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The Challenge
This project centred on a major residential build in Moorlands, just outside Port Macquarie, on a 20‑acre property positioned high on a hill with sweeping views of the western mountain ranges. With an approximately 800 m² roof, the architect needed a solution that could span large distances, maintain a clean, modern profile and contribute significantly to the home’s comfort and efficiency.
The specification called for an insulated roofing system capable of delivering a strong R‑value while also enhancing acoustic comfort in a rural setting that is open to wind and weather. The roof needed to do more than provide shelter; it had to be an active part of the building’s performance envelope.
The structural design posed its own challenges. Traditional construction would typically involve extensive timber bearers and joists to support the roof over such long spans. However, the design team wanted to simplify the structure, reduce the amount of timber framing and maintain clear lines across the roof.
Span length and panel continuity were also central issues. The architectural design called for panels from 8 metres up to 22 metres long, beyond what many conventional systems can achieve in a single panel. For this project, the architect was looking for a solution that could handle these long runs in single, continuous spans, preserving both performance and aesthetics.
On a hilltop site, exposed to driving rain and changing wind directions, the roof also had to offer robust long‑term weather protection. Minimising joins across a large, uninterrupted roof plane was critical to reducing the risk of water ingress.
The Solution
Bondor’s 200mm SolarSpan® insulated roofing panels were selected to meet this challenge, delivering an approximately 800 m² roof in single lengths up to 22 metres, with no joins and no compromise on aesthetics or performance.
The key advantage was Bondor’s ability to produce single‑length panels that could run the full span of the roof without intermediate joins. This eliminated the need for multiple pieces to achieve the required lengths, simplifying installation and dramatically reducing potential leak points.
“The real winner for Bondor here, is that we can produce a panel with no joins, which minimises any opportunity for that roof to leak,” said Bondor’s NSW State Manager Barry Mitchell.
Performance outcomes were equally important. The 200 mm SolarSpan® panels delivered the targeted R‑rating of 4.5, ensuring strong thermal insulation and supporting the home’s energy efficiency. At the same time, the composite “sandwich” construction provided excellent acoustic performance, helping to manage external noise and create a more comfortable internal environment.
Behind the finished product is a precision manufacturing process at Bondor’s Sydney factory that underpins consistency and quality.
Bondor’s Operations Manager, Peter Kean, explained that production starts with Bluescope coil rolled into the roofing profile, with styrene added as a sandwich core and the panel glued and pressed.
“It goes through the cutting line where it’s cut to length, it’s hot wire cut, and then we take it off the line into the packing area and from there onto the truck,” Peter said.
This end‑to‑end process ensures the panels arrive on site cut to precise lengths, ready for efficient installation.
Structurally, SolarSpan®’s spanning capability enabled the project team to significantly reduce the amount of conventional timber framing. The long spanning insulated panels are structural, meaning fewer timber bearers and joists were needed to support the roof, aligning directly with the architect’s intent to simplify the structure. It also reduced materials, labour and build complexity while preserving structural performance.
For Bondor, this project was more than a one‑off success; it is a showcase of what SolarSpan® and InsulRoof® products can achieve on large residential builds
“Our products more than meet the requirements of the building code, and we’re excited to show that off to other builders and explore opportunities to use our panels on their houses,” Barry said.
