01. Site Survey & Client Requirements
The existing site was an open concrete terrace behind a newly built modern villa. The sunroom had to connect directly to the rear facade while maintaining the minimalist proportions and dark window-frame language of the existing architecture.
- Cold-season usability: The homeowner wanted to convert the exposed terrace into a year-round family living space.
- Winter snow and freezing conditions: The roof and framing concept needed to account for seasonal snow accumulation and sub-zero temperatures described in the project source.
- Thermal performance: The enclosure required thermally broken framing and multi-pane glazing rather than a basic patio cover.
- Indoor-outdoor flexibility: Wide sliding-glass openings were required to reconnect the room with the garden during warmer months.
- Architectural continuity: The frame finish and geometry needed to align with the villa's modern charcoal-and-white exterior.
02. Conceptual Design & 3D Modelling
SUNRAY developed a contemporary mono-pitch sunroom that extends the rear living area without changing the visual character of the existing villa.
2.1 Mono-Pitch Roof Geometry
The roof falls toward the front eave beam, creating a simple modern profile while directing rainwater and snowmelt toward the integrated front drainage zone.
2.2 Symmetrical Sliding-Glass Facade
The 8.4 m front elevation is divided into two 3,975 mm glazed bays separated by a 140 mm central structural post. Multi-track sliding sashes create a wide garden opening when the room is opened in summer.
2.3 Panoramic Glass Enclosure
Floor-to-ceiling glazing across the exposed elevations maximizes daylight and garden views while the insulated Low-E glass specification supports year-round comfort.
03. Shop Drawings & Dimensional Coordination
Approved production drawing set No. SK-25-08 established the dimensional grid for the enclosure, including the facade bays, central structural post, eave height, roof depth and sliding-door layout.
- Overall length: 8,400 mm
- Overall depth: 3,900 mm
- Interior clear depth: 3,600 mm
- Front eave height: 2,260 mm
- Two facade bays: 3,975 mm each
- Central structural box post: 140 mm
- Multi-panel sliding-glass doors across both front bays
- Pre-engineered roof rafter grid with integrated drainage detailing
04. Precision Manufacturing & Factory Quality Control
Manufacturing focused on thermally broken aluminum framing, roof-glass support details, durable surface finishing and repeatable fit-up before trial assembly.
4.1 Thermally Broken Aluminum Frame
The primary structure uses the project's 70-series 6063-T6 aluminum system with thermal-break barriers described in the source case study.
4.2 Roof Glass Support Details
The roof rafters include pre-fitted glass support lugs and stop blocks intended to locate the overhead glazing and resist panel movement on the sloped roof.
4.3 Anthracite Architectural Finish
The aluminum frame uses a dark anthracite-gray architectural finish selected to coordinate with the villa's existing window frames.
05. 1:1 Factory Trial Pre-Assembly & Sliding Commissioning
Before export, SUNRAY completed a full-scale 1:1 trial assembly of the 8.4 m × 3.9 m sunroom inside the factory.
5.1 Full-Scale Frame Alignment & Roof Check
- The 8.4 m facade frame and central structural post were assembled for dimensional verification.
- Frame squareness and alignment were checked before shipment.
- The continuous mono-pitch roof line was checked across the rafter bays.
5.2 Sliding Door & Locking Verification
- Sliding sashes were installed in both 3,975 mm facade bays.
- Manual sliding movement was tested along the multi-track system.
- Lock engagement and EPDM perimeter gasket compression were checked.
06. Export Packaging & Container Logistics
After factory verification, the structural frame, roof members, sliding-door components and glazing hardware were protected for shipment to Europe.
- Major aluminum members and hardware were separated and wrapped with protective materials.
- Components were packed in reinforced plywood export crates.
- Crates were secured inside the shipping container for international transit to Slovakia.
07. On-Site Installation & Structural Commissioning
At the villa, the prefabricated system was assembled onto the existing concrete terrace and connected to the rear wall using the prepared connection details.
7.1 Wall Ledger & Base Fixing
The rear ledger beam was fixed to the existing wall and weather-sealed, while the base tracks and structural posts were anchored to the concrete terrace.
7.2 Post-and-Beam Assembly & Rafter Installation
The long front beam, central post and sloped roof rafters were mechanically assembled without the need for site welding described in the source.
7.3 Triple-Glazed Unit Installation & Sealing
Triple Low-E insulated glass units were installed into the roof and wall frames, followed by EPDM sealing and perimeter weatherproofing.
08. Final Handover & Residential Use
Following final sealing and cleaning, the four-season sunroom was handed over as a 32 m² extension to the villa's living area.
- Year-round use: The enclosed room provides a more controlled environment than the original open terrace.
- Cold-climate strategy: Triple glazing, thermal-break framing and the mono-pitch roof were selected for winter use.
- Large garden opening: Multi-track sliding doors maintain strong indoor-outdoor flexibility during warmer months.
- Added living area: The project converts approximately 32 m² of terrace into enclosed family-use space.
- Architectural integration: The anthracite frame complements the villa's modern exterior.
09. Application Scenarios
The same design approach can be adapted to other Central and Northern European projects where an existing terrace needs to become a conditioned glass living space.
- Cold-climate suburban villas
- Patio and garden terrace conversions
- Four-season winter gardens and conservatories
- Hospitality and restaurant winter-garden extensions