Sundance Supply, LLC

"Cap Only ( & Trim ) " Installation

To order Polycarbonate & Aluminum see > sundancesupply.com

Note: We do not sell framing or ridge flashing material, shop local.

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.

H A D C A

Freestanding

Attached (Lean-To)
G B

A C A E B D F Note: Use of U-Profile around doors, windows, fans and inlet shutters is highly recommended. See next page for typical installation details.

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Typical Framing Layout For Cap & Trim Over Wood Frame
(Standard 48" or 72" Polycarbonate Sheets)
Sloped (roof) Sheet or Front Wall Sheet (lean-to) Side Wall Sheet (freestanding)

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

ledger board

U-Profile

blocking

Cap

U-Profile

Corner Trim

Corner Trim

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Flashing

Freestanding Greehouse

U-Profile blocking

blocking

End Wall

Side Wall

Cap

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. 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 11 & 12 ) Remember, bronze poly. moves a lot. (5)

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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.
Prior to poly install, moisten rag with ArmorAll, run only along exterior of frame that comes in contact w/ poly. Lube helps free poly for expansion and contraction. Buy 10 sheets & order form sends you email that presents foam tape option. (p 11-12 ) 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 and cover "outside" of joint with a flat bead of sealant. 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 the roof for Trim, screw and sealant placement on flashing is best done from a step ladder positioned in between the rafters where polycarbonate has not been set yet. Installation of 1st and last sheet offers the ease of placing a ladder outside the structure. Working from one of the steps towards the top of the ladder your body should be positioned so you can reach over the sheet to do the required work. The 4 foot wide sheets are much easier to reach over to set screws and are highly recommended for roof applications. Starting at one end of the greenhouse work your way towards the other end of the greenhouse. Do all the steps as you go, as detailed in Ridge method #1 below, and it will not be necessary to gain access to the roof again. Cleaning of sheet may be done with a hose. Do often, dirt will not build up.
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 a 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 and architectural medium bronze 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 }. 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. Do not place same finger in mouth after tooling. The sealant is sticky and somewhat toxic. Joints at the interface of the Trim Components should be clean and securely fastened. Make sure U-Profile is butted tightly so that spiders do not get in and build a web. Clean all joints with isopropyl (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. 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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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.

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. Follow instructions for Cap Only ( and Trim ) System. Purlin & Blocking Note: Tape also required on purlins or blocking that comes in contact with polycarbonate. 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. (11)

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

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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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