuring that it overlaps by at least 6 inches at the seams. Secure the felt using roofing nails or staples, spacing them every 6-8 inches along the edges and every 12-18 inches in the field.

3. Marking Nail Lines and Overlaps

Once the roofing felt is in place, mark the nail lines where the corrugated roofing will be secured. To ensure proper alignment, use a chalk line or a string to create parallel lines spaced according to the manufacturer’s recommendations. Similarly, determine the required overlap for each sheet of roofing by following the manufacturer’s instructions. Typically, the side laps should overlap by 1-2 corrugations, and the end laps by 6-12 inches.


Roofing Felt Characteristics:	Weight: 15-30 pounds per square Type: Compatible with the chosen roofing material Overlap: 6 inches at the seams Secure: Roofing nails or staples every 6-8 inches (edges) and 12-18 inches (field)

Positioning the Corrugated Roofing Panels

Step 1: Calculate Overlap and Eave Extension

Determine the overlap between adjacent panels and the overhang at the eaves. Typically, 6-12 inches of overlap is recommended, and an eave extension of 8-12 inches helps protect against rain and wind.

Step 2: Plan Panel Alignment

Align the first panel at the corner of the roof, with the edge of the panel flush with the eave and the top edge aligned with the desired starting point. Fasten the panel securely using roofing screws.

Step 3: Position Subsequent Panels

Positioning for Lengthwise Overlap:

Distance from Previous Panel	Overlap Amount
1 Corrugation	1/2 to 1 corrugation
2 Corrugations	3/4 to 1 corrugation
3 Corrugations	1 to 1-1/4 corrugations

Positioning for Side Lap: Overlap by 1-2 corrugations, ensuring the ribs of the panels align for proper water drainage.

Fastening: Secure the panels to purlins or roof framing using roofing screws with washers. Space screws 3-4 inches apart along ribs and 6-12 inches apart at side laps.

Securing the Panels with Nails or Screws

Once the roofing panels are in place, they must be securely fastened to the roof deck. This can be done using either nails or screws.

Nails are the traditional method of securing corrugated roofing, and they are still widely used today. However, screws are becoming increasingly popular, as they offer several advantages over nails.

Screws are self-tapping, which means that they do not require a pilot hole. This makes them easier to install than nails, especially in thicker roofing materials.

Screws also provide a more secure hold than nails. This is because they have a larger surface area than nails, and they are less likely to pull out of the roofing material.

When choosing fasteners for corrugated roofing, it is important to consider the following factors:

The type of roofing material
The thickness of the roofing material
The slope of the roof
The climate in which the roof is located

Number and Placement of Fasteners

The number and placement of fasteners required for corrugated roofing will vary depending on the factors listed above. However, as a general rule of thumb, the following spacing should be used:

Roof Slope	Fastener Spacing
Less than 3:12	6 inches on center
3:12 to 6:12	8 inches on center
Greater than 6:12	12 inches on center

Fasteners should be placed in the center of the corrugations, and they should be driven in straight. Overdriving fasteners can damage the roofing material.

In addition to the fasteners listed above, it is also recommended to use ridge caps and flashing to seal the roof and prevent leaks.

Installing Ridges and Flashings

Installing ridges and flashings is a crucial step in completing your corrugated roofing system. Here’s a detailed guide to ensure a watertight and durable roof:

Ridge Caps

Ridge caps cover the peak of the roof, where two roof panels meet. They prevent water from penetrating and ensure a smooth transition between panels.

Position the first ridge cap at one end of the ridge and secure it using roofing screws.
Overlapping the next ridge cap by 6-12 inches, slide it into place and fasten it.
Continue installing ridge caps along the entire length of the ridge, ensuring proper overlap.

End Caps

End caps seal the exposed ends of the roof panels. They prevent water infiltration and provide a finished look.

Measure and cut end caps to the appropriate length.
Slide the end caps over the exposed end of the roof panel and secure them using roofing screws.
Ensure that the end caps overlap the ridge caps for added protection.

Side Flashings

Side flashings are strips of metal that are installed along the sides of the roof, where it meets walls or other structures. They prevent water from seeping through gaps and ensure a weathertight seal.

Measure and cut side flashings to the desired length.
Fold one edge of the flashing over the top of the roof panel and secure it using roofing screws.
Bend the other edge of the flashing downward against the wall or structure and fasten it.
Overlapping the adjacent flashing by 4-6 inches, continue installing side flashings along the entire length.

