01. Site Survey & Client Requirements
The project was developed around an existing two-story brick residence with a stepped rear terrace, projecting bay window and multiple deck levels. The new structure therefore required a tailored L-shaped geometry rather than a standard rectangular enclosure.
- Cold-climate use: The homeowner wanted a more comfortable enclosed space for use beyond the warm season.
- Existing architecture: The sunroom had to coordinate with the red-brick facade, bay window, terrace steps and existing dark-bronze window trim.
- Roof snow and freeze-thaw exposure: The enclosure needed a robust roof and framing concept suitable for Canadian winter conditions.
- Summer ventilation: The design needed operable roof vents and sliding wall panels to release warm air during summer.
- Dual-purpose space: The client wanted both a four-season lounge and a secure glass-enclosed motorcycle display area.
02. Conceptual Design & 3D Modelling
SUNRAY developed an L-shaped architectural scheme that wraps around the existing house corner and divides the extension into a lounge zone and a motorcycle display wing.
2.1 L-Shaped Split-Level Layout
The overall 7.37 m × 7.30 m footprint is divided into two connected wings that follow the existing terrace geometry and preserve circulation around the projecting house bay.
2.2 Single-Pitch Roof & Motorized Skylights
The roof slopes from the 3,125 mm wall connection toward the lower front eave. Three motorized skylights are integrated into the roof grid to support natural ventilation during warmer periods.
2.3 Indoor-Outdoor Transition
Large sliding-glass openings connect the sunroom to the garden terrace, while the glazed perimeter and dark-bronze frame maintain visual continuity with the existing residence.
03. Shop Drawings & Dimensional Coordination
Approved production drawing set P-2, P-3 and P-4 for client Subin Abraham established the dimensional grid, roof slope, front portal and skylight positions used for fabrication.
- Overall roof depth: 7,370 mm
- Overall roof width: 7,300 mm
- Main bay depth: 4,230 mm
- Secondary wing depth: 3,140 mm
- Structural columns: 150 × 150 mm
- High wall connection: 3,125 mm
- Front eave beam: 2,320 mm
- Front portal width: 3,650 mm
- Central bi-parting door opening: 1,690 mm
- Three dedicated roof skylight openings
04. Precision Manufacturing & Factory Quality Control
The frame was manufactured around the 150-3.0 structural aluminum system, with machining and sealing details prepared for cold-weather exposure and modular site assembly.
- 150 mm structural box posts and perimeter beams were cut and machined for the L-shaped frame.
- Dark coffee bronze architectural coating was applied to coordinate with the existing house and improve outdoor durability.
- EPDM weather seals were integrated into glazing and opening interfaces.
- Drainage detailing was incorporated into the glazing pockets and perimeter frame system.
05. 1:1 Factory Trial Pre-Assembly & Roof Inspection
Before export, SUNRAY completed a full-scale 1:1 trial assembly of the L-shaped sunroom to verify the geometry and roof interfaces.
5.1 L-Shaped Corner Geometry Verification
The internal corner angle and step-out dimensions were checked before shipment to confirm the L-shaped frame geometry matched the approved shop drawings.
5.2 Roof Slope & Skylight Fit Inspection
The continuous roof fall from the 3,125 mm wall connection to the 2,320 mm front eave was verified across the rafter bays. All three motorized skylight sub-frames were also checked against their designated roof openings for flush fit and alignment.
5.3 Door Sliding & Gasket Compression Verification
Sliding-door frames were dry-fitted into the front portal to verify roller movement, locking alignment and uniform EPDM perimeter gasket compression before export.
06. Export Packaging & Container Logistics
After factory inspection, the structure was disassembled, protected and packed for international transport to Canada.
- Columns, girders, purlins, sliding-door components and skylight units were separated and protected.
- Major components were wrapped with foam and stretch film before placement in reinforced export plywood crates.
- The crates were prepared for 40 ft High-Cube container transport.
07. On-Site Installation in Canada
At the residence, the prefabricated frame was installed against the existing brick facade and terrace using the prepared connection geometry.
- Wall connection: The high-level ledger and flashing were fitted to the brick facade at the documented connection height.
- Post-and-beam erection: Structural columns and side beams were installed on the prepared terrace supports.
- Roof glazing: Low-E insulated glass roof panels were fitted into the sloped roof grid.
- Skylights: The three motorized skylight units were installed within the prepared roof openings.
- Perimeter glazing and doors: Sliding glass walls were installed and adjusted to complete the enclosure.
08. Final Handover & Residential Use
After final glazing, sealing and cleaning, the L-shaped sunroom was handed over as a multi-purpose extension connected directly to the existing villa.
- Four-season living: Low-E double glazing, enclosed walls and operable skylights create a more controlled indoor environment across changing seasons.
- Cold-climate strategy: The heavy-duty frame, sloped roof and sealed glazing system were selected with Canadian winter conditions in mind.
- Architectural integration: The dark-bronze frame complements the existing brickwork, roof tones and window trim.
- Multi-purpose use: The finished enclosure combines a family lounge with a secure motorcycle display area.
09. Application Scenarios
The same design approach can be adapted to other cold-climate residential projects that require a custom glass extension around complex existing architecture.
- Cold-climate suburban villas
- L-shaped and wrap-around terrace enclosures
- Four-season garden rooms and conservatories
- Hobby rooms, display spaces and collector-vehicle enclosures