Sundance Supply, LLC

"Cap Only ( & Trim ) " Installation

To order Polycarbonate & Aluminum see > http://www.sundancesupply.com

See Web Site Step #2 Choose Install System Cap Only - For All Install Details.
(Also read instructions printed on the film that covers the sheet, for proper placement.)
Note: We do not sell framing or ridge flashing, shop local. Store poly out of sun or film will stick.

Cap & Trim Specification: When properly installed, these components will provide an attractive
and watertight skin for your greenhouse. The details on the following pages illustrate usage of the
components in most of the common applications. The drawings below indicate details that
correspond to a specific location in a greenhouse, sunroom or similar structure. Letters
correspond to details on next page. Also see details on our web site to ensure proper install.
For Ends of Cap detail that shows interface of Cap & U-Profile see page 13.
Screw Counting Procedure: Basically place one screw every 12" along Cap & Corner face
(Cap requires 9 screws, Corner 18). Screw every 12" along perimeter of roof & walls, Details
show screw placement. !!!!Screws also used at mid-sheet, as shown on page 6.

Freestanding

H
A
D
C
A

Attached
(Lean-To)

E
B

A
F

Note: Use of U-Profile around doors,

windows, fans and inlet shutters is
highly recommended. See next page
for typical installation details.

A
E
B

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(2)

Cap
(at sheet
seams)

Double Slope
Rafter Detail:

Angle Wall or Hipped Roof:

Screw & Washer 12" O.C.
(no silicone required)

U-Profile
3/8" Self-Drill
Screw place
8" on-center

Screws &
Washers
12" O.C.

weep holes

Silicone
135
Mimimum
Angle

Cap
(at sheet
seams)

Roof Valley: Sheet Joining

Custom Flashing: Minimum of .019" aluminum
or 30 gauge steel. Do color match.
Sikaflex 295 UV

Poly to existing roof: Top, sides & lower edge

Note: Drawings below show poly shingling over roofing below.
One may also set poly. at same level as surrounding plywood
sheathing and continue to eave, effectively shedding water.

silicone
Double layer o f
adhesive roll
flashing

adhesive roll flashing

covered w / metal flashing

roof sheet

roofing

Screw & Washer

12" O.C.
plywood

Screws
12"
O.C.
Sides
& Top

Joint sealed with double layer of Roll Roof Flashing

with butyl adhesive on side facing Polycarbonate.
An aluminum backing faces the weather.
Cover with flashing, see above.
See local custom sheet metal shop for fab.

Note: Close poly.

channels with alum.
tape at top edge.
Flashing may be
adhered to top of
roofing if this works
best in your situation.
U-Profile

Roof Valley & Poly. to Existing Roofing:

silicone

Adhesive Roll Flashing (shown above & to the right) has

a 15 mil Butyl Adhesive (facing down) and an Aluminum
backing (that faces the sun). For wider than 3" areas
simply overlay. Make sure the polycarbonate is securely
fastened to structure with screws we sell. To purchase
see the Hardware Section of our Online Order forms.

roof sheet

Screws
12"
O.C.
Lower
Edge

Surfaces must be clean and free of moisture and

contamination. Do Not Stretch during application.
Peel off a few inches of release liner. Apply accurately
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.

adhesive roll
flashing covered
w/ metal flashing

plywood

roofing

Note: Drill 1/16" holes,

12" O.C., in U-Profile
for moisture release.
Place silicone after
sheet screwed down.

Flashing: Have local sheet metal shop fabricate flashing for your specific needs. Use sturdy gauge material.
U-Profile: U-Profile requires a 1/16" weep hole, every 12" along lower edge, for moisture release.
Satin Spar Varnish or Verithane: To protect wood, coat only surface of wood that polycarb. comes in contact with.
ArmorAll: Moisten rag, run along exterior edge of frame for ease in expansion, after varnish completely dry.
Order 10 ft. sheets & order form sends you an email presenting a foam tape option. Remember bronze moves a lot.

