Rion assembly
The panel is coated on one side only, and the film you are about to peel off is the only thing that says which side.
Manufacturers mark the UV-coated face on the protective film, and one guide puts it plainly: do not remove the film until you are ready to fasten the panel, because once it is off you are guessing, and a fifty-fifty guess is not good enough. Guess wrong and the panel hazes and goes brittle in one or two seasons.
The instructions are printed on the thing that looks like packaging
Twin-wall polycarbonate has a co-extruded UV-resistant layer on one side. Not both. The panel looks symmetrical, weighs the same either way, and fits the frame identically in either orientation, and one of those orientations is wrong in a way that will not be visible for a year.
What tells you which is which is the protective film. Manufacturers cover both faces and mark the coated side, sometimes with printing and sometimes with a colored film. One guide states the rule and the reason in the same breath: do not remove the film until you are ready to fasten the panel in place, because it is your only guide, and once it is off you are guessing, and a fifty-fifty guess is not good enough when the stakes are this high.
The stakes, spelled out: the unprotected side will begin to yellow and haze over in as little as one or two seasons, becoming brittle and susceptible to cracking from hail or a hard-thrown ball, losing the light transmission that was the whole point and turning the structure into a cloudy fragile box. Another source notes that incorrect orientation accelerates degradation and voids warranties, so the manufacturer will not be helping either.
What makes this worth a page rather than a footnote is the shape of the trap. The information is printed on a film, over a panel, in a box that also contains cardboard and packaging, during a build that owners describe as taking dozens of hours. Everything about the situation encourages peeling the film off early to see what you have got, and doing so deletes the one piece of information you cannot recover by looking at the panel.
What it actually takes
Nothing here is slow. Most of it is resisting the urge to tidy up before you are ready.
| Model | Time | People |
|---|---|---|
| Storing panels cool, dry and out of the sunSun-baked film may never come off at all. | until fitting | — |
| Reading the film for the UV markingPrinting, or a colored side. Before anything else. | 2 minutes | 1 |
| Marking the outside face on the frame sideA pencil arrow on the flute end survives the peel. | 5 minutes | 1 |
| Drilling oversized holesLarger than the fastener. Deliberately loose. | 20 minutes | 1 |
| Orienting flutes verticallyDrainage and strength, both. | planning | 1 |
| Fitting solid tape at the top of the flutesKeeps moisture and dust out. | 20 minutes | 1 |
| Fitting vented tape at the bottomLets condensation out, keeps bugs out. | 20 minutes | 1 |
| Blowing debris out of cut flutesAnything left inside is there permanently. | 10 minutes | 1 |
| Peeling the film, lastOnce the panel is fastened in place. | 10 minutes | 1 |
The whole page reduces to one sequence: read the film, mark the frame, fit the panel, and only then peel. Every failure here comes from doing the last step first.
What to get right, specifically
Do not peel the film until the panel is fastened
The single instruction that matters most, and the reasoning is worth carrying because it is what makes it stick. The UV coating is on one side only, manufacturers mark the coated face on the protective film with printing or a colored side, and one guide states it directly: the film is your only guide, and once it is off you are guessing, with a fifty-fifty guess not being good enough. The failure is delayed and total. The unprotected face begins to yellow and haze in as little as one or two seasons, becomes brittle enough to crack from hail or a thrown ball, and loses the light transmission the material was chosen for. And incorrect orientation is noted as voiding warranties, so there is no recovery on that side either.
Mark the frame before you peel, not the panel
A small habit that solves the practical problem the rule creates, because you will be handling panels, turning them over, setting them down and picking them up again across a long build. Once you have read the film and know which face goes out, put a pencil mark somewhere that survives the process: on the flute ends, or on the frame member the panel is about to sit in, or on the inside face if the film there is coming off anyway. What you are protecting against is not ignorance but the middle of a fifty-hour assembly, where a panel gets moved three times and nobody can remember whether this is the one that was already checked.
