Pergola Roof replacement project in Mulgrave

A customer in Mulgrave had an ageing Colorbond pergola with deteriorating corrugated polycarbonate sheets that were over 20 years old. They decided to replace the entire pergola roof with a flat, glass-like polycarbonate solution. After reviewing the options presented by the Excelite team, the customer selected the W800 Solid Polycarbonate Locking Roofing System in tinted grey — providing a premium glass-like appearance, ample natural light, and effective heat and UV reduction.

With stock readily available at the Rowville warehouse, the project commenced promptly. The full removal of the old roofing and installation of the new system was completed in a single day, causing minimal disruption to the customer.

Project Key Points

1. Structure

The existing steel pergola featured battens without rafters — an ideal configuration for the polycarbonate locking system. Without rafters to work around, there were no rafter spacing constraints, allowing for a wider span without risk of sagging.

2. Frame Condition

The steel structure was in excellent condition — no rust, minimal cleaning required, and the existing paint was well-preserved. This simplified the installation process significantly and meant no remedial work was needed before the new roof could go on.

3. Installation Process

The installation followed a clean, straightforward process:

1. Old corrugated roofing removed and battens thoroughly cleaned.
2. Aluminium H joiners installed on the battens, screwed down at each crossing point.
3. Tinted polycarbonate sheets placed into the joiner channels.
4. Joiners secured to lock the sheets in place without penetrating the sheet surface.
5. Anti-noise foam tape applied wherever the sheet contacted the battens, preventing wind-induced creaking.

Result

The customer was delighted with the outcome. The new tinted polycarbonate roof brought significantly more natural light into the pergola while blocking harmful UV rays — creating a comfortable, usable outdoor space they can enjoy year-round.

Considering a similar pergola roof replacement? Browse our Solid Polycarbonate Locking Roofing System or contact the ExcelitePlas team for a free quote and on-site assessment. Call us on 0452 396 680.