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Pergolas & Arbors Systems

Lightweight and durable outdoor structures designed to bring beauty, shade, and architectural charm to any space
25+ years
expirience
5000+
projects
Custom
designs

Our Solutions Are Perfect For

Pergolas & Arbors Systems

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Width (W), in Length (L), in Height (H), in
116 1/2" 104 1/2" 100"
118" 118" 112"
120" 120" 107 1/2"
120" 168" 98 1/2"
140 1/2" 164 1/2" 100"
145 1/2" 145 1/2" 107 1/2"
Length (L), in Depth (D), in Height (H), in
24" 4" 65"
26" 4" 65"
28" 4" 65"
32" 4 1/2" 70"
34" 4 1/2" 70"
36" 4 1/2" 70"
48" 5" 90"
52" 5" 90"
56" 5" 90"
60" 5 1/2" 105"
64" 5 1/2" 105"
68" 5 1/2" 105"
Width (W), foot Height (H), in Depth (D), in
10' 8" 7"
10' 10" 7"
12' 8" 8"
12' 10" 8"
14' 8" 8 1/2"
14' 10" 8 1/2"
16' 8" 9"
16' 10" 9"
18' 12" 9 1/2"
20' 12" 9 1/2"
24' 12" 10"
32' 12" 10"

Door Surround-Door 016

Door Surround-Door 016

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Door Surround-Door 002

Width (W), in Height (H), in Depth (D), in
48" 72" 7"
48" 80" 7"
54" 72" 8"
54" 80" 8"
60" 80" 8 1/2"
60" 82" 8 1/2"
72" 82" 9"
72" 84" 9"
110" 82" 9 1/2"
110" 84" 9 1/2"
120" 82" 10"
120" 84" 10"
Length (L), in Depth (D), in Height (H), in
24" 4" 65"
26" 4" 65"
28" 4" 65"
32" 4 1/2" 70"
34" 4 1/2" 70"
36" 4 1/2" 70"
48" 5" 90"
52" 5" 90"
56" 5" 90"
60" 5 1/2" 105"
64" 5 1/2" 105"
68" 5 1/2" 105"
Width (W), foot Height (H), in Depth (D), in
10' 8" 7"
10' 10" 7"
12' 8" 8"
12' 10" 8"
14' 8" 8 1/2"
14' 10" 8 1/2"
16' 8" 9"
16' 10" 9"
18' 12" 9 1/2"
20' 12" 9 1/2"
24' 12" 10"
32' 12" 10"

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Width (W), in Height (H), in Depth (D), in
48" 72" 7"
48" 80" 7"
54" 72" 8"
54" 80" 8"
60" 80" 8 1/2"
60" 82" 8 1/2"
72" 82" 9"
72" 84" 9"
110" 82" 9 1/2"
110" 84" 9 1/2"
120" 82" 10"
120" 84" 10"
Length (L), in Depth (D), in Height (H), in
24" 4" 65"
26" 4" 65"
28" 4" 65"
32" 4 1/2" 70"
34" 4 1/2" 70"
36" 4 1/2" 70"
48" 5" 90"
52" 5" 90"
56" 5" 90"
60" 5 1/2" 105"
64" 5 1/2" 105"
68" 5 1/2" 105"
Width (W), foot Height (H), in Depth (D), in
10' 8" 7"
10' 10" 7"
12' 8" 8"
12' 10" 8"
14' 8" 8 1/2"
14' 10" 8 1/2"
16' 8" 9"
16' 10" 9"
18' 12" 9 1/2"
20' 12" 9 1/2"
24' 12" 10"
32' 12" 10"

Our material vs Competitors

Property Our Material (EPS) Wood Concrete Polyurethane Fiberglass
Weight Very lightweight Medium Very heavy Light Light
Thermal Insulation Excellent Moderate Poor Excellent Good
Moisture Resistance High (does not absorb water) Low (absorbs moisture) Medium High Medium
Durability Long-lasting, stable Can rot or warp Very durable Durable Fragile over time
Fire Behavior Melts under high heat Burns Fire-resistant Flammable (treated variants available) Non-combustible
Ease of Installation Easy, fast, low labor cost Moderate Difficult, labor-intensive Moderate Requires protection gear
Customization Highly customizable shapes & sizes Limited Very limited Moderate Limited
Cost Affordable Medium to high High High Medium

We offer 9 finish types. For custom color, we have mixes that allow us to make arhitectural products in almost any color.

