Precision-built Cooldek® Patio For Year-round Comfort

Challenge

In May 2025, a homeowner in Mambourine, VIC (3024) approached Sam Outdoor Living with the goal of converting a 32m² outdoor area into a high-performance space for year-round use. The primary objective was to achieve a structure that combined thermal insulation, weather resilience, structural integrity, and visual continuity with the residence. The site presented constraints related to orientation and exposure to varying weather conditions, which demanded a carefully engineered solution with reliable thermal control, water drainage, and structural stability. The client also required integration of lighting and heating elements without compromising design uniformity or ongoing maintenance efficiency.

Solution

Sam Outdoor Living proposed and executed a custom-engineered flat patio solution in an L-shaped layout (6.7 x 7 metres) using Stratco Cooldek® insulated roof panels with a 75mm core. These panels incorporate a high-tensile external skin bonded to an insulating polystyrene core, designed to minimize radiant heat transfer and deliver structural rigidity over large spans without intermediate supports. The roofing system was paired with a 200mm integrated edge gutter to manage water runoff effectively, ensuring compliance with local drainage codes.

The structure was supported using powder-coated 150x150mm aluminium posts, offering high corrosion resistance and load-bearing capacity. Roof loads were distributed using 140x50mm Probeam galvanised steel beams—selected for their high moment capacity and compatibility with long-span roofing systems. Translucent roof sections included Ez-glaze infill panels and Sunlite® 10mm TwinWall polycarbonate sheets from Palram, allowing filtered daylight transmission while maintaining UV protection and thermal performance.

Electromechanical components included six flush-mounted LED downlights for general illumination, three directional spotlights for task lighting, and a ceiling-mounted radiant strip heater—selected for its low-profile installation and efficiency in outdoor environments. Electrical conduits and junctions were integrated into the roof cavity and beam system to conceal all cabling, ensuring a clean architectural finish.

Results

The completed structure delivered measurable improvements in thermal control, weather protection, and spatial usability. The Cooldek® panels maintained interior temperatures by reducing heat gain during summer and retaining warmth during colder months, supported by the strategically placed radiant heater. The polycarbonate glazing provided diffuse daylight without glare, and the sealed joints minimized water ingress and dirt accumulation. Structural testing confirmed compliance with regional wind load requirements and building code standards.

Overall, the project resulted in a high-performance, technically robust outdoor enclosure. Material selection and assembly methods were optimized for longevity, serviceability, and aesthetic consistency. The completed build now functions as a multi-purpose extension of the client’s living space, with minimal maintenance needs and full environmental adaptability.