Sundance Supply, LLC

Base & Cap Installation

Also see details on web site for proper install.

To order Polycarbonate and Base & Cap see > sundancesupply.com

Note: We do not sell framing or ridge flashing material, shop local. Install 8, 10, 16 or 25mm polycarbonate on structures with horizontal purlins set above rafters & posts, arched roofs or metal building frames. Base attaches to roof purlins & wall girts. Base may also be attached to vertical rafters & posts, proper blocking required for Load Support. - Cover a greenhouse, pool enclosure, large skylight or metal building frame. - Rafter & Post framing lets inner sheet condensation move past blocking. If condensation an issue on Purlin & Girt structure choose 16mm. 25mm best for high humidity pool enclosure. Easy-To-Install. Attach Base to purlins or rafters, lay on Polycarbonate & attach Cap. Leakproof. Aluminum Cap seals tight on polycarbonate. Cap Screws set quickly. Cap screws seal tight. Versatile. Specify Polycarbonate thickness & Cap Screw length will accommodate. Strong. Structure of aluminum Base profile will span over and attach to purlins, see load chart p 3.

Roof Access Notes for Install on Horizontal Purlin & Girt or Rafter & Stud Frame: Access to roof for Cap, screw & sealant placement on flashing done from step ladder positioned where polycarb. not set. Install of 1st & last sheet done by placing ladder outside structure. Work from upper step so you can reach over sheet. 4 foot wide sheets easier to reach over to set screws and are best for roof applications. Start at one end of the structure, work towards other end. Do all steps as you go and it will not be necessary to gain access to the roof again. Clean sheet with a hose. Do often. Access to the ridge to install and/or seal the flashing may also be achieved by placing 3 x 4 sheets of plywood, with Non-Slip Rug Padding glued to the back, over the installed polycarb. Select a construction grade spray glue for best results. Advance planning to proceed as described in the previous paragraph may result in an easier installation. Your situation and skill level will dictate the best way to proceed.

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General Install Note: Sheet must be supported on all 4 edges with a min. of 1/2" of sheet bearing on the Base or frame. When using sheets that are cut along the width, and no longer have a rib at the edge, position sheet so first rib is supported by a minimum of 1/2". For high winds see P 14. Position sheet so UV protected side faces sun and remove film from Both Sides of sheet prior to installation. Screw counting and attaching procedure for screws attached along perimeter of roof & walls, thru Corners and thru Flashing. For Horizontal Purlin & Girt or Rafter & Stud Framing:

#10 x 2" wood or #12 x 1-1/2" self-drilling metal screws with 3/4" sealing washers are used when screwing through 8mm, 10mm & 16mm polycarbonate. #10 x 2-1/2" wood or #12 x 2" self-drilling metal screws with 3/4" sealing washers are used when attaching through 25mm polycarbonate. Roof Use 1 screw per foot along the top edge of roof slope. Set screw through ridge flashing and into purlin or blocking below. Use 1 screw per foot along the lower edge of sheet, positioned between Base & Cap. Aluminum Corner Trim (use 1 screw 2" from ends and every 12" along each leg of Corner). Walls Aluminum Corner Trim (use 1 screw 2" from ends and every 12" along each leg of Corner). On side or front walls, use 1 screw per foot along the top & bottom edge of sheet, position between Base & Cap. Screw goes through sheet and into girts or top & bottom plates. On gable ends, with Corner Trim at top of sheet, place 1 screw per foot along the bottom edge of sheet, position between Base & Cap. Screw goes through sheet and into girts or bottom plates. See above for screw placement in Corner Trim. Around Doors, Windows, Fans & Shutters 1 screw every 12" around perimeter of these items as needed. Cover cut edges with U-Profile.
Note: Screws provided with Base & Cap System to attach Base to Frame and Cap to Base. Screws to hold on U-Profile also provided. Base screws are attached to roof purlins and wall girts (or rafters & studs) as laid out in your design. Cap screws positioned 1-1-2" from ends and about every 12" on-center. Installation Tools & Supplies: - Marking Pen (medium point for laying out cuts on plastic film that covers polycarbonate) - Saw Horses & Planks (for laying sheet on when cutting) - Circular Saw and fine tooth plywood blade for cutting polycarbonate, or - Jig Saw with Fine Blade (option to using a circ. saw for polycarbonate, best for curved cuts) - Utility Knife & Sharp Blades (change often when cutting 8mm polycarb. for quick, safe cuts) - Fine Tooth Key Hole Saw (for cutting fan opening in sheet if jig saw not available) - Power Miter Box with fine tooth blade (for cutting extrusions) - Hacksaw (optional method of cutting extrusions) - Vacuum or Blower (for cleaning polycarbonate chips from center of sheet) - Straight Edge (for cutting polycarbonate when using a utility knife) - Spring Clamps w/rubber tips (for holding straight edge when cutting sheet) - Cordless Drill w/ adjusting chuck for driving screws to proper tightness or Socket Wrench - Magnetic Hex Head Drivers & 1/16", 3/16", 1/4" sharp steel cutting drill bits - Caulking Gun - Satin Spar Varnish or Verithane: Coat surface poly. rests against to protect wood. Prior to poly install, moisten rag with ArmorAll and run only along exterior of frame and Base that comes in contact w/ poly. Lube helps free poly for expansion and contraction. If you order 10 sheets or longer, order form sends an email that presents a foam tape option and easy order process. ( See p 14 & 15 ) Remember, bronze poly. moves a lot. (2)

