01. Site Survey & Client Requirements
The project site is a large outdoor aquatic zone within a luxury estate in Uzbekistan. The pool is surrounded by composite decking, four hip-roof poolside cabanas and a modern glazed clubhouse, with open agricultural and steppe landscapes nearby.
- Dust and agricultural debris: Strong dry winds carried dust, sand and crop residue toward the exposed pool.
- Extreme summer heat: High temperatures increased evaporation and reduced daytime comfort around the open pool.
- Cold-season closure: The client wanted better seasonal protection during winter conditions.
- Large-span requirement: The enclosure needed to cover the full 20 m × 10 m aquatic zone without intermediate interior support columns.
- Convertible resort experience: The owner wanted a large central opening for open-air swimming while retaining enclosed operation when required.
02. Conceptual Design & 3D BIM Modelling
SUNRAY developed a six-bay faceted-arch enclosure with symmetrical center-split movement and generous side-walkway headroom.
2.1 Monumental Faceted Arch Profile
The side walls provide approximately 2,500 mm of vertical clearance, while the segmented roof rises a further 500 mm to a 3,000 mm central crown. This creates comfortable covered circulation beside the pool while maintaining a clear large-span roof profile.
2.2 Six-Bay 3+3 Bi-Parting Kinematics
The six 3,380 mm modules divide at the center. Three telescope toward the left end and three toward the right, forming compact stacks at both ends.
2.3 13.24m Open-Sky Central Span
With both module groups retracted, the system creates a 13,240 mm central opening for open-air pool use.
03. Shop Drawings & Dimensional Coordination
Approved production drawings established the 20 m baseline, 10 m width, pool-water span, six-module breakdown and faceted arch cross-section before fabrication.
- Total track baseline: 20,000 mm
- Clear central opening: 13,240 mm
- End stack footprint: 3,380 mm each side
- Verification formula: 3,380 + 13,240 + 3,380 = 20,000 mm
- Overall structural width: 10,000 mm
- Pool-water width: 8,770 mm
- Covered side walkway: 615 mm each side
- Maximum crown height: 3,000 mm
- Perimeter vertical clearance: 2,500 mm
- Faceted roof rise: 500 mm
- Module division: 6 bays × 3,380 mm
04. Precision Manufacturing & Factory Quality Control
Manufacturing focused on the monumental multi-track system, wide-span aluminum members, drainage interfaces and repeatable geometry for all six telescoping modules.
4.1 Multi-Cavity Aluminum Tracks & Structural Profiles
The source documents heavy-gauge 6063-T6 aluminum multi-track floor sills and faceted arch profiles with reinforced internal cavities and stepped wheel guides.
4.2 CNC Machining
Automated machining was used for roller-track cavities, mounting pockets and drainage slots to support the moving system.
4.3 Dark Charcoal Architectural Finish
The aluminum structure received a dark charcoal fluorocarbon finish selected to coordinate with the modern clubhouse and cabana roofs.
05. 1:1 Factory Trial Pre-Assembly & Kinematic Testing
Before export, SUNRAY completed full-scale trial assembly and kinematic testing across the complete 20.00 m baseline and 10.00 m width.
5.1 Baseline Alignment & Six-Bay Nesting
- Track parallelism and diagonal squareness were checked across the full 20 m × 10 m assembly.
- All six modules were tested for smooth bi-parting movement without binding or profile interference.
- End-stack clearances were checked against the 3,380 mm nesting footprint.
5.2 Motor Synchronization & Weather-Seal Inspection
- Synchronized electric drives were cycled repeatedly for opening and closing.
- The project source records a complete open / close cycle of approximately two minutes.
- EPDM sweep-gasket contact was checked along module overlaps to support dust and weather sealing.
06. Export Packaging & Cross-Border Logistics
After factory testing, the modules, tracks and polycarbonate panels were protected for rail and road transport to Uzbekistan.
- Aluminum members were wrapped with foam, edge protection and stretch film.
- Disassembled modules, track sections and glazing components were packed into reinforced export plywood crates.
- Crates were secured for international rail freight and onward delivery to the project site.
07. On-Site Installation in Uzbekistan
After delivery, the prefabricated enclosure was installed on the composite deck around the existing pool complex.
7.1 Ground Track Installation & Laser Leveling
The 20,000 mm guide tracks were positioned on the deck structure and anchored into reinforced sub-base supports, then laser-leveled for coplanar and parallel alignment across the 10 m span.
7.2 Module Assembly & Polycarbonate Installation
The six pre-machined modules were assembled on the tracks and fitted with the specified UV-resistant polycarbonate panels.
7.3 Motor Wiring & Bi-Parting Calibration
The electric drive units were connected to the central controls and calibrated for synchronized remote-controlled movement toward both ends.
08. Final Handover & Operational Use
The completed enclosure converts the outdoor aquatic center between protected and open-air operation while preserving generous circulation space around the pool.
- Large open-sky span: Retraction creates a 13,240 mm clear central opening.
- Standing headroom: 2,500 mm side-wall clearance allows comfortable covered circulation.
- Dust protection: The enclosed mode helps reduce steppe dust and agricultural debris entering the pool.
- Fast conversion: The system opens or closes in approximately two minutes according to the project source.
- Architectural integration: Dark charcoal framing coordinates with the clubhouse and poolside cabanas.
09. Application Scenarios
The same monumental bi-parting concept can be adapted to large residential, hospitality and wellness pools requiring wide spans and convertible enclosed / open-air operation.
- Luxury estate and resort swimming pools
- 10 m+ wide aquatic pavilions
- Dust-prone continental-climate pool facilities
- Hotels, wellness retreats and sports clubs requiring motorized seasonal enclosures