Store them out of the sun, or the film may never come off
A compounding failure worth knowing before the delivery arrives. Guidance is to store panels in a cool dry location away from the sun, with one builder warning that if you store them in the sun you may never get the protective film off. Put that next to the first rule and the bind is obvious: the film has to survive until installation, and it also has to come off afterward, and leaving the stack leaning against a sunny wall for three weeks breaks both requirements at once. A shaded garage or under a tarp is enough. Cool and dark is what the suppliers ask for.
If the film is already gone, there are two tells and both are brand specific
For a secondhand greenhouse or unmarked sheets found in a garage, the honest answer is that there is no general test, but somebody who has sold and installed these since 1993 offers two manufacturer-specific ones. One maker puts an invisible tint on the UV protected side which shows up only under a black light. Another prints their name along the edge of the sheet, and if you can read the name the correct way up, the UV side faces the sun, though this only works on a full sheet that has not been trimmed at the sides. The same source is candid that other suggestions in the discussion may not work at all. A black light is a couple of dollars and worth trying before writing off a stack of panels.
The holes are deliberately too big and the screws deliberately not tight
Counterintuitive and the source of a lot of cracked panels. Polycarbonate has a high coefficient of thermal expansion, so pilot holes through the sheet must be oversized, with one source giving three eighths of an inch for a standard quarter inch fastener and another giving holes an eighth of an inch larger than the fastener, specifically so the sheet can move freely without buckling or cracking around the screw shank. Tight holes cause stress cracking. And the screw itself is not driven home: over-tightening damages the internal structure and reduces the insulation value, which is why the fasteners come with neoprene or rubber washers. In a proper bar-cap system, most screws do not pass through the panel at all, holding the cap instead.
Flutes vertical, and the failure is algae inside the wall
Two reasons and one memorable consequence. Panels installed with the channels running vertically drain condensation properly and also maximize strength, and on a roof the equivalent is to run the flutes along the slope so moisture moves downward. Get it wrong and horizontal channels trap moisture, which promotes algae and reduces clarity. That is the version worth picturing: algae growing inside the wall of the greenhouse, in a sealed channel a few millimeters wide, where it cannot be reached or cleaned and will only get worse. It is not a repair, it is a panel replacement, and it was decided at the moment somebody chose which way to face the sheet.
The top and bottom tapes are different products doing opposite jobs
Easy to get wrong because they look similar and often arrive together. Guidance is specific: seal the top of the channels to keep out moisture and dust, and seal the bottom with a tape that allows condensation to drain while keeping bugs out. So solid at the top, vented at the bottom. Fit solid tape at both ends and the flutes become sealed tubes that collect condensation with no way out, which produces exactly the clouding and algae the vertical orientation was supposed to prevent. Fit vented tape at the top and you have let dust and water in from above. Two tapes, two ends, and no visual difference once they are on.
Cut carefully, clear the flutes, and size for your snow
Three practical items. On cutting, use fine-tooth blades designed for plastics, support the panel fully, and blow the debris out of the flutes afterward, because sawdust and plastic swarf left inside a sealed channel is permanent and visible. On thickness, four to six millimeters is described as standard for backyard greenhouses with eight and ten millimeters recommended for larger structures or harsher climates, and manufacturers publish load tables giving maximum spans and spacing rather than leaving it to judgment. In heavy snow regions the levers are thicker panels, shorter spans, or added purlins. And one reassurance, since people ask: the UV coating protects the sheet from degradation and does not block the light plants need for photosynthesis.
Before the panels come out of the box
Store the stack cool, dry and out of direct sun until fitting day.
Read the protective film for the UV marking before handling anything.
Decide how you will mark the outside face so it survives the build.
Plan flute orientation: vertical on walls, along the slope on roofs.
Get the manufacturer’s expansion guidance and size holes accordingly.
Buy fasteners with neoprene or rubber washers, and resist driving them home.
Buy both tapes and know which end each goes on.
Check the load table for your span, spacing and snow region.
Who this is really for
Anybody building a polycarbonate greenhouse, which is most greenhouses sold now. The frame and the anchoring get all the attention because they are visibly difficult and they are covered elsewhere in this category. The panels are the part where a mistake is invisible on the day and terminal within two seasons.
It matters most in the middle of a long build, which is exactly when the film gets peeled. Owners describe these assemblies taking dozens of hours across multiple sessions, and the film is the least durable-looking thing in the box. Knowing before you start that it is load-bearing information changes how it gets handled.