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Typical Framing Layout For Cap & Trim Over Wood Frame
Sloped (roof) Sheet or
Front Wall Sheet (lean-to)
Side Wall Sheet
(freestanding)

(Standard 48" or 72" Polycarbonate Sheets)

Spar
Varnish

24 1/8"

24 1/8" O.C.

24 1/8" O.C.

24 1/8"

End wall framing determined by wall size. Maintain 1/4" space between sheets. Place studs as needed.

Or set intermediate rafters & studs 48-1/4" on-center. First & last member 48-1/4" from outside of frame
to center of 1st or last rafter or stud. First and last less if sheet to overhang gable end. Poly sheet must
be supported on all 4 edges, with min. 1/2" of sheet bearing on frame. When using sheets cut along the
width, and no longer have a rib at the edge, position so first rib supported by minimum of 1/2" of frame.

Lean-To (attached)
Greenhouse
U-Profile

ledger
board

blocking

Cap

U-Profile

Corner
Trim

Corner
Trim

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Flashing

Freestanding Greehouse

U-Profile
blocking

blocking

End
Wall

Cap

Side
Wall

U-Profile
Corner
Trim

Corner
Trim

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
Jig Saw with Fine Blade (option to using a circ. saw for polycarb., best for curved cuts)
Utility Knife & Sharp Blades (change often when cutting 6, 8mm poly. 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 to drive screws to proper tightness or Socket Wrench
Magnetic Hex Head Drivers & 1/16", 3/16", 1/4" sharp steel cutting drill bits
Satin Spar Varnish or Verithane: Coat surface poly. rests against to protect wood.
On sheets less than 10 ft, prior to poly install, moisten rag with ArmorAll and run only along exterior of
frame that comes in contact with 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.
( See p 12 ) Remember, bronze poly. moves a lot.
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(6)

Multi-Wall Polycarbonate and Cap Only ( & Trim ) Installation

Read entire section carefully. Plan sequence of steps for install. See drawings on page 2.
Letters in brackets below, identify relevant drawings, also on page 2.
On sheets less than 10 ft, prior to poly install, moisten rag with ArmorAll and run only along exterior of frame that
comes in contact with 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. (See p 12 ) Remember, bronze poly. moves a lot.
Screws: See drawings on page 2, basically 12" on-center along Cap, Corner & U-Profile (set in).
Sealants: See p. 10, Sealant Selection & Application, to achieve watertight integrity.

1. Procedure
Wall Installation Overview: Inspect frame for proper on-center placement, blocking, etc. Walls are
generally covered first. Begin with either the end walls or the side walls (front wall for lean-to
greenhouses). Corner Trim is installed after all polycarbonate is in place, { D & E }. Use
aluminum tape on the top edges of the end wall sheets, { D }. The lower edge of the sheet is
capped with the U-Profile, { B }. Drill 1/16" weep holes, 12" on center, prior to installing U-Profile.
With protective film still on sheet, cut sheets to length, (width if required). Removal of film creates
static electricity. Always remove film, from both sides of sheet, after cutting is done and away
from any dust and dirt that may be attracted. Shake sheet and vacuum or blow out channels to
remove cutting shavings prior to installation. Movement of condensation through layers will
continue cleaning cavity over time, but get as clean as possible. Custom cut and install end wall
sheets, one at a time, so top and lower edges remain consistent.
Use U-Profile on open channel edges next to doors, windows, etc. Cut out fan opening, after the
sheet is attached. Drill holes at corners of opening. Use jig saw or fine tooth key hole saw to
make cuts. Inlet shutters typically at lower edge of sheet, cut out made prior to sheet installation.
Start at one end. Prior to installing polycarbonate (after sheet cut), look for printing on sheet that
indicates which side faces the sun, peel protective film off Both Sides of the sheet, remembering
which side faces the sun. Position sheet on frame. Check for proper alignment and minimum
sheet bearing on frame. Drill 1/4" pilot holes in sheet and attach to frame at mid-sheet fastening
points, via screws with sealing washers. Install screws snug, not too tight. Once confident
position correct install remaining screws in upper, lower & mid points of sheet, firmly attach sheet
to frame. Attach adjacent sheet and cover the joint with Narrow Profile Cap { A }, sealing butt
joints of Cap as you go. See below and p. 6 cutting, mid-sheet fastening & attachment.
Narrow Profile Cap Installation - Drill 3/16" holes in Cap for screws to pass through. Start 1"
from ends of Cap & drill holes every 10-12". Attach Caps to frame. Butt upper edge of Cap
against any adjoining material. After poly & Caps in place, wipe Cap joints with rubbing alcohol.
Lay a bead of sealant to compensate for expansion-contraction. Screws to be snug, not too tight.
Cap now effectively covers both sheets, providing a clean, tight detail, { A }. Never place sealant
under Cap. When joining two lengths of Cap, butt them close together, cover Outside of joint with
a flat bead of sealant see p. 13. Install with 1/8" gap between two lengths of Cap if a cold day,
tight if a hot day. (see Expansion & Contraction note below or on next page). Sealant info p. 10.
U-Profile - Simply slid over ends of sheet as required, see Install Details for locations.
Corner Trim - Proceed in the same fashion as described above for Cap.
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Important Note - Expansion & Contraction of Polycarbonate and Trim Components.