All textures and colors are fully customizable for each individual project, ensuring complete flexibility in design and appearance.

Each our decorative architectural foam product is unique. We don’t “print” identical beams — we craft them as individual architectural pieces.

Discuss my project
Color palette

Why choose us

Value / Service Our company Competitors
Free Design Support Included in every project Usually not available
Product Customization Fully customized solutions Limited options
Engineering Consultation Direct access to engineers Rare or paid
Unique Prototype Development Yes, tailored prototypes Not offered
Personal Project Manager Dedicated manager for each client Not standard
Speed of Production Fast turnaround Slower processes
Client Support Ongoing support at all stages Limited after-sales support
Flexibility Tailored to any client requirements Standard solutions only

How it Works

Step 1. Adaptation
If you have a finished project, we adapt it for production and installation, preserving every detail.

Step 2. Define your vision
Capture a clear picture of the client’s ideas before moving to design and rendering.

Step 3. Plan specifications
Outline measurements, production methods, and finalize materials, components, and finishes.

Step 4. Installation
Our team ensures precise setup, perfectly aligning your custom surround with the space.

Step 1. Define your vision
The aim of this step is to capture a precise picture of the client’s vision before proceeding to technical design and visual rendering.

Step 2. Plan specifications
During this phase, we define the specifications, production methods, and measurements, while finalizing the look by selecting materials, elements, and finishes.

Step 3. Installation
Once fabrication is complete, our installation team will handle every aspect of the setup, ensuring your custom surround is fitted with accuracy and seamlessly integrated into your space.

Let's bring your project to life!

Map of the United States with the cities Royal Foam serves marked

Areas We Serve

We proudly serve clients across the United States, including major cities such as

· Jacksonville · Orlando · Miami · Atlanta · Dallas · Los Angeles · New York City · Chicago · Washington · San Francisco ·

Our Partners

Voices of our clients

After two wooden pergolas rotted out in Florida's humidity, we switched to Royal Foam US. The difference is night and day. No maintenance, no repainting every two years, no insect damage. The arbour looks beautiful, and our landscaper says it photographs better than any wood pergola she's worked with.

Maria Fontaine

We installed a Royal Foam US pergola system over our outdoor kitchen area. The EPS beam profiles with hard-coat polyurea look exactly like painted wood from any reasonable distance - but they weigh almost nothing and will never rot or warp in Arizona heat. Setup was genuinely easy. Outstanding product.

Nathan Bergman

We specified Royal Foam US pergola beams for a resort pool deck project. The weight reduction made installation on the existing concrete structure straightforward - no structural reinforcement needed. The Hard Coat Polyurea is handling Nevada's UV intensity without any visible degradation after 18 months.

Karen Whitaker

Let's bring your project to life!

Frequently Asked Questions

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A pergola is a large outdoor canopy structure. It is typically 10x20 feet or larger. People use them for patios, decks, and backyard seating areas. An arbor is a smaller and more decorative garden structure. People use them to frame entrances or walkways. Pergolas provide functional shade. Arbors serve primarily as aesthetic accents in the garden.
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Pergola systems create shaded outdoor seating areas, delineate patio and deck areas, support lighting and ceiling fans, grow climbing plants, and reduce UV exposure. Commercial applications include restaurant patios, resort pool areas, and covered walkways.
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Standard pergolas with open rafters provide partial shade. This is approximately 40-60% coverage. This depends on the rafter spacing. Pergola systems with adjustable panels and louvers can provide up to 100% shading when fully closed. Add shade fabric or a polycarbonate roof to increase sun protection.
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We custom-build every pergola to your exact dimensions, material preferences, roof style, color, and accessory specifications. There are no standard sizes or catalog limitations. We design each structure from scratch to meet your project's requirements.

Blog Posts

Pergola and Arbor Systems for Outdoor Living Spaces

These wonderful elements define space, filter sunlight, and enhance the aesthetics of a patio, deck, or garden. These stunning additions will make any outdoor space better. In Florida and similar hot and humid regions, the wrong choice leads to rapid deterioration, costly maintenance, and poor UV protection. So, how to choose the right structure requires style, the right materials, precision engineering, and climate compatibility?  This guide covers everything you need to know about structural differences, material performance data, installation processes, and key selection criteria, especially for outdoor Pergola and Arbor Systems in hot climates.

