01. Site Survey & Client Requirements
The original rear patio was covered by an aging open-sided timber structure with corrugated roofing, limited weather protection and no insect barrier. The homeowner wanted to replace it with a clean, enclosed room that could function as part of the home rather than as a seasonal patio.
- Coastal storm exposure: The new enclosure needed a robust structural frame and reliable weather sealing.
- Heavy rainfall: The roof and eave interfaces needed controlled drainage rather than an exposed open-patio arrangement.
- Mosquito and insect nuisance: The client wanted screened natural ventilation without leaving the room fully open.
- Indoor-outdoor flexibility: Large folding glass doors were required so the garden-facing wall could open widely in good weather.
- Year-round family use: The space was intended for relaxing, indoor planting, exercise equipment and pets.
02. Conceptual Design & 3D BIM Modelling
SUNRAY developed a contemporary lean-to sunroom using a clean white post-and-beam structure to visually integrate with the existing villa.
2.1 White Post-and-Beam Geometry
The enclosure uses a simple single-slope roof and white aluminum framing to create a brighter, lighter appearance than the original timber patio structure.
2.2 Mixed Fenestration Strategy
The design combines fixed glazed panels, four screened lift-sash windows, a wide multi-panel bi-fold facade and a side sliding-glass wall to balance views, ventilation and access.
2.3 Insulated Lean-To Roof
The roof slopes from the rear wall connection toward the front eave, using insulated composite panels and an engineered eave water-deflector profile.
03. Shop Drawings & Dimensional Coordination
Approved production drawing Sheet 7 established the final structural bay layout, window modules, roof heights and glazing configuration before fabrication.
- Overall length: 7,750 mm
- Overall projection: 4,640 mm
- Rear ledger height: 2,900 mm
- Front eave height: approximately 2,210 mm
- Structural columns: 150 mm
- Longitudinal bay 1: 3,550 mm
- Longitudinal bay 2: 3,750 mm
- Four lift-sash window units: 1,000 mm each
- Lift-window glazing: 5+20A+5 insulated glass
- Factory-integrated insect screens
04. Precision Manufacturing & Factory Quality Control
Manufacturing focused on the structural frame, connection accuracy, hardware pre-fitting and durable architectural finishing for the coastal installation.
4.1 6061-T6 Aluminum Processing
The structural posts, perimeter beams and roof members were produced from 6061-T6 aluminum profiles and machined for the project-specific connection geometry.
4.2 Connection Hardware Pre-Fitting
Internal brackets, rafter connectors and alignment hardware were pre-fitted in the factory to reduce field cutting and simplify installation.
4.3 White Architectural Finish
The aluminum components were finished in architectural white to coordinate with the house and provide a clean coastal appearance.
05. Export Packaging & Logistics
The supplied case-study file does not document a separate full-scale 1:1 factory pre-assembly stage. After manufacturing and hardware pre-fitting, the components were protected for export.
- Structural columns, beams, insulated roof panels, window modules and door panels were wrapped and protected.
- Major components were packed into reinforced plywood export crates.
- The crates were loaded onto transport vehicles and dispatched for containerized shipment to the U.S. East Coast.
06. On-Site Installation in the United States
After delivery, the prefabricated system was assembled on the existing concrete patio under local contractor supervision.
6.1 Base Anchoring & Frame Erection
The 150 mm structural columns were fixed to the prepared concrete slab, followed by the perimeter beams and rear wall ledger.
6.2 Roof Framing & Insulated Panels
Pre-machined roof members were installed between the rear ledger and front eave beam before the insulated roof panels were fitted.
6.3 Lift Windows & Bi-Fold Glass Walls
The four screened lift-sash windows, wide multi-panel bi-fold facade and side sliding-glass wall were installed and adjusted for final operation.
07. Final Handover & Residential Use
After interior flooring, final sealing and cleaning, the completed room was handed over as an approximately 32.5 m² extension to the villa's living area.
- Year-round use: The enclosed room provides a more controlled environment than the original open patio.
- Natural ventilation with insect control: Screened lift windows allow fresh air without fully opening the room.
- Wide garden connection: The bi-fold glass facade can be opened to reconnect the room with the backyard.
- Insulated enclosure: Double glazing and insulated roof panels support improved thermal comfort compared with the former open shed.
- Lifestyle conversion: The completed space functions as a lounge, garden room, exercise area and pet-friendly family space.
08. Application Scenarios
The same design approach can be adapted to other residential renovation projects where an outdated covered patio needs to become a brighter, enclosed and more flexible living space.
- Suburban patio and deck conversions
- Coastal residential sunrooms
- Garden rooms and family lounges
- Pet-friendly enclosed patios with screened ventilation