01. Site Survey & Client Requirements
The existing site was a paved rear terrace against a two-story brick villa. A raised concrete basement lightwell with a black safety railing occupied part of the future enclosure footprint, making a standard rectangular patio enclosure unsuitable.
- Cold-weather use: The homeowner wanted a genuine four-season room that remained usable during Ontario's sub-zero winters.
- Heavy snow exposure: The single-slope roof and primary frame had to be designed for the snow-load requirement stated in the project source.
- Basement lightwell integration: The new structure had to bridge around and enclose the existing lightwell without compromising waterproofing or lower-level daylight.
- Natural daylight: The client wanted large floor-to-ceiling glazed panels rather than opaque walls.
- Fresh-air ventilation: Operable side windows and double doors were required for spring and summer use.
02. Conceptual Design & 3D BIM Modelling
SUNRAY developed a lean-to single-slope solarium that follows the existing brick facade while enclosing the terrace and basement lightwell within one continuous thermal envelope.
2.1 Single-Slope Roof Geometry
The roof projects 3,150 mm from the brick wall and slopes toward the 2,680 mm front eave. This geometry supports drainage toward the integrated front gutter and helps move rainwater and snowmelt away from the house wall.
2.2 Symmetrical Panoramic Facade
The 10,120 mm facade combines a 1,202 mm double French door with wide 1,500 mm glazed modules, creating a bright garden-facing elevation with a strong visual connection to the backyard.
2.3 Basement Lightwell Integration
The floor and perimeter framing were adapted around the existing basement lightwell so it could remain protected inside the new sunroom while continuing to receive daylight.
03. Shop Drawings & Dimensional Coordination
Approved production drawings established the final enclosure footprint, roof projection, eave height, door module and panoramic glass bay dimensions before fabrication.
- Overall facade length: 10,120 mm
- Projection depth: 3,150 mm
- Front eave height: 2,680 mm
- Approximate footprint: 31.88 m²
- Double French door clear opening: 1,202 mm
- Typical panoramic glass bay: 1,500 mm
- Roof rafter projection: 3,150 mm
- Thermal-break structural system: 6063-T6 aluminum with PA66 GF25 isolation strips
- Integrated structural front gutter beam
04. Precision Manufacturing & Factory Quality Control
Manufacturing focused on cold-climate thermal-break framing, reinforced structural connections and accurate machining for modular installation.
4.1 CNC Cutting & Profile Machining
Thermal-break aluminum profiles were cut and machined for rafters, posts, drainage channels and connection interfaces according to the approved production drawings.
4.2 Reinforced Structural Connections
The source case study documents internal steel gussets and multi-bolt reinforcement at key rafter and beam connections for the project's stated snow-load requirement.
4.3 Surface Finish & Weather Preparation
The aluminum components received a dark charcoal architectural finish, while glazing and perimeter interfaces were prepared for insulated glass and EPDM weather sealing.
05. 1:1 Factory Trial Pre-Assembly & Fit Verification
Before export, SUNRAY completed a full-scale 1:1 trial assembly of the primary sunroom frame to verify fit-up before shipment.
5.1 Frame Geometry & Roof-Pitch Verification
- Overall frame squareness was checked across the 10.12 m facade.
- Roof-rafter seating and the 3,150 mm projection were checked for consistent pitch.
- Front eave and gutter alignment were verified before disassembly.
5.2 Door, Window & Glazing Fit Check
- The double French doors were installed and tested for smooth swing and lock engagement.
- Side awning windows were dry-fitted and checked for opening clearance.
- Glazing pockets were checked against the triple-pane insulated glass specification.
06. Export Packaging & Container Logistics
After factory verification, the frame members, rafters, doors, windows and triple-glazed units were protected for ocean transport to Canada.
- Thermal-break aluminum members were wrapped with protective foam and film.
- Major components were packed into reinforced plywood export crates with internal dividers and corner protection.
- Triple-glazed Low-E glass units were packed on reinforced A-frame stillages with shock-absorbing pads and moisture-control protection.
07. On-Site Installation in Ontario
After arrival in Ontario, the prefabricated system was assembled against the existing brick facade under local site supervision.
7.1 Wall Anchorage & Flashing
The rear ledger was mechanically anchored to the brick wall, and the wall-roof interface was sealed with flashing and waterproofing membranes.
7.2 Frame Erection & Triple-Glazed Installation
Front posts, the structural gutter beam and the 3,150 mm roof rafters were erected before triple-pane Low-E glass panels were placed into the prepared glazing pockets.
7.3 Basement Lightwell Encapsulation
Custom perimeter detailing was completed around the raised concrete lightwell so the existing opening could be incorporated within the finished interior.
08. Final Handover & Residential Use
Following final glazing, sealing and cleaning, the sunroom was handed over as a year-round extension to the villa's living space.
- Four-season use: Thermal-break aluminum and triple-pane Low-E glazing provide a more insulated enclosure than the original open terrace.
- Protected lightwell: The basement window well is now sheltered from rain, snow and debris while remaining inside a naturally lit glass room.
- Natural ventilation: Side awning windows and the double French doors support fresh-air circulation in warmer weather.
- Architectural integration: The dark charcoal frame creates a contemporary contrast with the existing red-brick villa.
- Added living space: The project converts approximately 31.88 m² of patio into an enclosed family-use area.
09. Application Scenarios
The same single-slope thermal-break solarium approach can be adapted to other cold-climate residential projects with complex terrace conditions.
- Cold-climate villa terrace conversions
- Homes with basement lightwells or split-level patios
- Four-season garden rooms and breakfast lounges
- Residential glass extensions requiring thermal-break framing and triple glazing