01. Site Survey & Client Requirements
The project centers on a deep travertine-clad rooftop lightwell within a multi-story villa. The open atrium admitted strong solar heat, wind-driven rain and dust directly into the building core, so the client required an automated glazed roof that could close for weather protection and open for natural ventilation.
- Existing lightwell geometry: 3,170 × 3,190 mm clear masonry opening within a 3,810 × 3,530 mm outer curb.
- Parapet conditions: 360 mm coping thickness on the front and rear, and 400 mm on the right side.
- Heat-control requirement: The deep lightwell required solar-control glazing and an operable opening to release rising hot air.
- Weather protection: The skylight needed reliable sealing against sudden downpours and wind-driven rain.
- Architectural integration: The frame needed to remain slim and visually compatible with the cream travertine villa architecture.
02. Conceptual Design & 3D BIM Modelling
SUNRAY developed a low-profile, curb-mounted four-panel skylight with two fixed outer panels and two center sashes that slide outward in opposite directions.
2.1 Low-Profile Curb-Mount Architecture
The structural perimeter frame sits directly on the masonry curb, while a single slope across the 3,330 mm projection directs rainwater toward the front parapet. A 40 mm rear flashing upstand forms the weather interface against the back wall.
2.2 Symmetrical Bi-Parting Sliding Logic
In the closed position, the two active center panels meet at the middle and seal against EPDM weather gaskets. On command, both 933 mm sashes slide outward over the 859.7 mm fixed panels.
2.3 Stack-Effect Ventilation
The open configuration produces a 1,649.6 mm clear central aperture, allowing warm air accumulated in the vertical atrium to escape naturally through buoyancy-driven ventilation.
03. Shop Drawings & Dimensional Coordination
Approved production drawings established the curb dimensions, frame geometry, four-panel division, glass specification and drainage interface before fabrication.
- Inside lightwell opening: 3,170 mm × 3,190 mm
- Outside concrete curb: 3,810 mm × 3,530 mm
- Overall aluminum frame: 3,590 mm × 3,330 mm
- Panel widths: 859.7 + 933.0 + 933.0 + 859.7 mm
- Clear central opening: 1,649.6 mm
- Retracted active-sash footprint: 932.8 mm each side
- Rear flashing upstand: 40 mm
- Glazing: 6 + 1.52 + 6 mm Low-E laminated safety glass
- Integrated internal power-routing provision
04. Precision Manufacturing & Factory Quality Control
Manufacturing focused on accurate aluminum machining, seamless welded corners, surface preparation and durable finishing for long-term sliding performance and weather sealing.
4.1 CNC Cutting & Mitering
6063-T6 aluminum profiles were cut on automated double-head equipment to the approved dimensions and miters before assembly.
4.2 Laser-Welded Corners & Precision Grinding
Frame corners were laser welded and then ground flush to create smooth, rigid joints before coating and final assembly.
4.3 Dark Bronze Architectural Finish
The structural frame received a dark bronze / matte black fluorocarbon finish selected for high UV exposure and compatibility with the villa architecture.
05. 1:1 Factory Trial Pre-Assembly & Kinematic Testing
Before export, the complete skylight was assembled on calibrated factory test benches for mechanical, electrical and sealing verification.
5.1 Frame Alignment & Sliding Verification
- Frame squareness and curb seating were checked across the 3,590 × 3,330 mm assembly.
- Both 933 mm active sashes were repeatedly opened and closed by remote control.
- End-of-travel limits and the 932.8 mm stacking positions were verified.
- The 1,649.6 mm central opening was confirmed against the production drawing.
5.2 Weather-Seal & Control Commissioning
- EPDM inter-panel compression was checked along the center meeting line and perimeter seals.
- Wireless remote-control response and actuator synchronization were verified.
- Internal power routing was checked before disassembly and packing.
06. Export Packaging & Container Logistics
After factory commissioning, the glazed sashes, fixed panels and perimeter frame components were protected for ocean shipment to Australia.
- Glazed panels and curb assemblies were placed in reinforced wooden export crates.
- Aluminum profiles and corner joints were wrapped with protective film and foam cushioning.
- Crates were staged and secured for containerized sea freight to Australia.
07. On-Site Installation in Australia
After delivery, the skylight was installed onto the existing concrete parapet using the pre-engineered curb dimensions and electrical routing provisions.
7.1 Parapet Preparation & Base Anchoring
The masonry curb was checked for level, weatherproofed at the contact surfaces and prepared for the 3,590 × 3,330 mm aluminum frame.
7.2 Glazed Sash Installation & Electrical Connection
The two fixed outer panels and two motorized center sashes were placed into the guide system and connected to the control circuit through the designated power-routing point.
7.3 Final Calibration & Rain-Sensor Integration
The sliding travel limits, remote control and synchronized actuators were calibrated on site, and the system was integrated with a roof-mounted rain sensor for automatic closing during sudden rainfall.
08. Final Handover & Residential Use
The completed skylight converts the formerly open lightwell into a controllable glazed roof that balances natural light, heat management, weather protection and automated ventilation.
- Natural ventilation: The 1,649.6 mm center opening supports stack-effect exhaust from the multi-story atrium.
- Solar control: Low-E laminated glazing reduces direct solar heat and UV exposure while maintaining daylight.
- Weather protection: Closed panels and perimeter sealing protect the lightwell from rain and airborne dust.
- Smart operation: Remote control and rain-sensor automation improve day-to-day convenience.
- Architectural integration: The low-profile dark bronze frame complements the travertine-clad villa.
09. Application Scenarios
The same bi-parting sliding skylight concept can be adapted to other residential and commercial projects requiring a low-profile glazed roof with controllable natural ventilation.
- Luxury villa atriums and central lightwells
- Penthouse and rooftop courtyard skylights
- Boutique hotel and restaurant atriums
- Architectural roof openings requiring motorized ventilation and rain-sensor control