Removing a fibreglass roof panel from a pergola is a job most handy homeowners can tackle themselves, provided you respect the material's fragility, protect yourself from fibreglass irritants, and work safely at height. Here's how to do it properly.
Understand What You're Working With
Fibreglass (also called fibreglass-reinforced plastic, or FRP) roofing panels are lightweight but brittle, especially older panels that have been exposed to UV for many years. When cut, drilled, or broken, they release tiny glass fibres that can irritate your skin, eyes, and lungs. Older panels — particularly those installed before the 1990s — may also contain other compounds, so it's worth knowing the age of your pergola before you start.
Important: Fibreglass roofing is not the same as asbestos-containing material, but if your pergola is very old (pre-1990s) and you're unsure what the panels are made of, treat them with caution. Asbestos was used in some older corrugated roofing products in NZ. If in doubt, have a sample tested before proceeding. WorkSafe NZ has clear guidance on identifying and handling asbestos safely.
Gather Your Safety Gear and Tools
Before you climb up, assemble the following:
- Personal protective equipment (PPE): Long-sleeved shirt, long trousers, chemical-resistant gloves, safety glasses or goggles, and a P2-rated dust mask (not just a paper dust mask)
- A stable ladder or scaffolding rated for your weight plus tools
- A cordless drill or screwdriver
- A flat pry bar or panel lifter
- A utility knife or jigsaw (if cutting is needed)
- A helper on the ground to steady panels and the ladder
- Plastic sheeting or a tarpaulin to collect debris
Work Safely at Height
Falls are one of the leading causes of serious injury in NZ home DIY projects. Keep these points in mind:
- Never stand on fibreglass panels — they will not support your weight and can shatter without warning.
- Use a ladder that extends at least 1 metre above the working surface, and have someone foot it at all times.
- If your pergola roof is more than 3 metres above the ground, consider hiring scaffolding or engaging a professional.
- Work on a calm, dry day — wet fibreglass is extremely slippery.
WorkSafe NZ provides free guidance on safe ladder and working-at-height practices for homeowners.
Step-by-Step: Removing the Panel
1. Inspect the Fixing Method
Most fibreglass pergola panels are fixed with tek screws (self-drilling screws) through the panel crown into a purlin or rafter below, often with a rubber or neoprene washer to seal the hole. Some older installations use roofing nails or clips. Identify your fixing type before you start.
2. Remove the Fixings
Using your cordless drill in reverse, back out each tek screw carefully. If screws are corroded and won't budge, apply a penetrating lubricant, wait 10 minutes, and try again. Avoid forcing them — a snapped screw can crack the panel and send fibres into the air.
3. Check for Overlap and Sealing
Fibreglass panels typically overlap adjacent panels by at least one corrugation. Check whether the panel you're removing is underneath or on top of its neighbour. If it's underneath, you may need to partially lift the overlapping panel first. Some installations use a bead of sealant along the overlap — run a utility knife along the join to break this seal gently.
4. Lift and Lower the Panel
With all fixings removed, lift the panel carefully from one end. Fibreglass panels can flex and crack if lifted from the middle. Have your helper on the ground ready to receive the panel — lower it slowly rather than dropping it. Lay it flat on the tarpaulin.
5. Clean Up
Sweep or vacuum up any fibreglass dust or fragments using a vacuum with a HEPA filter. Bag all waste securely in heavy-duty plastic bags before disposal. Check with your local council for the correct disposal method — most fibreglass roofing can go to a general construction waste skip, but confirm this locally.
Does This Work Require a Building Consent?
Removing a single roof panel for replacement is generally considered maintenance and is unlikely to require a building consent under Schedule 1 of the Building Act 2004. However, if you're removing panels as part of a larger pergola demolition or alteration, consent rules may apply. Always confirm with your local council before starting any structural work. MBIE Building Performance has a useful overview of when consent is and isn't required.
Disposing of Old Fibreglass Panels
Fibreglass roofing is not recyclable through standard kerbside collections. Options include:
- Taking panels to a transfer station that accepts construction waste
- Hiring a skip bin from a local waste company
- Contacting your local council for guidance on accepted disposal sites
Always bag broken or fragmented panels to prevent fibres from becoming airborne during transport.
When to Call a Professional
Consider engaging a qualified demolition contractor or roofing tradesperson if:
- The panels are at significant height (above 3 metres) or the roof is steep
- You suspect the material may contain asbestos — this is restricted work requiring a licensed asbestos removalist
- The pergola structure appears damaged, rotten, or unstable
- You need to remove a large number of panels or the entire pergola roof
- You're not confident working at height safely
A licensed professional will have the right equipment, insurance, and experience to get the job done safely. You can find qualified local demolition contractors and roofing tradespeople on tradedirectory.co.nz.
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