Berowra Heights Passive House, Sydney

The Challenge

Nestled in the leafy suburb of Berowra Heights, this innovative home designed by Envirotecture and built by Red Cedar Constructions represents a masterful blend of sustainable design and site-specific architecture.

The clients, John and Prue, sought a home that would maximise the potential of the corner block, characterised by Sydney sandstone just 100 millimetres beneath the soil.

John and Prue wanted to build the home on a single level. Due to the this and the sloping block, a by-product was the ability to create a storage area, a workshop for John and an area for 30KL of rainwater storage under the single level home. 

To address the site’s constraints and the clients’ desires, Trent Clark and the Red Cedar Constructions team implemented a Passive House approach, noting the project would reach “premium” Passive House certification. This meant incorporating double-glazed windows, an airtight construction method, and high-performance insulation.

Bondor’s prefabricated insulated SolarSpan® long-spanning roofing panels were a crucial component in achieving this, allowing for complete air-tightness and offering a 4.85 R Value.

The result is a home that not only meets the clients’ functional requirements but also provides exceptional thermal efficiency and a strong connection to the surrounding bush land.

Photos: Jonathan Cohen Photography

The Solution

The completed 4-bedroom home was designed to blend natural materials with a minimalist aesthetic. The home’s skillion roof is a standout feature, with its dramatic, extended lines creating a striking visual impact from the street.

The roof was constructed using 200mm SolarSpan® structural insulated roofing panels, with the entire 300m2 roof installed in just five hours.

Trent said the SolarSpan® panels offered multiple benefits, including high insulation, an almost airtight roof line, and can be installed as fully finished system that doesn’t require painting.

“It’s basically just one large structural insulated panel by Bondor that we just plonked in place,” he said.

“Underneath the eaves, we don’t need to paint it. It’s a fully finished system.”

The design prioritised creating an extremely well-insulated and airtight environment, with Bondor panels playing a crucial role in achieving Passive House standards.

“Because of Bondor, we actually are able to get a really well airtight home because of the fact that it’s just so easy to airtight the actual roof line,” Trent said.

“This home will become an accredited Passive House. We’re probably going to end up at Passive House “Premium”, because it’s such a well-insulated and such an airtight home, with 0.37 ach (air change per hour).”

The extended roof shelters another key feature of the home, an expansive 80m2 spotted gum timber deck that wraps around the home, offering stunning valley views and creating a seamless indoor-outdoor connection.

“You can look over the valley and really enjoy this afternoon here, just with a nice bit of shady Bondor roof over the top of you,” he said.

Manufactured in Australia by Bondor, SolarSpan® is Australia’s leading insulated roofing panel offering long-spans, low pitch and high thermal efficiency.

NOTE: This project a certified Passive House.

Prefabricated Home Extension, Melbourne

The Challenge

While a cosy triple fronted brick veneer house in Bulleen Victoria brought back fond memories of their childhood homes, Damien Crough and his wife knew that as a home for their family of six it would be a bit of a squeeze.

The size the property presented the perfect opportunity for a modern, no-fuss extension that balanced nostalgia with the practical requirements for their family.

No sooner had the family decided to undertake this project than Damien run into an old university friend and renowned architect, Paul Catalano from PC Architects.

“This really was the opportunity to build the house we had always wanted,” Damien said.

“When I told Paul about the project, he was all in. He got really heavily involved with the design, and we worked collaboratively to really make the most of the Northern aspect of the rear.

“For us it was important to keep it classic with simple, timeless materials—concrete, steel, timber, glass.”

As CEO & Founding Director of prefabAUS, Damien knew the perfect solution was Bondor’s prefabricated insulated SolarSpan® long-spanning roofing panels to hit the brief for a sleek, contemporary and timeless extension.  

The Solution

“We’ve used Bondor products in other projects. As soon as they’re up, the job is done. It’s the perfect low-maintenance building option that shortens construction timelines and provides unparalleled insulation to a home,” Damien said.

“Everything in prefabricated construction comes in a pre-manufactured panel off-site that slips in and bolts or screws together very quickly on-site.