The case for having somebody do it is partly the two-person reality of large panels and mostly the sequence. Somebody who fits these keeps the panels shaded until fitting day, reads the film before touching anything, marks the outside face somewhere that survives, drills holes larger than the screws on purpose, runs the flutes the right way for drainage, and puts the correct tape on each end. None of that is difficult. All of it is decided before the first panel goes in, and none of it can be corrected afterward.
What a correct installation looks like
- Panels stored cool, dry and out of sun until they are fitted.
- Protective film read for the UV marking before any handling.
- Outside face marked somewhere that survives the build.
- Film peeled only after the panel is fastened in place.
- Fastener holes drilled oversized per the manufacturer’s expansion guidance.
- Screws with neoprene or rubber washers, seated but not driven home.
- Bar-cap systems used so most fasteners hold the cap rather than the panel.
- Flutes run vertically on walls and along the slope on roofs.
- Solid tape at the top of the flutes and vented tape at the bottom.
- Cuts made with fine-tooth plastics blades, with flute debris blown clear.
- Panel thickness and span checked against the manufacturer’s load table.
Get it built by someone who has built one before.
Tell us your ZIP and what you bought. Installers near you will quote you directly, and you deal with them, not with us.
Questions people ask
Does it really matter which way a polycarbonate panel faces?
Yes, because the UV layer is on one side only. The unprotected face begins to yellow and haze in as little as one or two seasons, becomes brittle enough to crack from hail or a thrown ball, and loses the light transmission the material was chosen for. Incorrect orientation is also noted as voiding warranties. The panel looks and fits the same either way, which is precisely the problem.
How do I tell which side is coated?
From the protective film, which manufacturers mark with printing or a colored side to indicate the face that goes toward the sun. One guide is emphatic that the film is your only guide and that once it is off you are guessing, with a fifty-fifty guess not good enough. So read it first, mark the frame or the flute ends so you cannot lose track, and peel the film only once the panel is fastened.
I already removed the film. Now what?
There is no general test, but a supplier with decades in the trade offers two brand-specific tells. One manufacturer puts an invisible tint on the UV side that shows only under a black light. Another prints their name along the sheet edge, and if the name reads the correct way up the UV side faces the sun, which only works on an uncut full sheet. The same person is candid that other suggested methods may not work. A black light is cheap enough to try.
Why are the holes supposed to be bigger than the screws?
Because polycarbonate expands and contracts significantly with temperature. Holes must be oversized so the sheet can move without buckling or cracking around the screw shank, with figures given as an eighth of an inch larger than the fastener, or three eighths of an inch for a quarter inch screw. Tight holes cause stress cracking. And the screws themselves should not be driven home, since over-tightening damages the internal structure and reduces the insulation value.
Which way should the channels run?
Vertically on walls, and along the slope on a roof, so condensation drains downward. It also maximizes strength. Run them horizontally and the channels trap moisture, which promotes algae and reduces clarity, and that algae is inside a sealed channel a few millimeters wide where it can never be cleaned. That is a panel replacement rather than a repair, and it is decided at the moment somebody picks the sheet up.
Do I seal the ends of the channels?
Yes, but with two different products. Seal the top of the channels to keep out moisture and dust, and use a vented tape at the bottom so condensation can drain while bugs are kept out. Sealing both ends solid turns the flutes into closed tubes that collect condensation with no way out, producing the clouding you were trying to avoid. And if you have cut any panels, blow the debris out of the flutes first, because anything left in there is permanent.
Installers.org is not affiliated with, endorsed by, or sponsored by Rion, Palram, or any panel manufacturer or supplier referenced here. All marks belong to their owners and are referred to here only to describe the installation services that independent installers on this directory provide. Panel thickness, hole sizing, expansion allowances, span limits and sealing methods vary by product: follow the instructions and load tables supplied with your own panels and frame, which take precedence. The black light and edge-printing methods for identifying a UV face are described by a supplier as things particular manufacturers do, not as general tests, and no claim is made that they work on any given brand. Incorrect panel orientation may void the panel warranty.