Method #1 - Install Over Roof Purlins or Wall Girts. Read before install.

Recommended Purlin/Girt Spacing to Support Load, 48" wide Sheet, lbs. per sq. ft.
Purlin/Girt Spacing 8mm 10mm 16mm 25mm 6-Wall 25mm X-Wall 48 15 lbs. 20 lbs. 30 lbs. 45 lbs. 60 lbs. 45 20 lbs. 25 lbs. 35 lbs. 52 lbs. 69 lbs. 42 25 lbs. 30 lbs. 40 lbs. 60 lbs. 80 lbs. 36 30 lbs. 35 lbs. 50 lbs. 70 lbs. 93 lbs. 30 28 Bending Radius 8 feet 8 feet 9 feet 15 feet
Do Not Bend

35 lbs. 40 lbs. 50 lbs. 60 lbs. 65 lbs. 75 lbs. 80 lbs. 90 lbs. 106 lbs. 120 lbs.

Load in lbs./sq. ft. Roof slope over 7/12 snow tends to slide off. Spacing may be relaxed. No specs available

A. Place 1st panel A (in some cases cut to size) on roof purlins or wall girts. Dimension from outside of structure to center of 1st or last Base 48-1/2". First and last is less if sheet to overhang gable end. Intermediate Base 48-3/4" to 49" on-center. Then cover with Corner (see "B" above). B. Place Base C adjacent to panel & fasten with base screws to roof purlins or wall girts. Predrill holes in Base with 1/4 bit. Use care to set wood screws lightly by adjusting drill clutch to low setting and tapping on trigger. These screws are corrosion resistant, 300 series stainless steel, are relatively soft, but will not be adversely effected by pressure treated wood or react with aluminum. If a screw snaps it means the wood is too hard, pre-drill a 3/32 pilot hole. Leave about 1/8" between edge of sheet & vertical post in center of Base. Sheet should extend 1/2 past lower edge of roof Base & 3/4 past wall top and bottom of Base on walls, allowing for placement of U-Profile (drawings on following pages). At gable end, on the vertical surface, extend Base to top (3)

of frame, Corner Trim covers top of sheet. Aluminum tape covers sheet end under Corner, not UProfile. A rib of polycarb. sheet must bear a minimum of 1/2" on Base for proper support. C. Place the next panel D in the open side of Base Extrusion. D. Fasten Cap E to Base (over the 2 panels) using #2 phillips bit in portable drill. Cap screws positioned 1-1-2" from ends & every 12" on-center (see p. 14 if over 90 mph wind). Predrill 3/16" hole in Cap as required. Set clutch for snug fit, using care to not strip screw head or threads. Position drill perpendicular to screw for proper alignment of screw. Continue with other sheets. E. Fasten Corner Trim and U-Profiles according to appropriate drawing/s presented in this manual. Also see notes on screw counting and attaching on page 2. Please note all Base & Cap and small screws to hold U at lower edge of roof are included with your order. U-Profile is used at lower edge of roof sheets, top and bottom of side walls (freestanding structures) or front wall (attached structures), bottom of gable end walls and around doors, fans & shutters. Corner Trim used where roof meets gable end and on wall corners.

