Discount Metal Roofing Australia

The Challenge

Discount Metal Roofing Australia is a family business established by Chris Imre’s father, John, that is now run day-to-day by Chris alongside his sister, Christine, and brother, Tom. Based in Wollongong, the business manufactures its own roofing sheets onsite using two roll formers and a flashing machine, as well as supplying roofing materials, insulation, structural steel and accessories to customers across Australia.

Around two years ago, Chris saw an opportunity to diversify beyond the business’s traditional roofing supply into insulated panelling, a category he admits he knew little about at the time. No formal market research had been done with the decision coming down to recognition of unmet demand in the Illawarra region, where only a small number of suppliers dealt in insulated panels.

One of the biggest challenges was building the product expertise to meet this demand with confidence. As the sole person handling the insulated panel side of the business alongside its existing operations, Chris needed to understand the engineering and design considerations quickly, without pulling focus from the core business.

The Solution

Bondor’s local representative, Elvis, first approached Discount Metal Roofing Australia with product samples and information, inviting the business to take on the range. Over the following two years, Elvis provided hands-on support with product knowledge, design guidance and the engineering side of quoting, allowing Chris to build the confidence to handle most customer quotes independently.

What attracts his clients to the products, in Chris’s words, is their simplicity. Compared with traditional builds involving posts, girders, rafters and separate roof sheeting, insulated panel systems require far fewer components and a shorter install time, appealing strongly to smaller operators and one-person installers working on patios, extensions and awnings. Customers are also attracted to the product due to its finished aesthetic, a clean, uniform ceiling with no visible posts or beams, paired with high thermal performance from the insulation profile. The all-in-one insulated system is simple from start to finish with numerous options of insulation thickness and panel length allowing for a variety of purposes from industrial warehouses to a residential home or an outdoor patio.

Demand has been strongest in the growing residential corridor south of Wollongong, including new high-value estates in Shellharbour and Shell Cove, where large-scale home builds are driving demand for patios, awnings and outdoor living additions. Chris also credits word of mouth and growing product awareness with steadily increasing enquiries, as more customers become familiar with the benefits that insulated panelling offers over standard alternatives.

“It’s not just on top but underneath; you don’t see any posts, you don’t see any beams, it’s just uniform,” Chris said.

“A lot of people come in and say, wow, we’re really, really happy on how it’s been installed, and the look of the product.”

Against larger competitors, Chris positions the business’s family ownership and personal service as a key point of difference, pointing to consistent five-star customer reviews and a focus on after-sales support that he says larger operators don’t always match.

Moorland Homestead SolarSpan Reveal

The Challenge

Perched on a hilltop on the New South Wales coast, the Moorland Homestead project set out to deliver a modern, expansive family home that could fully capitalise on its surroundings.

With sweeping views across the landscape and a large, elevated block, the brief was clear: create a home that maximised outlook, delivered year-round comfort, and met the owners’ strong focus on energy efficiency.

From the outset, orientation was critical. The design team needed to carefully position the home to capture natural light, enhance solar gain and frame key sightlines, without compromising thermal performance.

Achieving that balance required extensive collaboration between Fraser Lyne Constructions, McNeil Architects and engineers Alan Taylor & Associates. The layout went through multiple iterations, with angles and positioning refined repeatedly to respond to the site’s unique conditions.

Alongside the visual goals, performance expectations were high. The homeowners specified a polished concrete slab paired with a geothermal heating system, supported by block construction to stabilise internal temperatures.

This demanded a building envelope that could work cohesively to control heat transfer and maintain consistent comfort.

Compounding the challenge was the sheer scale of the build, including what would become one of the largest SolarSpan roofs installed in Australia for a residential build.

Designing a roof structure that could span such a large area without compromising integrity or introducing long-term maintenance risks added further complexity to an already ambitious project.

The Solution

Bondor SolarSpan® insulated roofing panels played a central role in addressing the project’s architectural and performance requirements, delivering a roofing solution capable of meeting both scale and efficiency demands.

To achieve the expansive, uninterrupted roofline, Bondor supplied SolarSpan® panels at an exceptional length of 22.4 metres. This eliminated the need for joins across the roof span, a critical factor in meeting the builder’s performance expectations.

“At one stage, the design included a roof join, but I wanted to avoid the risk of long-term issues. Bondor was able to step in with a single, large-span solution that removed that concern,” builder Fraser Lyne said.

