Written by Rethinking Solar Part 3: Build a Solar Pergola
Shade, Style, and Power in One Project
Rethinking Solar Part 3: Building a Solar Pergola. If you missed anything in the rest of the series, links to them are at the bottom of this page.
This is Part 2 of the series – Going Solar. If you missed a part all the related articles are listed at the bottom of this page.
Why a Solar Pergola?
Solar doesn’t have to live on your roof. A solar pergola is a functional backyard feature that provides shade, powers your lights or devices, and offers a creative alternative, especially if your roof isn’t right for panels. Whether it’s a place to charge your phone or host off-grid garden parties, this project brings solar down to earth.
Planning Your Pergola
Location Considerations
- Sun Exposure: Place your pergola in a spot that receives at least 5–6 hours of direct sunlight per day.
- Orientation: South-facing is best in Canada for optimal year-round energy capture.
- Space Requirements: A practical size is 8’ x 10’ or 10’ x 12’—large enough for panels, shade, and use.
- Distance to Power Needs: If powering tools or outdoor outlets, locate it near your workshop or home.
Foundation & Structure
Permits
- Check with your municipality: in many areas, structures under 10 m² (~108 sq. ft.) don’t need building permits, but electrical and solar connections often do.
- You may need:
- A building permit for anything with a permanent foundation
- An electrical permit if tying into your home system
- Approval from your local utility for net metering (if applicable)
Foundation Options
- Concrete footings: Most stable. Dig below the frost line (~4’ in NB), pour quick-set concrete in sonotubes.
- Concrete deck blocks: Faster, easier, and good for freestanding builds not tied to the grid.
Materials & Tools
To the Big Box Store or…
Materials List (Frame & Roof)
| Item | Quantity | Estimated Cost |
| 4×4 Pressure-treated posts (10’) | 4 | $80–100 |
| 2×6 beams (10–12’) | 4–6 | $60–90 |
| 2×4 cross braces | 6–8 | $40–50 |
| Galvanized lag bolts/screws | 1 box | $20 |
| Joist hangers or angle brackets | 10–12 | $25 |
| Concrete or deck blocks | 4–6 | $40–100 |
| Solar panel rails/mounting brackets | per system | ~$100 |
| Sealant/weatherproof stain | 1 gallon | $30–50 |
Estimated frame materials cost: $300–$500 CAD
(Cost can vary based on wood prices and finish quality.)
Tools Required
- Cordless drill and driver
- Circular saw or miter saw
- Post hole digger (or auger)
- Level
- Wrench/socket set
- Ladder
- Safety gear: gloves, eye protection
Choosing Solar Panels
Best Panel Types for Pergolas
- Monocrystalline: Best efficiency (18–22%), sleek black finish. Ideal for smaller spaces.
- Polycrystalline: Slightly lower efficiency (15–17%) but cheaper. Great for larger pergolas. See what types of panels are available.
Weight and Mounting
- Average panel weight: ~18–22 kg (40–50 lbs) per 60-cell panel (~65” x 39”)
- For a basic 2-panel system: ~90–100 lbs total
- Ensure your frame can handle 20–25 lbs/sq. ft. of dead load.
Panel Cost
| Panel Type | Wattage | Price Range (CAD) |
| Monocrystalline | 300–400 W | $200–$350 |
| Polycrystalline | 250–350 W | $150–$275 |
You’ll also need a microinverter or string inverter, a charge controller, and a battery if you’re going off-grid.
Build Steps
1. Build the Foundation
- Dig post holes (below frost line if using footings).
- Set 4×4 posts in concrete or place into deck blocks.
- Ensure posts are plumb and spaced evenly (8–12 feet apart depending on panel size).
2. Frame the Top
- Attach 2×6 beams to posts using lag bolts or brackets.
- Use 2x4s as cross beams perpendicular to the panels.
- Allow spacing based on panel width plus mounting rails.
3. Create the Solar Mounting Surface
- Install mounting rails or panel brackets to your crossbeams.
- Maintain proper tilt (typically 20–35° for Canada).
- Ensure the structure allows for airflow behind the panels.
4. Anchor the Panels
- Bolt panels into rail system using the manufacturer’s clamps or brackets.
- Secure wiring along beams using UV-resistant zip ties or conduits.
5. Wiring & Power
- Connect to microinverter or charge controller depending on system type.
- Route wiring to battery system or outdoor outlets.
- Hire a licensed electrician if connecting to home power or the grid.
Timeline: Two-Person Build
| Task | Time Estimate |
| Foundation & posts | 3–5 hours |
| Building frame | 4–6 hours |
| Solar panel mount install | 2–3 hours |
| Wiring & commissioning | 3–4 hours |
Total build time: ~2 full days (weekend project for two people)
What Can It Power?
A basic 400–800W setup can power:
- LED lights for evenings
- Laptop and phone chargers
- Small tools
- Water features or garden lights
Add a battery and inverter to store energy for nighttime or cloudy days.
Final Thoughts
You’ve now created more than just a shaded structure—you’ve built a conversation piece, a power source, and a step toward grid independence. Want to take it further? Add a battery system, motion lighting, or expand into a full garden power hub.
Rethinking Solar Part 1: What It Offers You (and the Planet) *** Rethinking Solar Part 2: Solar Dollars & Sense *** ReThinking Solar Series Part 4: What Solar Can’t Do (Yet) and Innovations