Method #2 - Install Over Roof Rafter & Wall Studs. Read before install.
Recommended Rafter/Stud Spacing to Support Load, 48" wide Sheet, lbs. per sq. ft.
Blocking Placement Poly. Rafter/Stud Spacing 35 lb. load 45 lb. load 60 lb. load 80 lb. load 8mm 48-3/4" to 49" every 2.5 ft. every 2 ft. do not use do not use 10mm " every 3 ft. every 2.5 ft. do not use do not use 16mm " every 4 ft. every 3 ft. every 2.5 ft. every 2 ft. 25mm 6-Wall " every 5 ft. every 4.5 ft. every 3.5 ft. every 3 ft. 25mm X-Wall " every 6.5 ft. every 6 ft. every 4.5 ft. every 4 ft. 100 lb. load do not use do not use do not use every 2.5 ft every 3.3 ft

Load lbs./sq. ft. Roof slope over 7/12 snow tends to slide off. Spacing may be relaxed. No specs. Horizontal blocking (see above) required for load support. For condensation movement past blocking, set 1/4" back from outer surface of frame, place spacer in middle of blocking. Or place vertical members between rafters or studs to support sheet. With intermediate vertical members horizontal blocking most often eliminated, vertical member supports mid-sheet load. On loads of over 45 lbs. per sq. foot, with 8 or 10mm, place horizontal block every 8 feet.

1/4"

2x wood rafter

Blocking and 3/8" x 1" Neoprene Spacer set 1/4" from top of framing, spacer in center of blocking. Use min. 2 x 2 wood or 1.5" x 1.5" metal tube

2" x steel or alum. rafter

48 3/4" to 49" for 48" polycarbonate sheet

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A. Place 1st panel (in some cases cut to size) on roof rafters or wall studs. Dimension from outside of structure to center of 1st or last Base (rafter or stud) is 48-1/2". Then cover with Corner (see page 10). First and last Base position is less if polycarbonate sheet to overhang gable end. B. Place Base adjacent to panel (over roof rafters or wall stud) & fasten with base screws to roof rafter or wall stud. Predrill holes in Base with 1/4 bit from end and every 12 on-center. Use care to set wood screws lightly by adjusting drill clutch to low setting and tapping on trigger. These screws are corrosion resistant, 300 series stainless steel, are relatively soft, but will not be adversely effected by pressure treated wood or react with aluminum. If a screw snaps it means the wood is too hard, pre-drill a 3/32 pilot hole. Sheet should extend 1/2 past lower edge of roof Base and 3/4 past wall top and bottom of Base on walls, allowing for placement of U-Profile (see drawings on following pages). At gable end extend Base to top of frame, Corner Trim covers top of sheet. Aluminum tape covers sheet end under Corner, not U-Profile. Note: A rib of polycarbonate sheet must bear a minimum of 1/2" on the Base for proper support. ( With vertical running rafters & studs Intermediate Base positioning is 48-3/4 - 49" on-center.) C. Place the next panel in the open side of Base Extrusion. D. Fasten Cap to Base (over the 2 panels) using #2 phillips bit in portable drill. Cap screws are positioned 1-1-2" from ends and about every 12" on-center. Predrill 3/16" hole in Cap as required. Set clutch for snug fit, using care to not strip screw head or threads. Position drill perpendicular to screw for proper alignment of screw. Continue with other sheets. E. Fasten Corner Trim and U-Profiles according to appropriate drawing/s presented in this manual. Also see notes on screw counting and attaching on page 2. Please note all Base & Cap and small screws to hold U at lower edge of roof are included with your order. U-Profile is used at lower edge of roof sheets, top and bottom of side walls (freestanding structures) or front wall (attached structures), bottom of gable end walls and around doors, fans & shutters. Corner Trim used where roof meets gable end and on wall corners. Note: Base and Cap screw positioning decreased in high wind areas (see p. 14 if over 90 mph wind). General Install Note, for installing polycarbonate: Local building dept. can provide snow & wind loads for your areas The ability to support a specific snow load is a factor of frame strength and polycarbonate sheet rigidity. Wind load requirements are usually met by following standard screw placement guidelines as shown in the Installation Details. Cap receives screws at ends of each piece and every 1 ft. on center. When fastening Corner Trim or through polycarbonate (adjacent to U-Profile), screws with 3/4" sealing washers are to be set at corners of glazed areas and every 1 ft. on-center. For placement of screws in body of the sheet see Polycarbonate Positioning & Attachment (p 6). Difficulty getting the bldg. dept. to approve plans? Stress the frame is designed to support the load. Polycarbonate is a skin material only. If needed, suggest extra purlins or blocking to decrease unsupported panel size by 50%. Screw pattern can be increased for extreme high wind areas. See Structural Load on page 14. (5)