“The main benefits of this approach to construction are speed, performance, insulation, and using quality products that are made in a factory, and made for better tolerances.”

Damien engaged Advanced Offsite Group, specialist builders in modular, prefabricated, and panelised construction systems for the extension. They used 5m long SolarSpan® panels for the walls and roof of the extension, installing the panels after pouring the slab and setting up portal frames.  

“We stood the whole structure up in two days. The carpenters who helped us assemble it couldn’t believe it.

“Once installed I didn’t have to paint it. The panels come finished in COLORBOND® Steel in Surfmist, so as soon as you put it up, you’re done. You don’t have to paint it or touch it again,” he said.

Thermal performance and efficiency was another key benefit, with 150mm of insulation integrated into the all-in-one wall and roof panels.

The result is Damien uses just one small air conditioning unit for heating and cooling, demonstrating SolarSpan®’s superior insulation properties.

The final extension introduced a brand-new kitchen to the property with five bedrooms, as well as a long-awaited backyard pool and entertaining area which ties together an idyllic indoor-outdoor lifestyle.  

“We promised the kids a pool in our last house. With our renovation we step out of our bedroom and we’re around the pool enjoying each other’s company,” Damien said.

“The Bondor panel aesthetics contribute to our outdoor retreat, and with its low maintenance requirements our backyard will be looking immaculate for years to come.”  

Manufactured in Australia by Bondor, SolarSpan® is Australia’s leading insulated roofing panel offering long-spans, low pitch and high thermal efficiency.

prefabAUS is the peak body for Australia’s prefabricated construction industry, specialising in educating and identifying innovation in prefabrication technology and design.

Rocksberg Retreat, Queensland

The Challenge

For newlyweds Gemma and Christian Morris, the cherry on top of their honeymoon was stumbling across the block of land that would become their family home.

Located in the Morten Bay region an hour north of Brisbane, the rural setting of Rocksberg had everything the young family needed: a little peace and quiet, room to grow, and amenities a short drive away.

While starting quite literally from the ground up might be daunting for some, the Morris family had a trick of two up their sleeve.  

Christian comes from a family with deep roots in construction. His father Brett has been building homes for three decades, and Christian has followed in his footsteps, now working as father and son for Brett Morris Homes. Taking ‘a labour of love’ to whole new level, Gemma and Christian combined their know-how and experience to plan out and construct their dream home.

After the ‘quintessential Queensland lifestyle’ of indoor-outdoor living, they knew there was no compromise when it came to the roofing that would tie the space together.

Bondor’s SolarSpan® insulated, long spanning roof panels gave Gemma and Christian the right balance between style and comfort to create a space that would shelter their new family.

The Solution

“To us it was important to have a space that felt as open as possible from the minute we walked in. We wanted seamless integration between the indoor and outdoor spaces, not only in terms of how the space opened up but in terms of comfort,” Gemma said.

With an impressive 420m2 footprint, Gemma and Christian’s dream home blends multiple design styles, creating a unique aesthetic that complements the pair perfectly.

Always envisioning themselves in a low-set brick veneer fronted home, the finished home uses a Hampton-style colour palette as a base, adding Mediterranean and Palm Springs elements, with Tuscan rock strategically incorporated throughout to enhance the design without overwhelming it.

Boasting a generous interior with 5 bedrooms and 2.5 bathrooms, the large Bondor SolarSpan® alfresco area is, in Gemma’s opinion, is one of the best features of the home.

“Roofing and foundations are the crux of what makes a home. We have used SolarSpan® because it is the cover for changing climates,” she said.

“With our SolarSpan® roofing we’ve been able to use the outdoor as much as the indoor. In the warmer months we’re staying cool and during winter we can still enjoy our outdoor space.

“The skillion roof and insulation keeps us comfortable year-round.”

With a growing family, Gemma and Christian already spend Sunday afternoons watching their children play in the backyard from under their Bondor SolarSpan® alfresco deck. In the years to come they see this space housing birthday parties, celebrations, and all the big milestones.

Manufactured in Australia by Bondor, SolarSpan® is Australia’s leading all-in-one insulated roofing panel offering long-spans, low pitch and high thermal efficiency. 