Polycarbonate and aluminum will expand and contract at about the same rate. A movement of
1/32" per ft. of material during a 100 degree temperature swing is typical. Plan for expansion and
contraction along the length of each material. 8 foot Aluminum Trim installed during the summer,
when it is 90 degrees outside, will shrink 1/4" when the outdoor winter temperature reaches 20.
Provisions to accommodate for movement are fairly simple and straightforward. When installing
during the winter leave an 1/8 gap at joint, in summer butt tight. Cover joint with properly laid
bead of sealant, see p 10. Do not install so tight that polycarbonate can not expand & contract or
buckling can occur.
Roof Covering Installation: Follow wall procedures when preparing roof sheets. Start at one
end of roof & begin laying sheets. Top edge of roof sheets are most often closed with aluminum
tape, resting on blocking, { G & H }. Continue as described for wall sheets. After 2nd sheet set,
fasten Cap joining the 2 sheets { A } and seal joints (it is easy to reach now). Install lower UProfile & Corner Trim so it covers edges of the roof and end wall sheets { D }.

Roof Access Notes: Access to roof for Cap, screw & sealant placement on flashing
done from step ladder positioned in empty roof bay to left or right of already installed poly.
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 are 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 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.
Ridge Flashing: 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). Set screws so flashing presses against polycarbonate, place a bead of sealant at
this point { see G or H } and stop there. Lay the next sheet of polycarbonate and fasten the
Narrow Profile Cap so that it butts against the edge of the flashing that comes in contact with the
polycarbonate. 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 the 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.
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2) A more difficult, but a cleaner looking and tighter installation involves installing the
flashing after all sheets are set. See { G or H }. This involves acquiring access to the
ridge with all polycarbonate in place. As mentioned in the Roof Access Notes above, this
can be tricky and is best performed by individuals accustom to working on roofs or in
situations where balance and care during installation procedures is second nature. If you
are working on an attached greenhouse you may be able to gain access to this detail from
the roof of the adjoining structure. 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, the flashing rests flat on the polycarbonate and the 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 flashing 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 the Narrow Profile Cap slides under the flashing. See drawing below.