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Ridge Flashing Installation: Flashing sections, as detailed below, are typically fabricated in 8 ft. sections. There are two ways to proceed with the installation of flashing. 1) The easiest method of installation is to set and screw down a section of flashing that covers the first sheet of polycarbonate (on freestanding greenhouses install sheets on both sides of the greenhouse). Cut notch in flashing as shown on page 8. Set screws so flashing presses against polycarbonate, place a bead of sealant at this point and stop there. Lay the next sheet of polycarbonate and Cap. Now screw down the flashing and place a bead of sealant along the edge of flashing that comes in contact with the polycarbonate, and also where the Cap comes in contact with flashing. Continue installing more polycarbonate and flashing. Overlap seams in flashing a minimum of 4". Do not cut to length as this will create a slight curl at cut & an uneven overlap. If the overlap ends up being 4 ft., so be it. This method provides a watertight installation, but care must be taken to lay a smooth bead of sealant on a cleaned surface.

Screws with washers go through ridge flashing every 12 on-center. Drawing shows install on roof purlin. If using rafters a beveled ledger board is required. (7)

Detail similar for purlin or rafter style framing. If using rafters drawing shows blocking. 2) A more difficult, but a cleaner looking, tighter install involves installing the flashing after all sheets set. See Lean-To Ridge and Freestanding Ridge details. This involves acquiring access to ridge with all poly in place. As mentioned in Roof Access Notes, page 1, this can be tricky and is best performed by individuals accustom to working on roofs or in situations where balance and care during installation is second nature. If working on an attached greenhouse you may be able to gain access to this detail from the roof of the adjoining structure.

Ridge Flashing

Notch

Sealant Cap (at sheet seams)

When installing the flashing, first lay in place and mark where the flashing overlaps the Cap at sheet seams. Notch the flange at these locations to fit the Cap. When installed, flashing will rest flat on the polycarbonate and Cap. Failure to cut out for the Cap will result in a gap between the polycarbonate and the flashing, wavy looking flashing and a poor weather seal. Overlap seams a minimum of 4". Do not cut to length as this will create a slight curl at the cut and an uneven overlap. If the overlap ends up being 4 ft., ok. The only cutting required is an easy to cut, curved notch where Cap slides under the flashing. (8)

Purchase flashing from sheet metal fabricator. Do simple scale drawing showing dimensions, angle, etc. At edge of flashing that covers the poly we suggest a 1/2" long bend (flange). Draw so legs of flashing are tilted down 5 from actual pitch of your roof. This creates a small amount of pressure against the poly sheet, useful in achieving a watertight installation. Sheet metal should be a minimum of .019" aluminum or 30 gauge steel. Aluminum is easy to fasten through, easy to cut, but a little flimsy. Care is required in handling. Steel is more sturdy, harder to cut and requires predrilling prior to fastening. Availability may be the limiting factor. Look in the Yellow Pages under Sheet Metal Work. Some shops, especially those that cater to glass installation contractors, will inventory bright glossy white and architectural medium bronze sheet metal in the thickness you will be looking for. These colors will be a close match to the Aluminum Trim Components we offer. Sealant Selection & Application: Silicone used below eave, along Lean-To & Freestanding Ridge Flashing and interface between U-Profile and Existing Wall, see p 10. Also close end of Cap, p 16. Use 100%, silicone. 1/4" bead best. When splicing Cap or Corner place 1/4" bead of silicone over joint. Clean joints with rubbing alcohol and let dry. Gently tool bead flat with saliva covered finger. Do not place finger in mouth after tooling. Sealant is sticky, somewhat toxic. Joints at interface of Trim Components should be clean & securely fastened. Make sure U-Profile is butted tightly so spiders do not get in. Allow sealant to dry 24 hrs. before cleaning the polycarbonate and metal. Commercial Grade Dow 999-A Clear Silicone is available through Sundance Supply, LLC. Calculate running ft. of silicone required for project. One tube will do 25 feet of a 1/4 bead.

