PanelCraft™ Insulated Panels

The PanelCraft™ roof system is a technological marvel for your patio cover and sunroom.


This technological marvel is made using two aluminum skins bonded to stabilizing core material.

These “sandwich” panels are incredibly strong. Use them as a roof on your patio room or as a stand-alone aluminum canopy for your patio. Rely on PanelCraft™ aluminum panels to provide protection from the sun, rain, and snow. Enjoy outdoor gatherings or just relax in your favourite patio lounge chair on a hot summer day without worrying about the sun’s harsh effects.

Patio Cover by the Lake

PanelCraft™ aluminum roof panels provide attractive and maintenance-free protection for your patio enclosure, deck or sun porch. Installed as a carport, PanelCraft™ keeps you from getting wet or tripping through the snow as you get the groceries from the car to the house, as well as giving your car shelter.

PanelCraft™ polystyrene (“foam”) core panels are the best of the breed. They feature our unique Krystal Kote clear protective finish and a high-density foam core. PanelCraft™ foam panels are built to withstand our Canadian snow loads with the engineering to prove it.

PanelCraft™ structural insulated panels are your best choice for an insulated, maintenance-free roof system. Craft-Bilt’s laminated roof panels have been covering Canadians for over 35 years, longer than any other Canadian sunroom manufacturer.

PanelCraft™ structural insulated panels are an excellent choice for constructing a Hard Top Roof System. These panels provide superior insulation and durability, making them ideal for creating a robust, energy-efficient roofing solution.

Craft-Bilt also manufactures PanelCraft™ panels with our exclusive honeycomb core technology. Honeycomb technology is found in critical applications such as airplane wings, rocket gantry platforms and the floor and roof panels of the Acura Vigor, just to name a few. Our Honeycomb panels are even stronger than our foam panels, yet they only cost a small percentage more. Although they have less insulation than foam panels, many customers choose them for their Three and Four-season sunrooms. Occasionally, in some jurisdictions, obtaining a building permit is difficult with roof panels containing foam cores. Honeycomb core panels do not suffer from such building code issues.


Residential Insulated Roof Panel Applications

PanelCraft™ Insulated Roofing has many uses and excellent protection from rain, snow and UV rays. Spans of up to 18 feet with our thickest panels.

  • Patio Cover
  • Sunroom or Screen Room
  • Porch Cover
  • Carport
  • Pool Enclosure
  • Solarium or Conservatory
  • Porch Enclosure
  • Greenhouse
  • Balcony Enclosure
  • Permanent Deck Canopy
  • Patio Roof

Patio Cover by the Lake  Patio Cover by the Lake  Patio Cover, Shade, Railing  carport with walls protection from snow in Canadian winter  3 Season Sunroom with pool

Commercial Sandwich Panel Applications

  • Outdoor Cafe Patio Cover
  • Multi-Tenant Balcony Cover
  • Restaurant Patio Cover
  • Store Entrance Cover
  • Condominium Balcony Cover
  • Outdoor Employee Lunch Area

Multi Tenant Balcony Cover Replacement Project  Commercial Entrance Cover  Sunroom Panel  Sunroom Panel  Store Entrance Cover


PanelCraft™ Patio Cover Panels

PanelCraft™ panels come in three thicknesses: 3″, 4½” and 6″. The thicker the panel, the farther it can span and the more insulation it has. The 3″ panel takes care of most applications, however always obey your local building code.

Craft-Bilt™ also provides special foam core panels that are lined with OSB (Oriented Strand Board). These panels address particular concerns of a small percentage of building departments in Ontario.

