01. Site Survey & Client Requirements
The project site is the narrow open-air atrium between two symmetrical modern villas. The roof system had to bridge the courtyard without compromising ventilation, daylight or the visual relationship between the two buildings.
- Heavy tropical rainfall: The atrium was fully exposed to sudden monsoon downpours and runoff from the surrounding villa roofs.
- High humidity and heat buildup: A fixed glass roof risked trapping hot, humid air in the courtyard.
- Large opening requirement: The homeowners wanted a retractable roof that could expose most of the courtyard to the sky.
- Automatic rain response: The system needed to close automatically when rain was detected.
- Architectural integration: The frame color and geometry needed to coordinate with the dark tiled roofs and white villa facades.
02. Conceptual Design & 3D Modelling
SUNRAY developed a four-tier cascading overlapping skylight system tailored to the courtyard proportions and tropical rainfall requirements.
2.1 Four-Bay Cascading Telescopic Architecture
The 5.86 m span is divided into four longitudinal bays. Within each bay, four overlapping glass tiers slide along stepped tracks and stack toward the high end when opening.
2.2 High-Aperture Ventilation Strategy
The telescopic geometry allows the roof to achieve up to approximately 75% clear opening, helping release trapped heat and humidity from the atrium.
2.3 Integrated Gutter & Water Baffle
A dedicated front gutter beam, internal drainage paths and baffle detailing were integrated into the system to manage high-volume tropical rainfall.
03. Shop Drawings & Dimensional Coordination
Approved production drawing set No. MY-25-07 established the final footprint, bay spacing, stepped track geometry and water-management details before fabrication.
- Overall width: 5,860 mm
- Overall length / projection: 4,953 mm
- Four longitudinal glazing bays
- Each clear glazing bay: 1,420 mm
- 75 mm perimeter clearances at both outer sides
- 10 mm inter-bay structural track divisions
- Four-tier stepped telescopic profile system
- Front water-baffle and gutter detail integrated into the low end
04. Precision Manufacturing & Factory Quality Control
Manufacturing focused on stepped track accuracy, repeatable sash geometry, laminated-glass preparation and corrosion-resistant finishing for the tropical environment.
4.1 Stepped Aluminum Track Machining
The main rafter tracks were produced from 6063-T5 aluminum and machined with multi-level running guides and internal drainage features.
4.2 Telescopic Sash Fabrication
The sliding sash frames were CNC-cut and assembled to maintain consistent nesting clearances across the four roof bays.
4.3 Laminated Safety Glass Assembly
The project source specifies 6 mm + 1.14 PVB + 6 mm laminated tempered glass for the moving roof panels.
05. 1:1 Factory Trial Pre-Assembly & Kinematic Commissioning
Before export, SUNRAY completed a full-scale 1:1 trial assembly of the 5.86 m × 4.95 m skylight system.
5.1 Full-Scale Frame & Track Verification
- Overall width and length were checked against the production drawings.
- All four longitudinal stepped tracks were aligned and checked for parallel spacing.
- Frame squareness and stepped transition geometry were verified before motion testing.
5.2 Motorized Travel & Safety Testing
- All four bays were operated through repeated opening and closing cycles.
- Limit switches and end-stop positions were checked at full-open and full-closed states.
- EPDM seal compression between overlapping tiers was inspected.
06. Export Packaging & Logistics
After factory testing, the tracks, pre-glazed roof panels, motors and hardware were protected for shipment to Malaysia.
- Components were wrapped with foam and protective film.
- Major assemblies were packed into reinforced export plywood crates.
- Oversized crates were secured for truck transport to the shipping terminal.
07. On-Site Atrium Installation in Malaysia
After delivery, the skylight was installed between the two villa walls using the prepared perimeter supports and modular track system.
7.1 Perimeter Support & Flashing
The perimeter support beams were fixed to the reinforced concrete walls, followed by flashing and waterproofing at the building interfaces.
7.2 Stepped Track Grid & Gutter Installation
The four longitudinal tracks and front drainage beam were positioned and laser-aligned before the moving panels were installed.
7.3 Telescopic Glass Sash Installation
The pre-glazed laminated glass sashes were placed onto the stepped tracks and adjusted for running clearance and inter-panel sealing.
7.4 Motor & Rain Sensor Commissioning
The drive system, controls and rain sensor were wired and tested, including automatic closure triggered by moisture detection.
08. Final Handover & Operational Use
Following final water testing, electrical commissioning and cleaning, the motorized skylight was handed over to the homeowners for daily use.
- High-aperture ventilation: The retractable layout opens most of the atrium roof area for natural ventilation.
- Rain automation: The rain sensor can trigger closure when moisture is detected.
- Water-management strategy: Overlapping sashes, drainage channels and EPDM seals help manage tropical rain.
- Daylight and sky views: The glass roof preserves natural light when closed and provides open-sky access when retracted.
- Architectural integration: The dark frame visually connects the white villa facades and dark roof finishes.
09. Application Scenarios
The same overlapping telescopic roof concept can be adapted to other projects that require high opening ratios, weather automation and compact stacking.
- Villa atriums and connecting breezeways
- Restaurant and courtyard retractable skylights
- Indoor pool and lightwell roofs
- Tropical hospitality spaces requiring rain-responsive ventilation