01. Site Survey & Client Requirements
The existing site combined a raised two-story Queenslander-style residence, an exposed ground-level kidney-shaped pool, a timber balcony and a sloping rear yard. The new enclosure therefore had to coordinate multiple floor levels while forming a secure all-weather pool environment.
- Coastal marine exposure: Humidity, sea breeze and salt aerosols accelerated weathering of exposed exterior materials.
- Wind and storm exposure: The broad pool enclosure required a structural system appropriate for Queensland coastal wind actions.
- Pool safety: The completed envelope needed to function as a compliant swimming-pool safety barrier.
- Multi-level integration: The project had to connect the ground-floor pool zone with the +2.70 m living and verandah level.
- Natural light and comfort: The client wanted extensive glazing and skylights without turning the pool pavilion into an overheated greenhouse.
02. Conceptual Design & 3D Modelling
SUNRAY developed an integrated architectural scheme that connects the existing home, pool terrace and upper-level circulation under a single extension.
2.1 Multi-Level Spatial Integration
A double-height glazed foyer connects the +2.70 m upper living level with the pool deck below, while the main sunroom spans the pool and creates a protected internal leisure space.
2.2 Dual-Pitch Roof & Skylight Strategy
The main sunroom roof uses an 8° pitch, while the entrance foyer uses a 10° pitch. Continuous skylight zones introduce daylight into the deep plan while maintaining a coordinated relationship with the existing house roof.
2.3 Verandah & Outdoor Kitchen Integration
An elevated covered deck is incorporated along the side of the extension to create a sheltered outdoor kitchen and dining area overlooking the garden.
03. Shop Drawings & AS 1926.1 Pool Safety Coordination
Approved drawing set Project No. 32814, including Sheets A.05 and A.06, was used to coordinate fabrication dimensions, stepped elevations, structural grids and pool-safety hardware requirements before production.
- Overall transverse width: 14,000 mm
- Main roof run: approximately 10,000 mm
- Eave bottom level: +4.950 m
- Foyer entrance height: 4,119 mm
- Verandah deck clear height: 2,400 mm
- Key structural bay centers documented on the elevation drawings
- Pool-safety hardware operating height: minimum 1,500 mm above finished floor level
04. Structural Verification & Finite Element Analysis
The project source states that structural verification was completed before fabrication using a 3D finite element model to review the frame under gravity and wind actions relevant to the Australian coastal site.
- Australian wind design basis: AS/NZS 1170.2 Wind Actions is identified in the project source.
- 3D structural model: Portal frames, roof trusses and elevated floor elements were modeled as a coordinated structural system.
- Load review: Dead load, imposed loads and wind-load combinations were considered in the analysis.
- Design objective: Verify member stress and deformation performance before fabrication of the large-span enclosure.
05. Precision Manufacturing & Factory Quality Control
Fabrication focused on dimensional repeatability, corrosion resistance and preparation for modular overseas assembly.
- CNC processing: Structural aluminum profiles were cut and machined for the portal frames, trusses and glazing interfaces.
- Corrosion-resistant finish: Aluminum components received an architectural protective coating suitable for coastal exposure.
- Glazing preparation: Frame channels were prepared for laminated and insulated glass units together with EPDM sealing components.
- Pre-fitted connection hardware: Brackets and connection plates were installed and checked before trial assembly.
06. 1:1 Factory Pre-Assembly & Client Verification
Before export, SUNRAY completed a full-scale 1:1 trial assembly of the two-story structural frame inside the factory. This step was used to confirm fit-up across the large 14 m × 10 m envelope before the system was dismantled for shipment.
- Overall frame squareness and key dimensional control were checked.
- Truss-to-column connection points and bolted interfaces were verified.
- Roof drainage, gutter and flashing connection points were reviewed.
- The client team inspected the assembled frame at the factory and completed the project-stage sign-off recorded in the case material.
07. Export Crating & Container Logistics
After the trial assembly, the structure was dismantled, labeled and packed for marine transport to Australia.
- Profiles and glass components were protected with foam and moisture-resistant wrapping.
- Major assemblies were secured in reinforced export plywood crates.
- The crates were prepared for 40 ft High-Cube container transport.
08. On-Site Erection on Macleay Island
After delivery to Queensland and transfer to Macleay Island, the prefabricated system was erected on the residential site using modular mechanical connections.
- Substructure connection: Aluminum columns were fixed to engineered concrete supports and existing structural interfaces.
- Truss erection: Prefabricated roof trusses were lifted and secured over the pool enclosure.
- Glazing installation: Large-format glazing and insulated wall panels were installed into the prepared frame channels.
- Pool-safety coordination: Relevant operable hardware was installed to match the documented AS 1926.1 safety requirements.
09. Project Outcomes
The completed extension converts the previously exposed pool area into a more protected multi-level leisure space that is integrated with the existing residence.
- All-weather pool environment: The glazed enclosure provides protection from rain, wind and insects.
- Natural light: Skylights and large glazed elevations maintain daylight across the pool hall.
- Coastal durability strategy: The aluminum structure, protective finish and sealed glazing system were selected for the marine environment.
- Pool-safety integration: The enclosure design incorporates the pool-barrier requirements documented in the project drawings.
- Architectural integration: The new structure connects the pool, foyer, verandah and upper living spaces as one coordinated extension.
10. Application Scenarios
The same engineering approach can be adapted to other complex residential and hospitality extensions where a large glazed enclosure must integrate multiple floor levels, swimming pools and coastal exposure.
- Coastal and island luxury residences
- Multi-story villa and verandah extensions
- Private pool pavilions and conservatories
- Boutique hotel, resort and wellness pool enclosures