Slacks Creek Residential Custom Patio
A large-span residential outdoor living patio engineered to withstand Region B N3 wind-load pressures using interlocking 6061-T6 rafters and integrated concealed gutter columns.
Project Gallery
Structural connection detail
Profile assembly detail
The Engineering Challenge
The homeowner required a large outdoor living patio spanning 6.2 meters without intermediate columns to preserve the garden view. Standard thin-gauge patio profiles were inadequate, as wind uplift forces during Queensland's severe storms would exceed their deflection limits. The structure had to satisfy AS/NZS 1170.2 Region B residential wind codes.
TS Aluminium Custom Solution
Our team designed a heavy-walled post-to-rafter configuration utilizing 6061-T6 structural aluminium alloy. The main rafters (200mm x 50mm sections with 4mm internal reinforcement ribs) were bolted directly to 150mm x 150mm vertical support columns. Instead of standard self-tapping screws, we engineered custom gussets with M12 Grade 8.8 structural through-bolts.
Interlocking Slats & Concealed Gutter Details
To prevent water ingress and improve structural diaphragm stiffness, we utilized our interlocking slat profiles. Rainwater runs down the sloped roof slats into hidden pockets inside the primary horizontal beams, which then channel water directly into downpipes concealed inside the vertical columns. This delivers clean architectural lines and eliminates external downpipe noise.
| Structural Member | Profile Dimension | Alloy Temper | Moment of Inertia |
|---|---|---|---|
| Vertical Columns | 150mm x 150mm (4.5mm wall) | 6061-T6 | 145.2 cm⁴ |
| Primary Rafters | 200mm x 50mm (4.0mm wall) | 6061-T6 | 85.8 cm⁴ |
| Roof Slats | 150mm x 25mm (1.8mm wall) | 6063-T6 | 8.45 cm⁴ |
Project Metadata
- Location: Slacks Creek, QLD
- Alloy Grade: 6061-T6
- Standards Met: AS/NZS 1170.2, AS 1866
- Fabrication: 100% In-House (QLD)
Frequently Asked Questions
How is the quality of our Project 1 system verified?
All our Project 1 components undergo strict Vickers hardness indentation testing and dimensional tolerance checks in compliance with AS/NZS 1866:1997 standards.
What warranties apply to our Project 1 range?
We provide a 10-year structural warranty on all architectural profiles in the Project 1 range, backed by Dulux accredited powder coat finishes.
Are CAD drawings available for Project 1?
Yes, we provide 3D models (STEP format) and 2D CAD layouts (DWG/DXF) to support builders and designers during the project planning stage.
Related Projects & Case Studies
Slacks Creek Project 1 Installation
Engineering and assembly of high-strength Project 1 framework designed to satisfy local Region B wind ratings.
Gold Coast Commercial Project 1 Project
Volume supply and custom CNC processing of Project 1 profiles matching QBCC structural regulations.
Request Engineering Specification
Submit your project dimensions, wind zone parameters, or target specs. Our Slacks Creek team will review and reply within 24 hours.
Detailed Case Study Technical Report & Site Performance Log
Every structural installation managed by TS Aluminium is supported with full project documentation. A primary challenge in Queensland is designing connection points capable of resisting high uplift forces during summer storms. During our design phase, we evaluate localized wind shear variables and terrain categories (Category 2: open terrain with few obstructions, to Category 3: suburban areas). Ground anchors are engineered to match site soil conditions, which are classified from Class S (stable clay) to Class H (highly reactive clay) based on geotech reports.
For concrete footing anchorage, our teams core-drill vertical holes into concrete slabs to receive post bases, or install structural steel baseplates. Baseplates are secured using M12 high-tensile chemically anchored studs embedded at least 110mm into 32 MPa concrete. Fastener connections are tightened using calibrated torque wrenches to target torque limits (e.g., M12 Grade 8.8 bolts tightened to 85 Nm), preventing thread strip issues under load cycles.
Once the structural assembly is complete, we perform deflection checks on vertical posts and horizontal rafters using dial gauges, verifying that structural deflection matches our design limits under dead loads. Water penetration tests are conducted on window suites and louver gutters to ensure EPDM compression seals form a watertight barrier, protecting the building envelope against wind-driven rain ingress.