Detail similar for purlin & girt or rafter & stud style framing. (9)

Roof Corner and Wall Corner detail similar for purlin & girt or rafter & stud style framing. On purlin & girt style framing detail shows blocking laid between either purlin or girt. Lower Edge drawing shows install on wall girt or bottom plate, purlin & girt or rafter & stud style framing. U-Profile can also be used to close polycarbonate edges at top and end of walls. Gable install similar for purlin & girt or rafter & stud style framing. ( 10 )

Roof Valley & Poly. to Existing Roofing: Adhesive Roll Flashing (shown above & to the right) has 15 mil Butyl Adhesive (facing down) and a Aluminum backing (that faces the sun). For wider than 3" areas simply overlay. Make sure polycarbonate is securely fastened to the structure with the screws we sell. Surfaces must be clean and free of moisture and contamination. Do Not Stretch during application. Peel off a few inches of release liner. Apply exactly the first time and do not stretch. Press down firmly at the center and work towards the edge, removing bubbles. Edges must have no openings, tunnels or fishmouths. ( 11 )

See Load & Bend Radius Page

Purlin Bow Purlin Polycarbonate

At lower edge attach thru Cap, Base and into purlin for strength.

See Load & Bend Radius Page

Bow

Limit arched roof to 24 ft. or use 2 sheets as shown in Arch-Quonset Ridge Detail. For sheets longer than 24' add extra purlin where the two Base extrusions are spliced. Bending poly increases load. Purlin spacing can be further apart. Note, strong winds can lift sheets off so do not deviate far from spacing in load chart.

Base & Cap Splice on Purlin Frame: Same if joint is on continuous rafter.
Butt Base lengths and cover joint with silicone. Cap Butt Cap lengths at another location so that joints do not line up. This will create a stronger splice.
Purlin Base

Poly

Attach each Base with two screws if fastening to arch.

Load chart & bend radius on p #3

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Structural Loads & Special Screw Positioning for High Wind Areas.
Structural Loads are stresses to structure from external or internal forces. Dead loads are gravity loads that are constant throughout the structure's life. These include equipment such as fans, heaters and plants suspended from the frame. Live loads are temporary, such as snow loads and wind loads.
Snow loads are determined by factors influencing snow & ice accumulation on structure. Snow loads vary considerably by geographic location. Ask your local bldg. dept. for snow load in your area. ( 12 inches of light, fluffy snow or 2 to 4 inches of heavy, wet snow = about 5 lbs per sq. ft.)

Wind loads come from any direction, usually hit side walls perpendicular, most stress at edges. Figures are in lbs. per sq. ft

Wind

85 mph 90 mph 18 20

100 mph 25

120 mph 36

130 mph 43

140 mph 48

150 mph 56

160 mph 85

Above wind load figures provided by SABIC Innovative Plastics, the Lexan manufacturer. Wind speeds up to 90 mph: Screws with 3/4" sealing washers are to be set at corners of glazed areas and every 1 ft. on-center. Base & Cap System: Screws provided with system to attach Base to frame and Cap to Base. The Base, Cap and Corner receive screws at ends of each Trim piece and every 1 ft. on center. In winds of 110 mph+ decrease distance between screws to every 10". In winds of 125 mph+ increase screws to every 8 inches. In winds 135 to 150 mph increase screws to every 6 inches. In winds over 110 mph always consult with engineer to receive a stamp and bldg. dept. approval. For placement of screws in body sheet see Polycarb. Position & Attach, page 6. Increase quantity of screws in mid sheet, horizontally across sheet, to every 12" for wind speeds 110-130 mph. 10" for wind speeds 131-150 mph. Combination loads are common. For example, a snowstorm may include high winds. If bldg. dept. says design for a 45 lb. snow load & a 90 mph wind, snow will effect the roof with a 45 lb. load and wind will effect roof with a 20 lb. load. To safely design your roof framing, take the 45 lb. snow load, add 20 lbs. for positive loading effect the wind may have on the roof. Design for a 65 lb. load.