Baahouse Hinterland Home, Gold Coast

The Challenge

Claus Ejlertsen from Baahouse Architecture specialises in innovative residential design, particularly in creating efficient and luxurious small-scale living spaces.  

When Claus was approached to design a compact retirement home for a family downsizing to their children’s Gold Coast hinterland property, he knew he had to ‘get creative’ with council parameters. 

The clients—who originally lived near Gympie wanted a smaller dwelling designed to be a future-proof property where they could comfortably live as they got older. 

Working within a tight 60m2 footprint, 20% smaller than a typical free-standing Australian house, Claus’s challenge was to work with this limited space to create a comfortable retirement home that didn’t feel cramped. 

The local council parameters were strict, so he need to strategically expand the perceived space through clever architectural design to create an expansive, light-filled living environment that felt much larger than its compact footprint. 

Bondor’s SolarSpan® insulated, long spanning roof panels gave Claus the flexibility and aesthetic appeal to create a home that perfectly met his clients’ needs. 

The Solution

Claus tackled the project’s restricted footprint by thinking beyond traditional design. He maximised space through high raked ceilings, eliminating hallways, and creating an open-plan layout that seamlessly connected indoor and outdoor areas.  

Claus effectively doubled the size of the home by connecting an additional 40-50m2 outdoor deck to main home. This deck area was excluded from the council’s internal measurement, allowing for significant extra living space.  

He also created an additional rear deck and multi-purpose utility and laundry space, which effectively pushed the total usable area to around 100m2.  

Claus emphasised the importance of the indoor-outdoor connection being crucial to the home’s design. 

“With the subtropical Brisbane climate, it’s really important that we live outside, enjoy that outside deck space, and give that indoor, outdoor connection between the two spaces that we’re working with,” he said. 

“That really makes a small house feel like a big, large, open, family home.”  

The inclusion of high raked ceilings and open plan design also contributed to making the modest space feel much larger and more expansive. 

By using Bondor’s SolarSpan® roofing system, he streamlined construction and created a light-filled, airy interior.  

“Bondor is a fantastic product. It has a self-clipping together modular system that comes in long spans. For this project, we got six metres from one beam to the other beam. 

“It’s also quick and easy to install. Within that roof system, you’ve got the lining so you don’t have to paint underneath, the insulation, and the top of the roof, all in one panel.  

“The same day the electrician comes in, he does the lighting installation, and literally, within a day, you have a whole roof installed.” 

Through innovative design, seamless indoor-outdoor connections, and strategic use of natural light, Claus transformed what could have been standard granny flat into a luxury escape for his clients’ retirement years. 

Manufactured in Australia by Bondor, SolarSpan® is Australia’s leading all-in-one insulated roofing panel offering long-spans, low pitch and high thermal efficiency. 

Scone Historical Society

The Challenge

The Scone and Upper Hunter Historical Society needed to upgrade their archive shed to better preserve their valuable historical collection.  

Established in 1956, the historical society maintains a comprehensive archive of the area’s rich local heritage. The archive includes a wide range of documents such as photographs, books, and various written records spanning from the early settlement period of 1825 onwards. 

 The existing old fibro shed was in poor condition with malfunctioning roller doors and a possum inhabiting the space, making for unsanitary storage conditions for their venerable collection. 

A new shed was needed to address multiple preservation needs, from temperature and humidity control, to protecting against dust and pests. It also needed to meet the Development Authority’s requirements for storing heritage items.  

The project involved obtaining a grant, working with Great Value Garages, and navigating complex State Government planning portal requirements to create a suitable storage solution for their collection.  

Bondor’s InsulRoof® panels provided the specialised insulation and fire rating requirements needed to protect and maintain the historical society’s collection.

The Solution

For Great Value Garages, this project pushed the boundaries of the company’s traditional shed-building expertise. Unlike their standard builds using corrugated iron or weatherboard-style sheeting, this project marked their first complete shed using insulated panels for both walls and roof. 

The archive storage facility required highly specialised technical specifications, including a precise R5 insulation rating and specific fire protection standards.  