Component	Function
Ridge Caps	Cover the peak of the roof and prevent water penetration
End Caps	Seal the exposed ends of the roof panels and provide a finished look
Side Flashings	Prevent water infiltration along the sides of the roof and ensure a weathertight seal

Sealing Seams and Joints

Properly sealing seams and joints is crucial to prevent water infiltration and ensure a watertight roof. Follow these steps to achieve a weatherproof seal:

1. Clean the Surfaces

Remove any dirt, debris, or rust from the surfaces to be sealed.

2. Apply a Primer (Optional)

Apply a rust-resistant primer to the exposed metal surfaces to enhance adhesion.

3. Use Self-Tapping Screws

Secure the corrugated panels using self-tapping screws with neoprene washers or rubber grommets. The screws should be driven through the peaks of the corrugations.

4. Apply Sealant

Apply a generous bead of sealant along the overlapping edges of the panels and at the joints between the panels and roof penetrations (e.g., vents, chimneys).

5. Install Overlap Flashing

For roof penetrations, install flashing over the sealant and extend it over the surrounding corrugated panels.

6. Seal Lap Joints

For side lap joints between corrugated panels, apply a wide strip of self-adhesive bitumen tape or use mastic sealant to create a waterproof seal.

7. Cover Seams with Trim

To enhance the seal, cover the seams with corrugated trim that overlaps the edges of the panels. Secure the trim using self-tapping screws and sealant.

Flashing Details

Type of Penetrations	Flashing Details
Vents	Install a saddle vent over the roofing and use flashing tape or mastic sealant to create a watertight seal.
Chimneys	Install a cricket or saddle flashing around the chimney and extend it over the corrugated panels.
Pipe Vents	Use pipe flashing specifically designed for corrugated roofing and seal the base with sealant.

Using Proper Safety Equipment

Before beginning any roofing work, proper safety equipment must be worn. This includes gloves, safety glasses, ear protection, and appropriate footwear.

Gloves: Use heavy-duty work gloves to protect your hands from sharp edges and debris.

Safety Glasses: Wear safety glasses with side shields to prevent debris from entering the eyes.

Ear Protection: Use earplugs or ear muffs to protect your hearing from noise generated by power tools and heavy equipment.

Footwear: Wear sturdy work boots with non-slip soles to prevent falls.

Additional Tips:

Inspect all tools and equipment before use to ensure they are in good working order.
Follow the instructions provided by the manufacturer of the roofing materials.
Be aware of your surroundings and watch for potential hazards.
Use a ladder rated for the height of the work area.
Do not work on the roof in inclement weather.

Types of Roofing Nails

Corrugated roofing panels come with a variety of different types of nails. The type of nail you use will depend on the type of roofing panel you have and the climate where you live.

The following table lists the most common types of roofing nails and their corresponding uses:

Nail Type	Use
Galvanized Nails	Galvanized nails are the most common type of roofing nail. They are made of steel that has been coated with a layer of zinc to prevent rust. Galvanized nails are suitable for use in most climates.
Stainless Steel Nails	Stainless steel nails are more expensive than galvanized nails, but they are also more durable. Stainless steel nails are not subject to rust and can withstand harsh weather conditions.
Aluminum Nails	Aluminum nails are lightweight and corrosion-resistant. They are a good choice for use in coastal areas or other areas where the climate is harsh.

How To Attach Corrugated Roofing

Corrugated roofing is a popular choice for many types of buildings, including sheds, garages, and barns. It is a relatively inexpensive and easy-to-install material that can provide years of protection from the elements. If you are planning to install corrugated roofing, it is important to follow the manufacturer’s instructions carefully. However, here are some general tips on how to attach corrugated roofing:

Start by measuring and cutting the roofing panels to the desired length. The panels should overlap each other by at least 6 inches at the sides and 12 inches at the ends.
Install the roofing panels by starting at the bottom edge of the roof and working your way up. Secure the panels to the roof rafters with screws or nails, spacing them about 12 inches apart.
Overlap the panels by at least 6 inches at the sides and 12 inches at the ends. This will help to prevent water from leaking into the building.
Seal the seams between the panels with roofing cement. This will help to keep water out and prevent the panels from shifting.
Install flashing around the edges of the roof, chimneys, and other openings. This will help to prevent water from leaking into the building.

Once you have installed the corrugated roofing, it is important to inspect it regularly for any damage or loose panels. Repair any damage promptly to prevent water from leaking into the building.