Melbourne Luxury Villa：Solving The Heavy Glass Curtain Wall Challenge

Project Background

The client sought to modernize their villa, creating a visually striking, floor-to-ceiling double glazed glass curtain wall window that seamlessly connects the interior and exterior spaces. The project required the use of extra-large glass panels, with some individual panes approaching or exceeding 6 square meters and weighing over 300kg. This presented significant challenges in terms of profile design, glass strength, transportation safety, and on-site installation.

Solution

Based on our clients' needs for safety, aesthetics, and functionality, and in accordance with Australian Building Standards (AS/NZS), we provide a comprehensive, customized service from design and production to installation support.

1. Strictly adhere to Australian standards to ensure scientific and rational glass configuration

To ensure the long-term safety and stability of oversized glass, we strictly adhere to the Australian Window and Door Glazing Standard AS1288:2021 for glass thickness and structure design. We develop a detailed glass selection table based on glass size, installation height, wind pressure zone, and intended use to ensure each piece of glass has sufficient resistance to wind pressure, impact, and deformation.

All glass is AS1288-certified  tempered safety glass, and Low-E glass is configured according to energy reporting requirements, ensuring strength while also providing thermal and acoustic insulation.

2. Safe Transportation: Window Frames and Glass are Packed Separately, Each Piece is Reinforced

Transporting oversized glass was a key challenge for the entire project. Because a single pane of glass typically weighs over 300kg, traditional packaging for whole windows is highly susceptible to breakage during transportation or unloading.

To this end, we adopted separate packaging for the window frames and glass:

- Window frames are packaged individually with thickened pearl cotton foam;

- Each oversized glass piece is individually framed with plywood and reinforced at the four corners. Designated lifting holes are provided on the frame to facilitate safe unloading using a crane or forklift;

- All packaging meets ocean transport standards for earthquake resistance, moisture resistance, and impact resistance, ensuring the product remains intact after its ocean voyage.

3. Efficient Installation: Modular Construction Reduces On-Site Risks

To prevent accidents during the handling of overweight glass, we designed a step-by-step installation process:

1. The contractor first secures the window frame with pre-installed wooden frame to the wall opening, ensuring precise positioning;

2. Using specialized suction cups, the large glass is steadily lifted from the packaging rack and transferred to the window frame;

3. Gluing and crimping are performed on-site to complete the airtight installation.

This process significantly reduces the risks of working at height and manual handling, improving construction efficiency and safety.

4. 110 Thermal Break System: AS2047 Certified, Performance Far Exceeds Industry Standards

This project utilizes our independently developed 110 series thermal break aluminum alloy window system, which has passed comprehensive testing according to the authoritative Australian standard AS2047, demonstrating exceptional structural strength and wind pressure resistance.

Australia is divided into several wind zones based on geographical and climatic conditions, and aluminum window and door products must meet corresponding performance levels:

- N-Class (N1–N6): Suitable for non-cyclonic areas (Zones A and B)

- C-Class (C1–C4): Suitable for cyclonic areas (Zones C and D)

We subjected the 110 series to rigorous AS4420.2 deflection testing and AS4420.6 ultimate strength testing, with the following results:

*Rolansini 110 awning window test report                                            *Other company awning window test report

- Deflection Test: Achieved N6/C4 ratings

This means that even under extreme wind pressure, the window sash exhibits minimal deformation, maintaining structural stability and preventing operational degradation. In comparison, most similar products on the market only reach the N3 level.

- Ultimate Strength Test: Achieved N6/C3 rating

This demonstrates that the product maintains structural integrity in extreme weather conditions such as hurricanes and severe storms, resisting cracking or falling apart, significantly enhancing residential safety.

5. Design Aesthetics: Symmetrical Layout of Upper and Lower Glazing Creates a Visual Continuity

In addition to exceptional performance, the design also fully considered the overall aesthetics of the building. The symmetrical arrangement of glazing on the upper and lower floors achieves a unified and harmonious facade, enhancing the building's modern and luxurious feel.

The continuity of the large expanses of glass blurs the boundaries between indoors and outdoors, allowing natural light to flood the interior while framing the courtyard landscape, creating a living experience where "you are immersed in the scenery, your home is within a painting."

Conclusion

This high-end villa renovation project in Melbourne once again demonstrates our comprehensive capabilities in oversized glazing system design, structural safety verification, international standards compliance, and complex engineering implementation. We consistently adhere to the principle of "standards as the cornerstone and customer-centricity," and are committed to providing safer, more beautiful, and more intelligent door and window solutions for high-end residences around the world.

If you are planning a similar curtain wall or large glazing project, please contact us for customized solutions and technical support.