What Are Pergola and Arbor Systems?

A pergola system is a freestanding or attached outdoor living structure. It's great for a patio or backyard, with vertical posts and an open or semi-open roof framework. Pergola shade systems transform an ordinary pergola into a full-fledged shade structure, protecting from the sun and expanding the functionality of a patio or backyard. It supports climbing plants and creates a defined outdoor living area. Pergola structures typically span from 10×12 ft to 20×30 ft. It can support shade canopies, lighting, and fans.

An arbor system is a smaller and more decorative shade structure. Arbors mark garden entrances, frame pathways, or serve as focal points in landscaping. They are often arched or latticed and measure between 4×4 ft and 10×10 ft. Arbors serve a different functional role than pergolas.

Pergola systems and arbor structures fall under the broader category of outdoor shade structures. These architectural elements enhance outdoor living, manage sun exposure, and define spatial boundaries. 

The Difference Between Pergolas and Arbors 

Many homeowners and contractors confuse pergolas and arbors. Understand the difference to choose the right structure for your specific needs. 

  1. Pergolas range in size from 10 by 12 feet to 20 by 30 feet. Arbors are smaller. They usually range from 4 by 6 feet to 10 by 10 feet. Garden arches are the most compact. Their size is from 4 by 4 feet to 6 by 8 feet.

  2. People use pergolas to organize outdoor living and provide shade over a patio. Arbors can decorate a garden entrance or act as a transition area between areas. A garden arch serves a purely decorative function. 

  3. A pergola has open rafters or pivoting slats. An arbor has a partial lattice. A garden arch has a minimal, purely decorative covering. 

  4. A pergola can withstand up to 40-60 pounds per square foot. An arbor can withstand up to 20-30 pounds. A garden arch is designed for decorative loads only. 

  5. A pergola offers medium to high protection. An arbor offers low to medium protection. A garden arch offers low protection. 

  6. A pergola is suitable for terraces, patios, and open decks. An arbor is suitable for garden paths. A garden arch is suitable for entry points, gates, and wickets.

  7. Pergolas are larger, more functional, and provide better shade coverage. Arbors are primarily decorative. Your goal is an outdoor pergola shade system for a patio or deck? Then a full pergola structure is the appropriate choice.

What Materials Do People Use in Pergola Systems?

Material selection is the single most important factor in pergola performance, particularly for pergolas in Florida homes or other high-UV and high-humidity environments. Each material offers a different balance of durability, maintenance requirements, and cost.

EPS Foam Pergola Systems

Royal Foam US manufactures pergola frame supports from EPS foam, the primary material for our exterior roofing structures. EPS foam is lightweight, fully customizable, and resistant to moisture, rot, and insects. These properties make it suitable for the humid, high-UV conditions of Florida.

We coat each EPS foam frame support with a durable polyurethane coating. We apply it using specialized equipment under high pressure. The hard coat is seamless and durable. It prevents surface damage and provides complete moisture protection. It also maintains surface stability and flexibility, prevents cracking, and ensures high resistance to prolonged exposure to sunlight. The structure functions reliably even in coastal and subtropical climates, whereas competing materials wear out quickly in these climates. We have over 25 years of in-house manufacturing experience and manufacture custom-made polystyrene foam pergola frame supports to any size, profile, or project specification. There are no restrictions on standard sizes.

Comparison of EPS Foam with Traditional Pergola Materials

Other materials commonly used in pergola systems have their own significant drawbacks:

Aluminum Pergolas

Aluminum (6061-T6 alloy, tensile strength 38,000–45,000 psi) provides superior structural rigidity and is tested for UV resistance according to ASTM G154 for over 2,000 hours. However, it is a more expensive option and offers limited design flexibility compared to a custom-shaped EPS foam.

Vinyl Pergolas

Vinyl or PVC is moisture-resistant and contains UV stabilizers to prevent yellowing. However, vinyl expands and contracts in extreme heat. This is a known problem in Florida's climate. It can degrade the integrity of the joints over time.

Pergolas from Composite Materials

Wood fiber + polymer resin, rated to ASTM D7032 at 40-60 psi, provides a wood-like aesthetic with better weather resistance than natural wood. However, they are heavier and less flexible in customization than EPS foam.