By removing the need for joins, the system reduced potential failure points while delivering a clean, seamless finish that aligned with the home’s contemporary aesthetic. It also simplified installation across the large footprint, contributing to a more efficient build process.

“From an installation perspective, the Bondor roof went on smoothly and efficiently, and that really made it a standout feature of the home. One of the big highlights of this house is that roof,” Fraser said.

Thermal performance was equally critical. The SolarSpan® panels provided an integrated roofing, insulation and ceiling system, supporting the home’s broader passive design strategy.

Working in conjunction with the building’s orientation, geothermal system and thermal mass, the panels helped regulate internal temperatures while maximising the benefits of solar gain.

The slim profile also enabled the home to maintain a refined architectural look without compromising insulation performance.

Ultimately, SolarSpan® delivered a high-performance roofing system that aligned with the project’s scale, design intent and energy goals, helping bring the Moorland Homestead vision to life while ensuring long-term durability and comfort.

SolarSpan Delivers Comfort Above The Bay

The Challenge

For David Buntin and Nana Jernstrom, their Mount Eliza forever home was about creating a place that felt comfortable, practical and connected to its coastal surroundings.

Perched on an elevated site overlooking Western Port Bay, the design needed to maximise views and natural airflow while maintaining a stable indoor environment through changing coastal conditions.

“We wanted a home that made the most of the views, was highly energy efficient and allowed airflow through upper windows,” Nana said.

The brief also called for a building approach that could deliver long-term performance, reduce energy use and simplify construction.

Having used Bondor products previously, the homeowners brought a clear brief to Hugh Feggans of Aych Architects, including a preferred building system from the outset.

“Nana and Dave were fantastic clients to work with, because they knew exactly what they wanted and came to the project with a clear brief and a preferred building system to utilise,” Hugh said.

The challenge for the design team was to integrate these priorities into a home that balanced architectural intent with build efficiency and long-term liveability.

The Solution

Bondor insulated panels became central to the design response, used across both the walls and roof to create a cohesive, high-performing building envelope.

On the external walls, LuxeWall by Bondor® provided an integrated panel system that combines insulation and durability in a single product, reducing the need for additional construction layers.

For the roof, SolarSpan® insulated panels delivered both structure and insulation, streamlining construction while supporting the home’s thermal performance.

At 250mm thick, the self-supporting roof panels reduced the need for additional structural elements such as trusses, simplifying installation and minimising on-site complexity.

“The roof system is self-supporting, delivering both insulation and performance in one solution,” David said

For Hugh, working with a pre-insulated panel system influenced the design early, helping guide spans, building form and construction approach.

“Using a pre‑insulated panel system allowed for a more efficient outcome across the project,” Hugh said.

Used across the walls and roof, the system helps keep the home comfortable year-round by maintaining a more consistent indoor temperature.

Paired with smart passive design, including orientation, glazing and natural airflow, it reduces the need for heating and cooling and supports everyday comfort.

The result is a home that feels as good as it looks, balancing thoughtful design with practical performance in a coastal setting.

Architect-Designed Comfort with SolarSpan

The Challenge

Andrew and Denise designed and built their family home in Campbelltown, west of Sydney, on a modest budget but with ambitious performance goals.

As architect and owner-builder, Andrew wanted a naturally comfortable, draft-free home with minimal reliance on air conditioning, one that was also simple and economical to build while retaining a distinct architectural identity.

The roof needed to deliver strong insulation, airtightness and structural performance while remaining slim enough to support the design intent and a substantial solar PV system.

As first-time builders keen to minimise trades, they also needed a roofing solution that was fast to install, simple to detail, and able to keep the project moving.

To meet those goals, Andrew and Denise centred the build on a high-performing envelope, with SolarSpan® insulated roofing panels as a key component.

The Solution

Andrew’s strategy was to simplify the building form and materials, optimise orientation and shading, and maximise insulation across the building envelope.

Paired with a 24kW solar PV and 42kWh battery system, the result is a home that stays comfortable year-round with minimal heating and cooling, powered entirely by on-site electricity generation.

“We chose SolarSpan® very early in the design process. Other elements changed through the design iterations, but SolarSpan® remained a constant because it ticked so many boxes for us,” Andrew said.