Ridge Flashing

Notch

Sealant
Cap
(at sheet seams)

It is best to purchase this flashing from a sheet metal fabricator. Do a simple scale
drawing that shows dimensions, angle, etc. At the edge of the flashing that covers the
polycarbonate we suggest a 1/2" long bend (flange). Draw so that the leg(s) of the
flashing are tilted down 5 from the actual pitch of your roof. This will create a small
amount of pressure against the polycarbonate 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 is a little flimsy and care is required in
handling. Steel is more sturdy, harder to cut and requires predrilling prior to fastening.
Availability at your local sheet metal shop 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, architectural medium bronze and
clear satin anodized sheet metal in the thickness you will be looking for. These colors will
be a close match to the Trim Components we offer.
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Sealant Selection & Application: Silicone used below eave { C }, along ridge flashing {G &
H} and at interface between U-Profile and an existing structure { F }. See Install Details page
online for more details and greater explanation. Use 100%, plastic compatible, silicone. 1/4" bead
best. When spicing lengths of Cap or Corner place a 1/4" bead of silicone at joint. Clean all
joints with isopropyl (rubbing) alcohol and let dry prior to applying sealant. Gently tool bead
flat with saliva covered finger. Joints at interface of Trim Components should be clean and
securely fastened. Make sure U-Profile is butted tightly so bugs do not get in. Clean joints with
rubbing alcohol and let dry prior to applying the sealant. Allow sealant to dry for 24 hours before
cleaning the polycarbonate and metal. Commercial Grade Dow 999-A Clear Silicone available
thru Sundance Supply, LLC. Calculate running ft. of silicone required for your project. One
tube will do 25 feet of a 1/4" bead. In high wind areas use Sikaflex 295 UV, not silicone, to bond
tip of Ridge Flashing to poly. See Install Details page online for Sikaflex Product Data Sheet.
2. Step-by-Step Polycarbonate Installation. An outline of procedure covered above.
Note: Protective film on sheet indicates side to face sun, remove film from both sides just before
install. Begin with walls. Prior to poly install, moisten rag with ArmorAll & run along exterior
of varnish coated frame that comes in contact with poly. Also coat tips of Cap. Lubricant
helps free poly expansion. If installing sheets 10 feet or over use foam tape, do not use
AmorAll. Order form will send you email that presents a foam tape option. See p 11 & 12.
Remember, bronze poly moves a lot.
1) Leave film on sheet. Cut sheets to length & width as required. Clean out channels.
2) Cover channels at upper edge of gable end wall sheets with Aluminum Tape, { D}. Top edge of
the roof sheets are also closed with aluminum tape, resting on blocking, see { G & H }. Top edge
of gable end sheets covered with the Corner Trim, { D }.
3) Position sheet on frame, so outer ribs are supported by minimum of 1/2" of frame.
4) Drill 1/4" holes in mid-sheet fastening points (see Position & Attach notes on p 6) and attach to
frame, using screws with 3/4" sealing washers. After you are assured of proper alignment of
sheet, make screws snug, but not too tight. Install remaining screws required in upper, lower and
mid points of sheet, firmly attaching sheet to frame. Install adjacent sheet in same manner.
5) Place Narrow Profile Cap at sheet joining locations, { A }. First drill 3/16" holes in Cap, 1" from
each end & every 10" - 12" on-center.
6) Install U-Profile as required. Drill 1/16" weep holes, every 12", in the U-Profile to be placed on
the lower edge of the sheets. Position U-Profile over lower edge of roof with long leg of U-Profile
facing up, { C }. U-Profile at lower edge of roof sheets held in place with 3/8" self-drill screws.
Side wall sheets of freestanding greenhouses (front wall for attached) have U-Profile at on top
and lower edges of the sheets. Gable ends on have U-Profile at bottom and aluminum tape and
Corner at top. Pressure of sheet against frame holds U-Profile in place.
7) Install Corner Trim, predrill 3/16" screw holes, 1" from each end & every 12".
done on both legs of Corner Trim.
8) Place sealant at trim joints as required.

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This is best

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 at a perpendicular angle.
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 to be set at corners of glazed areas and
every 1 ft. on-center. The 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 Poly Position & Attach p 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.

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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.
Our 3/8 polyurethane foam tape gets applied as shown below for Cap Only and Base & Cap
System. Note: PVC will outgas and attack the poly. Only use our tape.
In Base there is a 1/2" channel to put tape in. Use care to not overlap 1/4" shelf to right and left of
channel. See below.
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. The 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 order.

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

Shown below is silicone bead where two Caps butt join each other.

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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.
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