Cedar and pressure-treated pine require annual sealing, impregnation, and pest control. In high-humidity conditions, these materials have the shortest lifespan of all pergola materials, and we do not recommend them for long-term outdoor pergolas in Florida or coastal regions.

EPS foam combines the design freedom of a moldable material with the weather resistance typical of Florida's climate. This makes it the primary design solution for Royal Foam US pergolas.

Why Are Pergolas Ideal for Florida Outdoor Spaces?

Florida's climate poses unique challenges for outdoor structures. UV index levels regularly exceed 10, average annual humidity exceeds 70%, and wind speeds during storms can reach over 100 mph. Pergolas for Florida homes must meet higher standards than those used in temperate regions.

According to the U.S. Department of Energy's passive solar design guidelines, properly positioned pergolas can reduce air conditioning loads by up to 30% in warm climates. A pergola canopy system acts as a passive cooling layer. It reduces direct solar gain on patios, decks, and verandas without the need for mechanical cooling.

Pergola systems offer lifestyle benefits beyond energy savings. They create clearly defined outdoor spaces. It makes backyards functional regardless of the time of day. When combined with louvered roofs or awnings, modern pergola systems provide adjustable UV protection suitable for Florida's high-intensity sunlight.

Which Option Should You Choose?

Many people are turning to durable outdoor pergolas. These structures can withstand wind, rain, and temperature fluctuations. Pergolas for patio shade are especially popular. The patio is often the most desirable area for creating a shady space without a heavy canopy. Arbor structures for gardens are a better choice for gardens. They compactly frame entrances and curves in paths, provide support for vines, and add a vertical accent to the landscape. However, the main trend of recent years has been maintenance-free pergolas. They don't require annual painting or treatment with a preservative.

Pergola systems for hot climates deserve special attention. In southern regions, ordinary wood quickly dries out and cracks, so manufacturers offer reinforced models with adjustable slats or fabric awnings. A well-designed outdoor living pergola combines all of these features: durable materials, sun protection, built-in lighting, and even the option of installing mosquito nets. As a result, the pergola transforms from a simple canopy into a fully fledged open-air room, comfortable both at midday and in the evening.

How to Choose the Right Pergola System 

Choosing a custom pergola requires a structured approach. Here's the process Royal Foam US follows with every client:

1. Do you want to use it for patio shading, garden design, poolside, or entertaining? 

2. Determine ceiling height for attached pergolas and any setback requirements in accordance with local zoning codes.

3. Select a roof type. 

4. Determine lighting, fans, climbing supports, privacy screens, or integrated gutters.

5. Review engineering data. Confirm load-bearing capacity, wind resistance, and anchoring methods.

6. Request a custom quote. Royal Foam US provides accurate estimates within minutes, even for complex custom pergola projects.

7. Approve the design and production. Our in-house production team manufactures the structure according to specifications without any delays from third parties.  

Key Benefits of Custom Pergola Systems

Royal Foam US offers prefabricated pergolas. This simplifies every stage of the project. We manufacture each structure to order. Just choose the exact dimensions and configuration you require. We control quality, eliminate intermediaries, and avoid unnecessary markups. We assign our clients a dedicated manager and offer flexible design options and convenient payment schedules to fit their project budget. Over 25 years of experience in producing architectural outdoor products guarantees our high level of craftsmanship.

Pros and Cons of Pergola Systems

Advantages

A pergola increases the value of a home and improves its appearance. In hot climates, it protects against UV rays and reduces air conditioning costs. The structure easily supports climbing plants, lighting, fans, and additional shading elements. You can choose any size, color, and design to suit your needs. A pergola clearly defines an outdoor seating area without completely enclosing it.

Disadvantages

The exposed rafters provide poor protection from rain unless an overhang or canopy is added. The initial cost of a pergola is higher than that of standard garden umbrellas or sunshades. Some cities and counties require building permits. Improper installation can compromise the structural integrity of the entire structure.

Explore More Architectural Products from Royal Foam US

Royal Foam US produces several architectural elements for exteriors. We create pergolas, columns, cornices, decorative elements, wall niches, keystones, brackets, custom signs, and more. Browse our catalog and contact us for a personalized consultation. Our team will assist you and help to design a pergola for your outdoor space.

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