Smartly Engineered Flyover Patio Built For All Seasons - Reservoir, Vic

Challenge

In April 2025, Sam Outdoor Living was contracted by a homeowner in Reservoir, VIC to design and construct a premium outdoor living area. The client sought a solution that would transform their existing backyard into a multifunctional space suitable for year-round use, specifically for entertaining guests and everyday relaxation. The proposed area spanned 58 square meters and required a design that could provide effective climate control, structural integrity, and long-term durability while visually complementing the residential environment. Key project constraints included ensuring compatibility with the existing dwelling, managing local environmental exposure (including high summer temperatures and occasional heavy rainfall), and minimizing future maintenance requirements.

Solution

To address the client’s requirements, Sam Outdoor Living engineered a 5.8m x 10m flyover-style patio system, utilizing Stratco’s Cooldek® insulated roofing panels. The flyover design was selected to improve vertical clearance, enhance airflow beneath the structure, and reduce heat buildup commonly experienced in enclosed or flush-mounted patio configurations. The roofing system employed 75mm-thick Cooldek® panels, consisting of a pre-painted steel outer skin bonded to a high-performance EPS (Expanded Polystyrene) insulation core, capped with a profiled steel underside ceiling. This composition delivers a dual benefit: thermal insulation (reducing solar heat gain and heat transference to the space below) and integrated water management via concealed drainage channels.

Structural integrity was ensured through the use of Probeam 140x50mm galvanised steel beams, which offered high flexural strength with minimal deflection over the span, and 150x150mm aluminium powder-coated support posts, selected for their corrosion resistance, especially in exposed outdoor environments. The frame was anchored with precision-mounted footing systems in compliance with local engineering codes, with rise brackets (50x50mm) used to elevate the structure above the eaves, ensuring adequate air circulation and an open, spacious feel.

The guttering system incorporated 200mm edge gutters designed for high-volume water collection, which were seamlessly integrated with downpipes to direct runoff efficiently and reduce overflow risk during peak rainfall. In addition to structural considerations, the patio included a range of comfort and usability enhancements: eight LED downlights and four directional spotlights were recessed into the Cooldek® ceiling, providing zoned lighting control and energy efficiency. Two infrared strip heaters were installed flush with the ceiling panels to supply radiant warmth in colder months without compromising headroom, while two smart ceiling fans enabled adjustable airflow through app-controlled settings, optimizing comfort based on temperature and humidity levels. Electrical systems were routed discreetly through pre-planned conduit paths within the structural frame, ensuring no visible cabling or compromise to the patio’s clean architectural lines. All fixtures were rated for exterior use, with IP ratings compliant with local building standards.

Result

Upon completion, the newly constructed flyover patio delivered a high-performing, visually striking outdoor space that exceeded the client’s expectations. The insulated Cooldek® panels significantly improved thermal comfort, reducing ambient temperatures beneath the structure by minimizing radiant heat from the sun, and helping to retain warmth during cooler periods. The elevated roof design not only enhanced airflow but also contributed to the sense of openness and architectural sophistication.

Functionally, the space became a versatile outdoor living area, fully equipped for both daytime use and evening gatherings thanks to the integrated LED lighting and climate control features. The combination of smart fans and radiant heaters allowed the client to tailor the environment to suit seasonal conditions, enhancing the usability of the space throughout the year.

From a durability standpoint, the use of premium materials—such as Stratco’s Cooldek®, corrosion-resistant aluminium, and galvanised Probeam—ensured structural longevity with minimal maintenance. The concealed drainage and wiring systems preserved the patio’s clean appearance and reduced exposure to weather-related wear. Overall, the project added significant lifestyle and aesthetic value to the property, turning an underutilized backyard into a refined extension of the home’s living space.