SolarSpan® was selected for its thermal performance, airtight design and structural capability, enabling a low north-facing single pitch, clear spans and raking ceilings without additional structure.

“It’s a complete system. There are no roof penetrations, no drafts, no leaks, and the panels provide excellent thermal performance,” he said.

It also delivered construction efficiencies: the roof, gutters and trims were supplied by Bondor and installed in a single day, helping the couple move quickly to the next stage of the build.

“The fast installation meant we could start the walls much sooner than with a conventional system. Even with the plasterboard ceiling, the roof is only about 250 mm thick overall, which is exceptional for this level of performance.”

“It also allowed the photovoltaic system to be installed early, reducing the time we needed scaffolding. Solar fixing is straightforward, and the panels easily accommodate the extra load.”

The high thermal performance of the SolarSpan® roof and insulated walls, combined with the solar PV and battery system, significantly reduces grid reliance and enables the rooftop solar array to generate a substantial surplus.

“We expect to generate around 36 megawatt hours a year, while using less than 12, so the home should consistently export a large amount of electricity back to the grid,” Andrew said.

By combining a carefully detailed insulation strategy with SolarSpan® insulated roofing panels, Andrew and Denise created a distinctive family home that is comfortable year-round, efficient to build, and strong in everyday thermal and energy performance.

“Choosing SolarSpan® simplified the design, detailing and construction without compromising performance. It was time- and cost-effective, with strong thermal and structural properties,” Andrew said.

“The thin profile and standard trims look sharp externally and made achieving raking ceilings easy. Bondor also provided excellent support throughout the project.”

“We feel like we’ve made a lot of good decisions in this project and going with SolarSpan® was amongst the best.”

Building Modular Homes at Scale

The Challenge

The cost of building in Australia continues to rise, making traditional home ownership harder to access. For many younger buyers, getting into the market is becoming less realistic, even when they already have access to land.

In many cases, the issue is not just land prices, but the cost and disruption of a conventional build. What might seem like a straightforward backyard project can quickly become expensive and time consuming, limiting the appeal of building altogether.

At the same time, there is growing demand from parents and grandparents wanting to live closer to family. For many, buying a new home or undertaking major renovations is not practical, particularly in a high-cost market.

Added to this are stricter energy performance requirements. New homes are expected to meet higher efficiency standards, often around seven stars, which can further increase build costs when using traditional construction methods.

Addressing these challenges requires a different approach. One that delivers on cost, performance and speed, while still creating a home that feels permanent and considered.

AJC Modular takes this approach with prefabricated homes designed to simplify the build process and improve cost certainty, while maintaining strong energy performance.

The Solution

Bondor’s Structural Insulated Panels (SIPs) sit at the core of AJC Modular’s building system. Used across both walls and roofing, they create a tightly sealed, well-insulated structure that can be assembled quickly on site.

“They’re a highly insulated steel panel that goes together basically like a Lego piece,” AJC CEO Andrew Copley said.

This simplicity also supports the way AJC Modular delivers projects at scale. “We’ve got a unique system that makes construction faster. We have a highly efficient, energy-rated building, but we can also build it at scale and speed.”

Because the panels arrive fully insulated, performance can be adjusted to suit each build. “The advantage of the Bondor product is it comes fully insulated, and you can choose your level of insulation as well,” Andrew said.

That flexibility is especially important when working to meet regulatory requirements.

“In Australia, all residential homes need to meet Class 1a standards, which in many states means achieving a high energy efficiency rating, often around seven stars. In those cases, we work with Bondor to increase the insulation levels in the panels to meet those requirements.”

At its Brisbane display centre, AJC showcases the Airlie, a 68 m² modular home designed to fit comfortably within a standard residential block.

“The Airlie is designed to accommodate a small family, with two bedrooms, two bathrooms, a full kitchen and living area, and a separate laundry,” Andrew said.

The design has evolved based on customer feedback, including changes such as converting a private ensuite into a dual-access bathroom to improve day-to-day usability.

Inside, the homes are finished with practical, durable materials including Polytec kitchen joinery, stone benchtops and tiled bathrooms. Combined with the panel system, this helps balance comfort, performance and cost.

AJC Modular currently delivers around 150 to 200 homes each year and has recently completed a new large-scale manufacturing facility to meet growing demand.

The new factory is designed to produce up to 1,000 homes annually and support a national rollout, allowing AJC Modular to service projects across the country with a consistent approach.

