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Sun-Lite FRP Roofing — Installation Guide
Follow these guidelines to ensure a weather-tight, long-lasting Sun-Lite FRP roof installation. Always refer to the full Installation Guide PDF for detailed drawings and specifications.
Step 1 — Site Preparation & Material Check
- Verify all structural purlins are correctly aligned, levelled, and fixed according to the engineer's design
- Check purlin spacing does not exceed 1,200mm (or as specified by engineer)
- Ensure the roof slope is a minimum of 10% (approx. 6°)
- Clear all debris, swarf, and drill filings from purlins before laying sheets
- Inspect all Sun-Lite sheets for damage, delamination, or surface defects before installation
- Prepare all necessary flashings, trims, and sealants in advance
- Mark purlin locations clearly for accurate fastener placement
- Check weather forecast — avoid installation during heavy rain or extreme heat
- Ensure adequate scaffolding and safe access is in place
- Pre-drill all holes in FRP sheets before positioning on the roof
Step 2 — Sheet Cutting & Pre-Drilling
- Cut sheets using a fine-tooth saw blade (carbide-tipped or diamond blade) at low speed to avoid chipping
- Support sheets fully during cutting to prevent vibration cracks
- Use a hole saw or stepped drill bit for round penetrations (e.g., vent pipes)
- All holes must be minimum 2mm larger than the fastener shank diameter to allow thermal movement
- De-burr all cut edges to remove sharp fragments
- For sheet end overlaps, drill oval ( slotted) holes to allow expansion
- Keep cut edges clean — do not leave exposed FRP edges overnight
- Apply acrylic or epoxy sealer to cut edges to prevent moisture wicking
- Label sheets in sequence of installation to maintain sheet alignment
- Cut all sheets before placing any sheets on the roof structure
Step 3 — Sheet Placement & Alignment
- Start installing from the ridge (top) and work downwards to the gutter
- Place the first sheet at one end of the roof, ensuring it overhangs the gutter by a minimum of 50mm
- Maintain the recommended side lap of 1.5 corrugations minimum (full corrugation preferred)
- Align sheets straight — a string line along the gutter edge helps maintain accuracy
- Do not walk on unsupported sheets — use crawl boards or platforms spanning minimum 3 purlins
- For long roof spans requiring end laps, maintain a minimum 150mm end lap (200mm for slopes below 10%)
- Ensure end laps fall on top of a purlin — never mid-span between purlins
- Stagger end laps in alternate rows to avoid a continuous joint line
- Position FRP sheets with the UV-protected film side facing upwards (film label indicates top surface)
Step 4 — Fastening
- Use only corrosion-resistant fasteners (stainless steel or hot-dip galvanised) with EPDM sealing washers
- Fasten at the crown (top) of the corrugation — never in the trough
- At end spans: fasten at every corrugation, approximately 300mm pitch
- At internal spans: fasten at every 2nd or 3rd corrugation, approximately 450–600mm pitch
- Side laps: fasten at every 2nd–3rd corrugation along the overlapping side lap
- Do NOT over-tighten fasteners — the EPDM washer should be just fully compressed, not deformed
- Ensure the fastener is perpendicular to the roof surface (not angled)
- All fasteners must engage a minimum 50mm into the structural purlin
- Check fasteners after the first round of installation for correct torque
- Replace any damaged or corroded fasteners immediately
Step 5 — Sealing & Flashing
- Apply neutral-cure silicone sealant along the top sheet's side lap corrugation before placing the overlapping sheet
- At end laps, apply sealant to both overlap surfaces and the top of the purlin before joining
- Use butyl rubber sealer tape at all fastener locations under the EPDM washer for extra weather protection
- For roofs below 10% slope, apply sealant to all laps, end laps, and penetration joints
- Install pre-formed ridge flashings at the ridge — secure one side to the FRP crown, leave the other side loose to allow movement
- Use gable end trims to close the roof edges neatly
- For wall penetrations, install counter flashings with a minimum 100mm overlap onto the FRP sheet
- Apply sealant around all penetration flashings — check seals after first rainfall
Step 6 — Completion & Inspection
- Inspect all fasteners for correct torque and sealing washer compression
- Check all side laps and end laps for complete sealant coverage
- Verify all flashings and trims are properly secured and sealed
- Remove all drill swarf, cutting debris, and loose material from the roof surface
- Check the gutter and surrounding area for fallen debris or fastener remnants
- Inspect during first rainfall to identify any leaks at laps, flashings, or fasteners
- Address any leaks immediately with additional sealant — do not allow water to pond
- Remove the UV-protective film from sheet surfaces after installation is complete (if still in place)
- Do not apply harsh chemicals or abrasive cleaners to FRP sheets
- Keep the roof surface clean — remove debris, leaves, and standing water promptly
Important Safety Notes
- Always use appropriate personal protective equipment (PPE): safety harness, non-slip footwear, gloves, and eye protection
- Ensure scaffolding and edge protection is in place before commencing work at height
- FRP sheets can be slippery when wet — do not walk on sheets unless absolutely necessary and with proper safety measures
- Do not use FRP sheets as a working platform or storage area during installation
- Dispose of all cut FRP fragments and packaging responsibly — follow local waste management regulations
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