01. Site Survey & Client Requirements
The existing pool sits within a large elevated composite deck surrounded by white balustrades and dense mature woodland. The pool was previously protected by a manual green mesh safety cover that blocked use of the water whenever installed.
- Heavy forest debris: Pine needles, leaves, pollen and seeds continuously fell onto the pool and deck.
- Manual cover inconvenience: The existing fabric cover required repeated manual handling and made the pool inaccessible when deployed.
- Large pool footprint: The new enclosure had to span a 12.2 m long pool within a broad 8.5 m deck zone.
- Open-air requirement: The homeowner wanted more than 10 m of clear central opening when the enclosure was retracted.
- Fast automation: Remote-controlled deployment and retraction were required for daily convenience.
02. Conceptual Design & 3D BIM Modelling
SUNRAY developed a wide-span faceted arch enclosure that combines full standing headroom with symmetrical bi-parting movement.
2.1 Faceted Arch Profile
The side walls provide approximately 2,000 mm of vertical clearance, while the segmented roof rises another 500 mm to a 2,500 mm crown. The profile provides comfortable access along the deck while helping shed rain, leaves and seasonal snow.
2.2 Six-Bay 3+3 Bi-Parting Kinematics
The six 2,580 mm modules split at the center, with three moving toward each end. When retracted, the modules form compact stacks at both deck ends and leave a 10,040 mm central pool opening.
2.3 Architectural Integration
The clean white enclosure frame was selected to coordinate with the existing white balustrades and light-toned composite decking.
03. Shop Drawings & Dimensional Coordination
Approved production drawings established the overall track baseline, clear opening, module stack geometry, transverse widths and faceted arch profile before fabrication.
- Total track baseline: 15,200 mm
- Pool coverage length: 12,200 mm
- End track extensions: 1,500 mm each side
- Clear central opening: 10,040 mm
- Stacked module footprint: 2,580 mm each end
- Module division: 6 bays × 2,580 mm
- Overall outer frame width: 8,500 mm
- Outer guide baseline: 8,543 mm
- Intermediate track baseline: 7,673 mm
- Inner clear basin span: 5,500 mm
- Crown height: 2,500 mm
- Perimeter vertical clearance: 2,000 mm
- Faceted roof rise: 500 mm
04. Precision Manufacturing & Factory Quality Control
Manufacturing focused on the wide-span track system, reinforced aluminum profiles, drainage details and repeatable interfaces for the six telescoping modules.
4.1 Multi-Cavity Aluminum Profiles & Tracks
The project 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 channels, mounting pockets and drainage slots required by the moving track system.
4.3 White Architectural Finish
The aluminum components received a white fluorocarbon architectural finish that visually matches the deck balustrades and supports outdoor exposure.
05. 1:1 Factory Trial Pre-Assembly & Kinematic Testing
Before shipment, SUNRAY completed full-scale trial assembly and movement testing of the six-module system on calibrated factory jigs.
5.1 Track Alignment & Six-Bay Nesting
- The 15.20 m baseline and 8,543 mm outer guide width were checked for parallelism and squareness.
- All six modules were tested for smooth center-split movement without binding or profile interference.
- End-stack clearances were checked against the 2,580 mm nesting footprint.
5.2 Motor Synchronization & Seal Inspection
- Synchronized electric drives were cycled repeatedly for opening and closing.
- The project source records a complete cycle of approximately two minutes.
- EPDM sweep-gasket compression was checked along the module overlaps for debris and weather sealing.
06. Export Packaging & Ocean Logistics
After factory testing, the modules, tracks and polycarbonate components were protected for ocean shipment to the United States.
- Aluminum extrusions were wrapped with protective foam and film.
- Disassembled frames, tracks and glazing components were packed into reinforced export plywood crates.
- Crates were secured inside an ocean container for delivery to the U.S. project site.
07. On-Site Installation in the United States
Following delivery, the enclosure was installed on the elevated composite deck using the prepared wide-span track geometry.
7.1 Deck Substructure Reinforcement & Track Anchoring
The 15,200 mm guide rails were positioned over the deck and fixed into reinforced timber joists below, then laser-leveled for coplanar and parallel alignment across the wide span.
7.2 Module Assembly & Polycarbonate Installation
The six prefabricated modules were assembled on the track system and fitted with the UV-resistant polycarbonate panels.
7.3 Motor Wiring & Bi-Parting Calibration
The electric drive units were connected to the control system and calibrated for synchronized remote-controlled movement toward both ends of the deck.
08. Final Handover & Residential Use
The completed enclosure replaces the manual fabric cover with an automated system that protects the pool while preserving a large open-air central span.
- Forest debris protection: The closed enclosure helps keep pine needles, leaves and pollen out of the pool.
- Large open-sky span: Retraction creates a 10,040 mm clear central swimming zone.
- Fast conversion: The system opens or closes in approximately two minutes according to the project source.
- Comfortable deck access: Approximately 2,000 mm perimeter headroom allows normal walking beside the pool.
09. Application Scenarios
The same wide-span bi-parting enclosure concept can be adapted to large residential and hospitality pools where debris protection and a large central open-sky span are priorities.
- Woodland and tree-canopy estate pools
- Large pools on elevated timber or composite decks
- Private villas requiring motorized seasonal pool protection
- Resort and club pools requiring convertible enclosed / open-air operation