“We’ll be able to produce 1,000 per year and service the whole country as well,” Andrew said.

AJC Modular operates on a national fixed-price delivery model, with delivery pricing calculated from the nearest Australian capital city, allowing customers across the country to benefit from simplified and transparent pricing.

At this scale, and with Bondor’s panel system, AJC Modular is creating a more realistic path into the housing market for both first-home buyers and multigenerational families.

Dual-Purpose Carport & Patio

The Challenge

A homeowner and car enthusiast in Aspley, on Brisbane’s northside, engaged Gerard Vella from Gerard By Design to create an insulated roof structure off the side of his home that could function as both a carport and an outdoor entertaining patio.

Initially, the client considered building an additional shed in the backyard. However, with limited green space available, this solution would have compromised the usability and openness of the yard.

Gerard proposed an alternative: a thoughtfully designed structure wrapping around the house that would preserve valuable backyard space while delivering a highly functional, visually cohesive, dual-purpose outdoor area.

The design needed to integrate seamlessly with the home’s existing layout, colour palette, and façade, while also supporting modern features such as ceiling fans, downlights, and security cameras.

The site itself presented several challenges. The home sat on an elevated block with a steeply sloping driveway, and the house featured non-standard angles, stepping and wrapping around the contours of the land.

The Solution

Gerard selected Bondor’s InsulRoof® insulated roofing panels for their versatility, durability, superior thermal performance, and lightweight ease of installation, particularly important given the site’s complexity.

Installation was completed in two stages: the lower, more accessible section was installed manually by Gerard’s team.

A crane was used to safely and accurately position panels on the higher section of the structure.

The result was a combined covered area of 160 square metres, wrapping around the home in an L-shape.

“Built to handle Brisbane’s hot and humid conditions, the structure keeps the sun and rain off the cars while allowing plenty of airflow thanks to the flyover design,” Gerard said.

“Whether they’re parking multiple vehicles or hosting a barbecue, the space works perfectly.”

The completed project delivers a true dual-purpose solution—functional, visually cohesive, climate-appropriate, and achieved without sacrificing the backyard.

Gerard highlighted that InsulRoof® insulated panels are particularly well-suited to Brisbane’s extreme heat, significantly improving year-round comfort in outdoor areas.

“The biggest tick for me is that InsulRoof® is manufactured here in Brisbane using Australian COLORBOND® steel with a high R-value insulated core.” he said.

“Bondor has a great reputation, offers a 20-year manufacturer’s warranty*, and produces products built to last. I have no hesitation in recommending Bondor SolarSpan and InsulRoof® to my valued clients.”

Start your next outdoor project with Gerard By Design

https://gerardbydesign.com.au/ 

admin@gerardbydesign.com.au

Sydney Factory Focus

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.

Transforming Perth Patios with SolarSpan

The Challenge

Brent Lambrichs is the owner of BL Carpentry Services, a Perth-based business with more than 15 years’ experience in carpentry. Over the past 7–10 years, Brent has specialised in premium outdoor living spaces for private homeowners, with BL Carpentry Services catering to higher-end and architecturally designed homes along Perth’s western coastal strip.

These homeowners want more than basic shelter. They are investing in large, beautifully detailed outdoor entertaining areas that function as true extensions of the homes. They want spaces where they can host friends, relax with family, and enjoy the coastal climate without compromising on comfort or aesthetics.

Standard metal patio roofs, exposed framing and bulky light fittings no longer meet the expectations or property values in these areas.

Climate is a major factor. Perth is known for scorching, dry summers with repeated 40°C days. Under a conventional single-skin metal roof, patios can become “hot boxes”, radiating heat and making the area uncomfortable during the afternoon and early evening—precisely when people want to be outside.

“Clients want to be able to sit outdoors at three or four o’clock on a Saturday afternoon, have a drink, and entertain without being blasted by radiant heat from above,” Brent said.

Clients are also looking for outdoor areas that feel as refined as internal spaces. This means smooth, ceiling-like finishes; integrated flush downlights; ceiling fans; feature LED lighting; and, in some cases, heaters. The structure must also visually tie in with the home’s architecture, matching or elevating the internal standard of finish and enhancing overall property value.