These unique requirements demanded significant engineering adjustments and a completely new approach to shed design, moving well beyond their usual construction methods. 

Having previously used Bondor products in carports, the company was familiar with the brand and knew they could provide the right panelling. After consulting with Bondor, they confirmed InsulRoof® panels would meet the critical protection requirements for storing historical documents. 

The completed archive shed is a 6x9m structure, standing 2.4m high with a 30-degree roof pitch, a waterproof concrete floor, properly closing roller doors, and improved structural design that prevents pest entry. 

It houses a unique collection of historical items such as glass negatives from early photographer Joseph Docker, portraits of early settlers, and some Aboriginal artifacts. The new shed will also house small pieces of historical furniture and other museum collection items that are not currently on display in the historical society’s main museum space. 

By constructing the new, specially insulated shed, the Scone and Upper Hunter Historical Society have ensured the area’s valuable historical records and artifacts are safeguarded for future generations. 

The insulating properties of the Expanded Polystyrene with fire-retardant (EPS-FR) core, together with an airtight joint, makes InsulRoof® panels an ideal solution for preserving the story of Scone and the Upper Hunter.  

Regional Shopping Complex – Tasmania

The Challenge

It isn’t every day that Bondor Metecno Tasmania are approached to supply product for a ‘ground up’ shopping complex build, but when the opportunity came up in regional Tasmania in 2024 it was a challenge the team were ready to tackle.

The shopping complex was centred around a supermarket with additional tenants to include a bakery, a takeaway, and a bottle shop, with concrete tilt-up walls and an exposed roof structure.

The brief that came across State Manager – Tasmania, Ashley Moore’s desk was to supply panelling that was not only thermally effective but commercially and aesthetically pleasing.

As with any project involving food and produce storage, not just any product would do.

The project needed to deliver in three key areas—thermal performance, ease of installation, and aesthetic qualities.

MetecnoSpan® roofing, MetecnoInspire® walling, and MetecnoPanel® for the cool rooms and freezers provided the perfect combination.

The Solution

“This project is a great example of the wide range of panelling Bondor Metecno can offer for various commercial and industrial applications in a single project,” Ashley said.

“The roof, walls, and cool room show how our products work together for quick installation, strong thermal performance, and a consistent, functional design.

“Although we’ve done several projects with cool rooms with food safety requirements, what is unique about this project is the choice of Monument dark panelling for the internal roof and wall finishes.

“The architect selected the colour scheme not only to complement the supermarket anchor tenant, but also because it helped camouflage exposed services like cable trays, electrical work, and ductwork that are visible on the underside of the roof.

“The uniform, dark appearance not only helped conceal internal building services but also offered visual simplicity and a clean, streamlined look to the building’s interior.

“In fact, the colour scheme has become a recurring design choice for the supermarket chain,” he said.

The final building features:

  • Roof: MetecnoSpan® Surfmist over Matt Monument x 2815m2

  • Perimeter lining internally: MetecnoInspire® 60mm Monument over White x 840m2

  • Cool rooms: MetecnoPanel® 100mm Monument over Monument x 274m2

  • Freezer: MetecnoPanel® 150mm Monument over Monument x 108m2

The outcome of the project proving that the client and complex truly could have it all: form and function.

Today, the regional shopping complex is visited daily by hundreds of locals stocking up on essentials who get to enjoy the ‘cool’ aesthetics and even cooler internal temperature with the application of the MetecnoPIR product.

MetecnoSpan®, MetecnoInspire®, and MetecnoPanel® all feature a polyisocyanurate (PIR) rigid core between layers of BlueScope® COLORBOND® steel. They deliver extreme thermal efficiency and are fire retardant, CodeMark™ accredited, GreenRate certified and FM Approved to FM 4880 and FM 4471.

Portarlington Amenities Block

The Challenge

The Portarlington Public Amenities Block project, undertaken by GR Design & Construct, aimed to replace an outdated 1970s-era toilet block with a modern, functional, and aesthetically pleasing facility.

Located on the Bellarine Peninsula near Geelong, Victoria, the project was part of the local council’s capital works and replacement program. The new facility was designed to cater to a diverse community, including retirees, families, holidaymakers, and individuals with disabilities and in particular with high support needs.

