Carport Roof

Update: 16 April 2024 Design

We have a 4x4 frame holding up a grid made of 2x6 @ 24" with 2x3 purlins spaced about @24". The SunTuf panels are solid blocked with plastic supports "horizontal" on the 2x3s (including the top and bottom edges) and "vertical" plastic closure strips at both shed rakes. The 2x6s have little bird's mouths to rest on a high and a low 4x4 beam, square cut at the top to align with the edge of the SunTuf, but plumb cut at the bottom. The roof structure is sized for exactly (10) 26" x 144" sheets of SunTuf--10 @ 26" = 240" with overlaps.

I considered wrapping the post bases with GenStone, but the pieces needed would cost about $2,500. One side of a pillar, 24" high is $50, so $400 for the 36-48" high pillar shown in the rendering. The pillar cap is $50 more.

Previous post (23 March 2024)

The carport roof looks like 12' sections of corrugated plastic, resting on 1x4 purlins @ 24" o.c. We'll need 10 sheets for 20'.

Suntuf installation tips: 

• Pre-drill a hole 1/16" larger than fastener diameter
• Tighten fastener until snug--if the EPDM washer becomes deformed, it's too tight.
• Never step on the panels. During installation, use a crawl board supported by 3 roof elements.

Here are my options:

ePlastics.com - 0.031" Bronze Greca 26" x 144" $62.94 (or $56.70 if you buy 10-24). Greca describes the hex corrugation, also called Suntuf, Palram, Dynaglas.

ePlast.com - 10mm Policarb, 2 walls clear 26" x 144" is $107.52. Needs an aluminum "H" connector (Poli-Lok). 

interstatePlastics.com - .032" 49.6" x 144" (4' x 12') sheet $100. Sunsky 12 Clear 0.039" x 38" x 144" is $132.37

Lowes 

Suntuf 26" x 6' corrugated Solar Grey polycarbonate $172.05/10

Tuftex Multi-Wall 6mm Panel Clear 4' x 8' corrugated clear polycarbonate $55.78. UV coated on one side. Made by Onduline.

Tuftex SeaCoaster 2.2' x 8' corrugated clear, white, tan, green PVC $19.48

Tuftex plastic closure strips, cross link polyethylene vented roof panel closure strip $6.97/6

Suntuf 26" x 6' corrugated clear polycarbonate $177.10/10

Sunsky 38" x 6' corrugated white polycarbonate $173.39/5

Ondura Premium 3.16' x 6.58' $20.98 Brown, Red, Green, Black. Like corrugated steel, but quieter.

Home Depot

Suntuf 26" x 12' corrugated polycarbonate clear, gray, green, white $35.98 - hex profile. 0.032" 6.4# 35% light transmission

Suntuf Polycarbonate panel in Solar Grey

Sunlite 2' x 8' Multiwall polycarbonate panel in clear $44.98

Suntuf 26" x 8' corrugated polycarbonate in clear, grey, white, green $24.98

Suntop 26" x 12' Corrugated foam polycarbonate in Castle Gray $31.98 0.063" thick. 7.7# per panel. 10 year manufacturer's warranty.

Palruf 26" x 12' corrugated PVC roof panel in clear $24.98

Suntuf 24" horizontal plastic roof closure strips $6.98/6

Palruf 24" horizontal plastic roof closure strips $6.98/6

Woodtite 1" hex-head wood screw with EPDM washer $5.98/50. 2" is $6.98/50