Building a Pergola Twice: When Access Constraints Force Creative Solutions

At first glance, it's striking: a fully slatted steel pergola stretching across the pool courtyard, serving as both functional shade and architectural focal point. What residents experience as a seamless amenity required us to build the entire structure twice—once in our shop, then again on-site.

The challenge wasn't the design. Our client's management team had arrived at the right solution: a ribbon-like slatted timber pergola that would transform an empty pool deck into a defined outdoor space. The challenge was getting it there.

The Problem: A Courtyard That Machinery Can't Reach

The pool sits inside a courtyard with severely limited access. Heavy steel beams and structural components couldn't be transported or installed using standard equipment. Traditional construction methods were off the table. The central question became: how do you build a structure of this scale when you can't get machinery into the space?

The Solution: Pre-Assembly as Quality Control

Two months before installation, we pre-assembled the entire pergola in our shop. This wasn't just about confirming fit and alignment, it gave us the opportunity to establish cross measurements that would become critical during on-site reconstruction. Once we verified everything worked, we disassembled it and developed our access strategy.

We brought in a mini SkyTrak to unload materials from the trailer. Custom-built dollies moved components through the limited access points. Custom-fabricated lifts hoisted the steel beams into position. The cross measurements from our shop build ensured every connection aligned precisely during reassembly.

What This Approach Delivers

The 30-day installation followed the design plans exactly. Once we solved the access and hoisting challenge, the work came down to careful sequencing and staying precise through every phase.

The result is a courtyard that feels intentionally designed rather than added onto. What residents don't see is the behind-the-scenes effort: a structure built twice, custom solutions engineered specifically for the site's constraints, and the level of problem-solving that makes complex work look effortless.

When site conditions limit conventional methods, we don't limit the vision. We find another way to execute it.