The challenge for Brent Lambrichs and BL Carpentry Services is to deliver outdoor structures that satisfy demanding homeowners on three fronts at once: thermal comfort in extreme dry heat, premium aesthetics consistent with high-value homes, and functional flexibility that allows for integrated services and everyday usability.

Photos: Brent Lambrichs

The Solution

To meet these requirements, BL Carpentry Services has moved almost all patio and pergola projects to Bondor’s SolarSpan® insulated roofing panels.

“Almost every single one of our patios is a SolarSpan® roof sheet… it’s a quality material,” Brent said.

SolarSpan® combines roofing, insulation and an internal ceiling underside in a single panel, giving Brent an all‑in‑one solution:

“By the time you were to build a patio, put a roof sheet on the top, insulate it, and then do ceiling lining, I can just buy a Bondor SolarSpan®  panel. It’s all in one and it’s just super-efficient,” he said.

From a build perspective, SolarSpan® simplifies construction. Brent calculates spans, overhangs and cutbacks, orders panels to length, and his crew prepares the ends on site before lifting them into place, resting them on the beams and fixing them together.

Most projects can be sheeted within a day, with flashing and gutters typically completed over another day. Even on larger jobs with panels around six metres long the four-person team can handle the panels without routinely needing cranes.

Thermally, SolarSpan® tackles the “hot box” issue common under traditional roofs in Perth’s 40°C summers. The insulated core (minimum 50 mm) reduces heat transfer, lowering the temperature under the pergola.

“If you put a standard roof sheet on, it gets very, very hot underneath; when you use SolarSpan® panels instead, the insulated core really helps bring the temperature down,” Brent said.

Aesthetics and functionality are just as important. The clean underside of the panel allows BL Carpentry Services to install flush downlights, fans, heaters and feature LEDs while keeping a smooth, ceiling-like finish.

Brent is also developing a side brand focused on cantilever pergola, intended as premium structures with posts only at the rear, allowing the roof to project forward with a clean, post‑free front edge.

For this concept, he plans to use insulated SolarSpan® panels as the primary roofing element, as they provide the strength, thermal performance and sleek underside finish needed at the very top end of the market.

This approach showcases SolarSpan® not just as a roofing panel, but as a key enabler of high‑impact, architectural outdoor design.

Start your next outdoor project with BL Carpentry Services

brent@blcarpentryservices.com

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Melbourne Factory Focus

The Challenge

The construction industry is under pressure to deliver buildings that are more energy efficient, faster to build, and cost‑effective, while meeting rising regulatory expectations and client demands.

Traditional cladding systems can introduce breaks in insulation, making it difficult to achieve a continuous, airtight thermal envelope. This can reduce thermal performance and contribute to condensation issues at the same time as the market is moving from a minimum six‑star requirement toward seven‑star buildings. Builders and designers are therefore looking for more effective ways to meet higher energy standards.

Speed is another key challenge. Conventional methods can make it harder to reach lock‑up quickly, particularly in single‑storey housing where additional time on site directly affects project cost and viability. The industry needs building systems that shorten construction timelines without compromising performance.

Adopting new construction systems can also slow progress. When builders first encounter insulated panels, there is often hesitation about using an unfamiliar product and uncertainty around planning, final measurement, and on‑site installation. This can delay the shift toward more efficient building methods.

At a broader market level, demand is growing for modular and factory‑built housing as a cost‑effective way of delivering homes at scale.

Achieving high volumes, consistent quality and strong energy performance through factory‑based construction and partial off‑site assembly requires manufacturers to produce precise, custom‑formed panels quickly and reliably.

Bondor’s insulated walling and roofing panels are now a trusted choice across domestic construction, modular housing, cold storage, food processing facilities, entertainment centres and sports stadiums, putting the company at the centre of these evolving requirements.

The Solution

Bondor addresses these challenges through a factory‑built insulated panel system that improves energy performance, accelerates construction, and supports the broader shift to modular and panelised building in both commercial and residential markets.

Its insulated wall and roofing panels, long established in cold‑store and food processing applications, are now widely used in entertainment centres, sports stadiums, as well as domestic and modular buildings. 

A core part of the solution is the quality of the building envelope. The panels form a continuous layer of insulation that, when installed correctly, helps improve airtightness, minimise thermal breaks and reduce the risk of condensation in walls and roofing, while supporting higher energy ratings than many conventional cladding options.

