01. Site Survey & Client Requirements
The existing central corridor was covered by an aging curved barrel-vault skylight with dark amber translucent panels. The old roof reduced natural daylight and visually compressed the long hallway.
- Daylight improvement: The homeowner wanted clean, color-neutral natural light instead of the yellow-orange tint from the old roof.
- Cold-weather performance: The replacement needed better insulation and sealing for Canadian winter conditions.
- Long-span continuity: The new skylight had to cover the full 17.27 m corridor without disrupting the interior circulation line.
- Snow and water management: The raised curb, sloped glazing and concealed drainage had to manage snowmelt, rain and interior condensation.
- Architectural modernization: The client wanted a contemporary dark-frame glass lantern rather than the dated barrel-vault appearance.
02. Conceptual Design & 3D BIM Modelling
SUNRAY developed a clean-lined architectural lantern skylight that transforms the corridor into a brighter linear gallery.
2.1 Contemporary Lantern Geometry
A 500 mm vertical curb raises the glazing above the roof deck, while the upper glass roof rises another 339 mm to a total structural height of 839 mm. This creates a distinct lantern profile rather than recreating the original curved tunnel.
2.2 14-Bay Daylighting Rhythm
The 17.27 m length is divided into 14 glazed bays, creating a regular structural rhythm that distributes daylight along the corridor rather than concentrating it in isolated roof openings.
2.3 Dark Frame / Neutral Interior Contrast
The dark charcoal framing visually defines the glazed roof against the light interior finishes while the clear Low-E glass preserves blue-sky views and neutral daylight.
3D design: proposed 17.27 m lantern skylight illuminating the villa corridor with clear overhead glazing.
03. Shop Drawings & Dimensional Coordination
Approved production drawings defined the three-section modular breakdown, structural splice locations, cross-section geometry and 14-bay glazing layout before fabrication.
- Total continuous length: 17,273 mm
- Section 1: 9,627 mm / 8 bays
- Splice post 1: 128 mm
- Section 2: 5,258 mm / 4 bays
- Splice post 2: 128 mm
- Section 3: 2,388 mm / 2 bays
- Interior clear width: 1,974 mm
- Outer base width: 1,980 mm
- Total structural rise: 839 mm
- Vertical curb height: 500 mm
- Sloped glazing rise: 339 mm
- Primary frame: 6063-T6 thermal-break aluminum
04. Precision Manufacturing & Factory Quality Control
Manufacturing focused on insulated-glass quality, thermal-break aluminum machining and accurate preparation of the splice and drainage details.
4.1 Low-E Insulated Glass Preparation
Double-glazed tempered Low-E units were prepared with warm-edge spacers and argon gas filling according to the source project specification.
4.2 CNC Aluminum Profile Machining
Thermal-break aluminum members were cut and machined for section splices, anchor interfaces and concealed drainage paths.
4.3 Dark Charcoal Architectural Finish
The structural frame received a dark charcoal architectural finish suitable for the indoor-outdoor roof environment and repeated seasonal temperature cycling.
05. 1:1 Factory Trial Pre-Assembly & Fit Verification
Before export, SUNRAY completed a full-scale 1:1 trial assembly of the complete 17.27 m structural aluminum lantern frame.
5.1 Three-Section Splice Alignment
- Section 1, Section 2 and Section 3 were joined using the designed structural splice interfaces.
- The two 128 mm splice locations were checked for alignment and continuity.
- Overall length was verified across the complete 17.27 m assembly.
5.2 Width, Glazing Rebate & Seal Check
- The 1,974 mm transverse clear width was verified.
- All 14 glazing rebates were checked for consistent panel seating.
- EPDM compression-gasket clearances were inspected before disassembly.
06. Export Packaging & Logistics
After factory verification, the three frame sections, curb members, splice components and insulated glass units were protected for international transport to Canada.
- Aluminum members were cushioned and wrapped before packing.
- Long structural components and accessories were placed in reinforced export wooden crates.
- Crates were loaded onto heavy transport vehicles for dispatch to the shipping port.
07. On-Site Installation in Canada
At the residence, the old barrel-vault roof was removed and the new three-section skylight system was installed over the existing corridor opening.
7.1 Old Skylight Removal & Curb Preparation
The original curved roof was dismantled, after which the supporting curb and waterproofing interfaces were prepared for the new lantern structure.
7.2 Frame Installation & Section Splicing
The pre-machined aluminum sections were positioned over the roof opening and connected into the continuous 17.27 m frame using the prepared splice joints.
7.3 Insulated Glass & Weather Sealing
Low-E insulated glass panels were installed into the 14 roof bays, followed by pressure caps, EPDM seals and perimeter weatherproofing.
08. Final Handover & Residential Use
The completed skylight transforms the previously dim corridor into a bright architectural gallery with continuous views of the sky.
- Natural daylight: The long glazed roof distributes daylight across the full central hallway.
- Modernized interior: The dark charcoal frame replaces the dated amber barrel-vault appearance with a clean architectural rhythm.
- Improved enclosure performance: Thermal-break framing and insulated Low-E glazing provide a more robust roof assembly than the former single-skin system.
- Condensation and drainage strategy: EPDM sealing and concealed water-management channels support long-term roof performance.
Long-span visual conti
09. Application Scenarios
The same continuous lantern-skylight approach can be adapted to other long-span roof-lighting projects where existing curved or opaque roof systems need modernization.
- Private villa spine corridors and long hallways
- Residential atriums and gallery spaces
- Boutique retail and hospitality circulation zones
- Retrofit replacement of aging barrel-vault acrylic or polycarbonate skylights