  • Facing: ASTM 3105 alloy maintenance-free aluminum skins with baked-on enamel finish, topped with our unique Krystal Kote clear coat
  • Core: Type II high density expanded polystyrene
  • Adhesive: Moisture curing, one part, 100% solids, non-volatile, type III urethane adhesive, bond strength (AL – EPS 1.5#) = 20 – 33 PSI
  • Extrusions: ASTM 6063-T6 alloy, Fu = 30,000 PSI, Fy = 25,000 PSI
  • Built-in gutter with large water capacity and a radiused inlet to reduce overspray

Available options include:

  • White, Sand or Earthstone colours (Earthstone is not permitted as a top roof skin colour)
    4 Track Window Colours
  • Colour matched aluminum extrusions
  • Special roof panel available for shingling
  • Fixed or venting skylight
  • Special foam panel available with OSB fire protection layer tested to CAN4-S124M
  • 3″, 4½” and 6″ thicknesses
  • Build-in gutter system

Patio Cover Panels


Engineered Patio Cover

Watch how PanelCraft™ Insulated Panels by Craft-Bilt are tested in the lab. PanelCraft™ Insulated Panels are engineering marvel consisting of two aluminum skins bonded to the core material. They are incredibly strong and can span great distances. Insulated Panels are used in sunrooms, patio covers, wall systems, and other projects.

Patio Cover Installation Instructions

How to Install PanelCraft™ Insulated Patio Cover?


Please visit our installation page for instructions.

These are the most common installation guides. If your specific situation is not addressed, please contact us at (800) 668-6430 or [email protected]

Instruction can be changed or updated without notice. Please inquire to Craft-Bilt for the most updated version.

Craft-Bilt’s warranty applies to a properly installed product only. Please contact us for warranty details. Labour and installation warranty are provided by the contractor who sells and installs the product. If you purchase products to install yourself (or have installed) then you are solely responsible for labour, installation, and building code issues. DIY’ers should have above average construction skills and knowledge of building practices and codes. Please carefully read the footnotes on your quote or sales order. Purchases are bound by our Terms and Conditions of Sale.

Patio Cover FAQ

Frequently Asked Questions for Patio Covers:

Q1 – What is a Patio Cover?

A1 – A patio cover is usually a lean-to roof system attached to the back of your house. The roof, columns, and beam need to be designed for your local snow load and your local building code. A patio cover is also referred to as a porch cover, veranda cover, or deck cover. On some homes, you could also attach your patio cover in a gable (a-frame) design.

Translucent Patio Cover

Northlander™ Skyview Patio Cover, Lean-to Roof Style

PanelCraft™ Insulated Patio Cover, A-Frame Style

Q2 – Are Craft-Bilt Patio Covers economical?

A2 – A cover for your patio is a fairly economical renovation. The most economical method is to use wood and shingles, but it won’t be maintenance-free. The next pricing level is our PanelCraft™ patio cover system which uses insulated aluminum panels. For a little bit more you can have our Northlander™ Skyview patio cover system which uses translucent sheets. These sheets allow pleasing amounts of light without the heat and glare of glass roofs.

If you plan it right, you can build an economical patio cover now, and in the future close it in with our 4 Track Windows, transforming it into a three-season room.

Q3 – What is Craft-Bilt’s Patio Cover’s warranty?

A3 – The aluminum members used in our PanelCraft™ and Northlander™ roof systems have a limited warranty of 20 years. Find more information on our warranty page.

Q4 – What are the best patio cover materials?

A4 – Aluminum of course! You want a patio cover that will stand up to the weather, won’t rot or corrode, and that you will never have to paint or re-shingle.

Q5 – Does a patio cover increase my property value?

A5 – We do not have any research data on this. But imagine yourself as a buyer looking at potential homes. Most of the homes you see will have a back deck, but when you see that patio cover you will start dreaming of all the wonderful times you will have in your new backyard. All things being equal, a house with a patio cover will outsell a house without one.

Q6 – How long does it take to install a Craft-Bilt patio cover?

A6 – Most patio covers installed by a professional will take one or two days. Please visit our installation instructions for more information.

Q7 – Will my patio cover be loud when it rains?

A7 – We have heard this question a few times. Light rain on your patio cover can sound romantic, but a really heavy rain might make conversation difficult. The sound of rain on a maintenance-free roof won’t be much different than a shingled roof, and it should not affect your decision to have a patio cover.

We can’t stop the rain, but we can stop it from landing on your patio 🙂

Q8 – Is a patio cover worth it?

