A free-form steel canopy suspended above Doha's marina boulevard — engineered to a millimetre, welded in our shop, lifted into place under a single accountable crew.
The Lusail Marina Yacht Club asked for a single, fluid canopy that could anchor a luxury waterfront and read as one continuous gesture from any approach. There was no off-the-shelf section that could hold that geometry — every node had to be modelled, every plate had to be cut to shape.
Metalyol owned the entire backbone. We took the architect's surface, broke it into a structural space frame, ran the analysis, fabricated the assemblies in our Istanbul shop, and erected on the marina edge with our own crews. One team. One signature. One contract.
Inspect the spec sheetThe canopy reads as a single gesture but breaks down into 124 unique structural assemblies. Every truss segment was BIM-modelled, dimensioned and cut on our 5-axis CNC.
The primary trusses use European S460-grade plate for stiffness-to-weight. Secondary members and bracings step down to S355, with hot-dip galvanizing across all exposed surfaces and a marine-grade epoxy top coat for the salt-air environment.
The original architectural rendering described the canopy as a continuous parametric shell — beautiful on screen, but with no structural rationality. There was no orthogonal grid, no repeating module, no obvious load path.
Marine wind loads added a second layer: vortex shedding off neighbouring towers translated into asymmetric pulses across the canopy, requiring node-by-node fatigue analysis instead of standard envelope checks.
Our engineers split the surface into 124 quad-paneled regions and ran a node-by-node optimisation. Each connection was modelled as a unique parametric joint — same family, different angles — and pre-fabricated in seven mega-sections that were trial-assembled in-shop before shipping.
On site, the assemblies were lifted with a 750 t crawler crane in eleven calendar days, stitched along match-marked seams, and surveyed to verify under 4 mm tolerance across the full canopy. The final shell came in at 1.2 mm off the BIM geometry — within the thickness of a paint coat.
BIM model, structural calc, wind & fatigue analysis, fabrication drawings.
Two full-scale node mock-ups validated weld geometry and tolerance assumptions.
9 weeks · 124 unique assemblies · 100% UT on full-penetration welds.
Seven mega-sections trial-assembled and surveyed inside the Istanbul yard.
750 t crawler crane lifted seven sections in 11 calendar days. Survey verified to ±4 mm.
Surveyed, painted, signed off and delivered to the operator for cladding.
From a single mill order to a full turnkey lift — one team owns the path from drawing to surveyed structure.