The project needed to meet stringent accessibility requirements, including a specialised ‘Changing Places’ facility that could safely accommodate people with disability and their carers.

The high-visibility and high-traffic location meant that a visual upgrade was also equally important in creating a more sophisticated public amenity that went beyond pure functionality. The facility needed to withstand heavy public use while maintaining cleanliness and durability.

Bondor’s SolarSpan® all-in-one insulated roofing panel, consisting of the roof, insulation, and ceiling in a single panel, provided a cost-effective and energy efficient solution to a traditional corrugated tin roof, and transformed the block from a basic ‘shed’ to a more visually appealing structure.

The Solution

The completed Portarlington Amenities Block stands out as a more functional, accessible, and attractive public space that goes far beyond a ‘typical toilet block’.

The project took about 8 months from design to completion, featuring five toilets, a storeroom, external showers for beachgoers, and a specialised ‘Changing Places’ facility to enable people with disabilities to comfortably and safely use public spaces.

Darren McIntosh of GR Design & Construct said the company was one of the few specialist contractors in Australia who build these facilities.

“Changing Places is a specialist facility that allows people with disability and high support needs to use the beach or public toilets anywhere,” he said.

“We had to meet multiple regulatory requirements, including DDA (Disability Discrimination Act) standards, ensuring full accessibility including door widths, space allocation, and privacy considerations.”

Darren said the Bondor SolarSpan roof was chosen to provide cost and energy efficiencies as well as enhanced aesthetics compared to a traditional corrugated tin roof.

“SolarSpan® offered a cost-effective solution through a single-panel solution incorporating roof, insulation, and ceiling. It also contributed to enhanced thermal efficiency by reducing heat gain and improving energy conservation.”

“The panels provided a streamlined, clean design that elevates the perception of public restrooms and set a new benchmark for public facility projects, demonstrating that practical infrastructure can also be visually appealing and environmentally.”

The Portarlington Public Amenities Block stands as a model for future public amenities, proving that investment in well-designed, high-quality materials like Bondor’s SolarSpan® can result in long-term benefits for both the community and local governments.

SolarSpan® is Australia’s leading insulated roofing panel offering long-spans, low pitch and high thermal efficiency to satisfy Section J requirements in commercial and industrial applications. Codemark approved and Australian Standards tested, SolarSpan® features a COLORBOND® steel exterior roof layer, EPS-FR rigid insulation core with a pre-finished COLORBOND® ceiling underside in a variety of profiles and colours to maximise creative expression.

Melton Beach House

The Challenges

Despite its location in Melton on Melbourne’s western rural–urban fringe, homeowner and building designer Jessica wanted to create a home with a beach house feel. A mum of three, Jessica’s vision was for a home that was not only sleek and modern, but also one that felt open, spacious, and able to accommodate her family and friends.  

With time to make up after COVID-related restrictions delaying build time, Jessica needed products that were quick and easy to install while making efficient use of the available space and giving plenty of natural lighting.  

As seen on the eighth episode of 9Life’s Open Homes Australia season 5. 

 

The Solution

Jessica decided to incorporate Bondor’s InsulRoof® and LuxeWall® in the design and construction of her home, giving it a modern and monochrome look and feel. 

“Although I live in Melton, I still wanted a beach house. Using the available space, I decided to build something similar to a beach house – something with a modern feel in the suburbs,” Jessica said 

 Jessica opted for LuxeWall® on the exterior of the upper floor to take advantage of the panel’s advanced lightweight cladding technology and decorative COLORBOND® 

Basalt finish, offering a cost effective and sustainable addition to the build. 

“I went with LuxeWall® on the upper level to complement the concrete panels on the lower level, which gave a slick, modern look to the home.”  

 “Using LuxeWall® prevented the need to build layers upon layers in the understory, keeping things light and fitting the sleek design.” 

 Jessica also incorporated Bondor’s InsulRoof ® panels in the COLORBOND®  Surf Mist.  

 “InsulRoof ® panels were the perfect inclusion to our design thanks to their span across our rooftop and low maintenance,” Jessica said.  