The factory production process is structured for speed and predictability, with wall and roofing panels manufactured to order rather than assembled from multiple components on site.

Panels are produced to the required length, and Bondor can supply custom‑formed elements such as corner panels, bulkheads and columns.

This reduces on‑site cutting and adjustment, simplifies installation, and helps projects move to lock‑up significantly faster than with traditional cladding systems, with fewer trades and less on‑site complexity.

Bondor also invests in supporting builders who are new to insulated panels. The team assists with planning and layout, helps with final measures, and provides on‑site guidance during early projects so that the transition to this construction method is smoother and more reliable.

This hands‑on approach often turns first‑time users into ongoing advocates for panelised construction, who continue to specify insulated panels and position them as a more efficient way of building, including for modular housing.

By combining factory‑manufactured, customisable panels with practical support for builders, Bondor enables modular and factory‑built approaches that deliver quality and volume more efficiently.

This aligns with trends in markets such as Europe, where factory‑based assembly is widely used to achieve higher throughput, more predictable programmes and energy‑efficient building shells that deliver long‑term performance benefits.

Warehouse 3 – Somerville Road Estate

The Challenge

In creating the vision for Warehouse 3 of the Somerville Road Estate, Alrio Group, on behalf of the Aliro Group Industrial Vehicle (AGIV), teamed up with Texco Construction to design a large-scale transport and logistics cold store facility to accommodate major supermarket chains or logistics companies.

Aliro Group speculatively developed the 22,163m2 state-of-the-art facility to address market demand for high-quality, flexible cold storage and logistics facilities. Unlike traditional builds tailored for a specific tenant, this project was designed to high specifications and with flexible features to attract a wide range of potential tenants.

The team was committed to delivering a highly energy-efficient and environmentally friendly facility, with a 5 Star Green Star sustainability rating a key priority. This required careful planning and execution, adding complexity to the design and construction phases.

Fire safety was also another major consideration for this project.

Aliro Group selected Bondor Metecno’s MetecnoPanel® PIR insulated wall panels for the internal cold rooms, the staging area, the negative 24-degree cold storage area, and most of the exterior walls of the facility.

The Solution

Warehouse 3 marks completion of Stage 2 of the Alrio Group’s Somerville Road Estate and the successful realisation of a premium industrial precinct in Melbourne’s inner west.

Designed for flexibility and capable of being configured into two tenancies, the project features four independent temperature-controlled chambers. Each chamber is fully fitted with premium, Australian-made double-deep racking, offering 33,563 pallet spaces and ensuring the facility is ready for immediate high-capacity operations.

This state-of-the-art freezer facility includes a 500kW rooftop solar system to reduce electricity costs and targets a 5 Star Green Star – Design & As Built v1.3 rating, reinforcing Aliro Group’s commitment to sustainable, high-performance industrial spaces.

MetecnoPanel® PIR insulated wall panels were used extensively throughout the facility and were integral to achieving the facility’s high standards for energy efficiency, fire safety and functionality.

The panels were installed internally for all the cold rooms, forming the primary lining for these temperature-controlled spaces. The panels were also used in the staging area, which is maintained at four degrees, as well as in the negative 24-degree cold storage area, ensuring optimal thermal performance across different zones.

The panels help to reduce overall energy consumption, supporting the project’s goal of achieving a 5 Star Green Star and contributing to lower operating costs for tenants

The panels’ PIR fire-resistant core also provided a higher level of fire resistance, especially important with cold storage facilities facing high insurance premiums due to the risks associated with less fire-resistant panels. By choosing high-quality, fire-resistant MetecnoPanel® panelling, Aliro Group aimed to reduce both energy and insurance costs, making the facility more attractive to potential tenants.

MetecnoPanel® was also used extensively for the exterior walls, providing both insulation and structural integrity, which was augmented on the loading dock side where steel and aluminium sheeting was used for added weather protection.

The result is a high-specification, energy-efficient cold storage facility designed for flexibility and ready to accommodate a range of tenants seeking modern, energy-efficient cold storage solutions.

MetecnoPanel® PIR insulated wall panels with a PIR fire-resistant core are manufactured in Australia exclusively with BlueScope® steel to suit Australia’s harsh conditions. MetecnoPanel® is GreenRate certified and FM approved to FM 4880 & 4881 – No Height Restriction and is suitable for all insulated panel applications, from cold storage to exterior warehouse walling.