A8 – A patio cover is sure to add value to your home. It extends the use of your deck and the amount of time you can spend on it. It protects your outdoor furniture year-round. It makes your backyard lifestyle better. Oh yeah, it’s worth it 🙂

Q9 – Can you walk on insulated patio covers?

A9 – PanelCraft™ insulated roof panels by Craft-Bilt are incredibly strong, and if installed correctly can easily bear a person’s weight. But this is not advised for a number of reasons: our unique Krystal Kote clear coating which is applied over the paint finish can make them slippery, if the panels are already laden with a large amount of snow, the added weight of a person’s “point load” could be dangerous and you could scratch the finish. Make sure to follow local guidelines for working at heights.

Working on a roof is dangerous, please use a professional.

Q10 – Can I walk on a polycarbonate patio cover?

A10 – Craft-Bilt’s Skyview Structural roof system is very strong. The large aluminum beams are spaced apart a maximum of 24 inches. It can bear the weight of a person but only on the beams. Never stand or apply any type of point load on the glazing.

If the roof is already laden with a large amount of snow, the added weight of a person’s “point load” could be dangerous and you could scratch the finish. Make sure to follow local guidelines for working at heights.

Working on a roof is dangerous, please use a professional.

Q11 – Do patio covers need footings?

A11 – A properly installed patio cover will have concrete pier footings designed to meet the local building code. Many contractors have moved away from concrete piers to steel helical piles.


Concrete Pier or Steel Helical Piles

Q12 – What is a good size covered patio?

Q12 – Typical patio covers range from 10 feet x 10 feet to 12 feet x 20 feet. But all of our patio covers are custom made, projections can be as long as 18 feet, and widths can go to 40 feet or more.

Q13 – What tools are required for a patio cover?

Q13 – Aside from the typical tools like drills, driver bits, hammer, level, ladder, etc., you will require specialized tools like a miter saw with carbide tipped blade for non-ferrous metal (also referred to as a blade for extruded aluminum), hammer drill, and heavy-duty snips.

You will need to install aluminum flashing where the roof meets the house, so if you do not own an aluminum brake you will have to arrange to get this flashing from a local siding shop.

For more on flashing, refer to our sunroom training course, ROOF CONNECTIONS – LESSON 9.

Your patio cover will need to resist wind and snow loads and meet local building codes, so a DIY project should not be taken lightly. Craft-Bilt deals with contractors across Canada that can supply and install your patio cover.

Q14 – How do I measure for a patio cover?

Q14 – Your patio roof should always have an overhang. So if your deck is 12 feet x 12 feet, you would be best served with roof dimensions of 13 feet projection x 13 feet wide.

Typical heights at the front are seven or eight feet but can be as high as 12 feet. The mounting point at the house should allow for a minimum 1:12 pitch. For example, a deck with a ten-foot projection will have a drop of 10 inches (minimum).

Q15 – Why should I use polycarbonate instead of glass?


Glass Roof:

  • Solariums are Hot! Very expensive glazing is required to control the heat properly.
  • Sunlight can cause glare and fading of furniture and other contents.
  • Purlins are required (cross bars separating multiple pieces of glass); this is where many glass roofs will form a leak at some point.
  • If tempered glass breaks, it covers the floor with thousands of tiny pieces of glass, and the replacement glass is very expensive to replace, both in labour and material.
  • There is a good chance of seal failure over the years, and again, solarium glass replacement will cost a great deal in labour and replacement glass.

Polycarbonate Roof:

  • Excellent value.
  • The multiwall structure refracts the light, resulting in a pleasing light distribution with no glare.
  • Over 99% UV resistance. Almost the entire relevant UV spectrum, meaning both UVA and UVB.
  • The multiwall sheets are light, incredibly strong, and won’t shatter or crack like acrylic or glass.
  • Craft-Bilt polycarbonate sheets have a flame resistance rating of ASTM E 84 Class A
  • Skyview roofs by Craft-Bilt use one continuous sheet; there are no purlins and no related leaks.