The expansion and contraction of poly can create noise, follow instructions below.
ON SHEETS LESS THAN 10 FT. - TAPE IS NOT REQUIRED PUT ArmorAll ON ALL SURFACES POLY COMES IN CONTACT WITH. Purchase poly sheets 10 ft. or longer and Order Form sends an email that presents foam tape option to help eliminate noise due to expansion and contraction of poly. An ordering option is presented. Simply follow the process. Foam tape gets applied as shown on next page for Cap & Trim System and Base & Cap System. In Base there is a 1/2" channel to place tape in. Use care to not overlap 1/4" shelf to right & left of channel. Purlin & Blocking Note: Tape also required on purlins or blocking that comes in contact with poly. Place row along top & lower edge of purlin or blocking. Foam tape online order form will not calculate quantity of tape required for purlins or blocking. Simply calculate needs and enter in form where it says "Add desired number of Additional Boxes of 6 Rolls in field to right:" Rolls are 108 ft., 648 ft. per box. 1 Box minimum. The expansion and contraction of aluminum is seldom a problem. Simply exercise common sense. Example: If it is 0 outside and you are butting the end of an aluminum extrusion to a wall leave a gap between the end of the extrusion and the wall. Bridge gap with a bead of appropriate sealant, creating an expansion joint. As the temp rises aluminum will expand into the joint.

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Sheets less than 10 No Tape Required. Put Armor-All on surfaces poly in contact with. ( 15 )

Notes: To seal ends of Cap fill with silicone. Not crucial in vertical applications, unless subject to direct rain. We highly recommend Dow 999 Plastic Compatible Silicone

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Install Policy - Important for novice builders. Crucial for Seasoned Builders:
Sundance Supply, LLC goes to great lengths to provide complete install guidelines for the Cap Only and Base & Cap Systems. Often customers do not follow install instructions and problems occur such as leakage, noise, excessive flexing of the sheet, etc. By placing an online (or faxed in) order customer agrees to policies via electronic (or physical) signature. In doing so, in regards to install, customer agrees to follow install guidelines and details or be fully responsible for adverse consequences due to not following instructions. If problems occur with materials at time of install Contact Us Immediately. Proceeding with your own solution could easily create more problems and may actually void polycarbonate warranty. Always avoid direct contact with PVC films or tapes. Plainly said, Sundance Supply, LLC is not responsible for any unfavorable situations created by customer not following install guidelines and details. Blocking & Purlins: These terms can have different meanings in different areas of the country and in different trades. To ensure successful framing and installation of polycarbonate, using our Cap Only or Base & Cap System, it is crucial that we agree upon One Definition. Below is how our details and printed material uses these terms. Blocking is a small (horizontally running) framing member that is positioned "Between" rafters or studs, and is on the same plane. This framing member is used in Cap Only frames and also Base & Cap frames. Purlins are long (horizontally running) framing members that are "Placed on the Outer Surface" of rafters, trusses, posts or other main frame elements. This framing member is used in Base & Cap frames only. The Base extrusion has sufficient strength to carry the load, acting as a structural support member, supporting the polycarbonate at sheet joining locations. Always refer to load charts for proper spacing of purlins. Girts are simply purlin like items that are on the walls. Purlins are technically on the roof. Terminology in General: Kindly refer to our product information and use our terminology in conversation with us and in your plans. Very Expensive mistakes have been made by customers using terms that are appropriate for other products and in other trades, or terms that are common in certain regions, but are not the terminology we use. We use standard architectural terminology and terms specific to our products. For this design and construction process we request your gracious compliance to our terminology. Often people call the U-Profiles - Caps instead. They are thinking the U-Profile shape but order Caps. Given that returned aluminum always arrives damaged, we do not accept returns. A costly mistake that can easily be avoided. Kindly go thru the 3-Step Process - This is easy if you take the time. Simple yet crucial. This will answer all your questions & help you quote your project. #1. Select Poly #2. Choose Install Method #3. Quote Online. Order if you choose.

You learn the required info and help keep prices low for everyone. Please do your part. Best of luck with your project. We look forward to being of service. ( 17 )