“We were able to incorporate this roofing solution to ensure we maintained the valuable natural light and regulated temperature.” 

 Despite not living on the beach, Jessica achieved her dream beach house – an open-plan home with plenty of natural lighting and space.  

Lady Galway, Enoggera

The Challenges

Semi-retired resident Kay was looking for a house that would be her forever home. However, not finding one to suit, she approached Jamin Design Group and Petroff Constructions to help  her create a mid-century modern home with a twist. 

Kay shared her portfolio of ideas with Jamin Design Group, who designed a unique home to bring to life Kay’s vision. Karl Petroff from Petroff Constructions made the home a reality, brining the outside in using Bondor’s SolarSpan® and InsulWall®. 

As seen on the fourth episode of 9Life’s Open Homes Australia season 5.

The Solution

Karl decided to incorporate InsulWall® and SolarSpan® roofing to ensure cross flow ventilation without the need for air conditioning thanks to the insulation value of the all-in-one insulated sandwich panelling. 

“Kay was looking to incorporate a mid-century modern look, blending an industrial feel into modern InsulLiving,” Karl said. 

Bondor’s InsulLiving® system combines the revolutionary, lightweight and strong InsulWall® and SolarSpan® panels, which together form a complete thermal shell to protect the home from extreme hot and cold weather. 

“What makes Bondor’s SolarSpan® so special is its insulation properties. Not only do they create a open, industrial feel, Kay’s house does not require air conditioning.

“The roofing panels interlock easily with the wall panels to form a complete thermally efficient shell. Combined with high level louvers to allow airflow, the home is naturally cooled to remain comfortable throughout the year.”

Kay’s home is her oasis – a place to keep her special memories and packed full of personality. 

“Kay loves her knick knacks, so her home has been purpose designed to reflect her travels. She is pleased to have a space to display her treasures and special memories,” Karl said. 

V Residence

The Challenges

A Brisbane family approached TONIC Architecture and Design to create a home that would work for their growing family; that was functional and filled with light and ventilation, capturing views while maintaining privacy. 

The existing 1970s era brick house featured city glimpses and a connected backyard, with high ceilings, sculpted voids, and an abundance of natural light inside. However, the home was orientated in wrong direction with living areas facing east and the backyard facing west. The lower level of the home also had the incorrect ceiling height and limited connection between the living areas. 

The family did not want to lose the elements of the existing house they liked such as the brick and mid-century modern style. They envisaged a renovated home that suited the lifestyle needs of a large busy family – a light filled sanctuary, offering escape for both parents and children whilst surrounded by greenery, trees, and landscaping.   

After viewing the property, TONIC Architecture and Design’s Managing Director Matthew Riley proposed an extension to the home to include a new double volume kitchen and dining space on the southern side of the home. This space was designed to connect the existing living spaces. The extension also featured a raised clerestory roof to capture the northern sun.  

As seen on the second episode of 9Life’s Open Homes Australia season 5. 

The Solution

Matthew decided to incorporate SolarSpan® roofing on the extended portion of the home, reducing need for large structural elements. 

“The SolarSpan® roofing in COLORBOND’s Surfmist enabled a simple clearspan roof, providing great insulation for the living space,” Matthew said.  

“In addition, we used Bondor Panels as window hoods on the existing house to link the new additions to the existing home. Bondor’s panels provided excellent weather protection and sun shading for existing window openings, creating a new and modern look for the home. 

“Having pre-finished products meant the ease of construction and time saving with the installation. The insulation properties were also considered when deciding to incorporate SolarSpan® panels.” 

The family was impressed with the meticulous design of the new area and the seamless integration with the existing home.  

“The owners were pleased with their new home, which catered for the whole family, and their busy lifestyle. The final product exceeded their expectations and vision of what was possible,” Matthew said.  

Matthew was impressed with the completed build, and credited the ease of using Bondor’s SolarSpan® and pre-finished panels in the home extension to meet the client’s ‘must-have’s.’ TONIC Architecture and Design regularly use Bondor products and will continue to do so in a range of upcoming projects.