"Qatar Petroleum’s lead engineer stated that this is “a piece of art that Tecman Industry is erecting on our project.”

The construction methodology system shaped by Tecman’s team for the chaotic façade is a masterpiece of engineering and craftsmanship. It is, in brief, a composite structure composed of a steel hot-dip galvanized structure and an aluminum chaotic pattern assembled in three composite layers of approximately 24,000 m2 each, equaling 72,000 m2 in total. More than 2,000 tons of structural steel built-up sections, in addition to more than 1,000 tons of aluminum profiles, were assembled to form the envelope and roof canopies of the NCCCP Iconic Feature in the Education City of the Qatar Foundation.

THE STEEL STRUCTURE It is composed of 2,000 tons of built-up section I Beams and a complex bracing attachment system that holds the structure at a distance of 4.5 m from the concrete building. All steel members have been customized in the Tecman Industry Manufacturing Facility in Nahr El Mott Industrial Valley in Beirut, Lebanon. Qatar Petroleum’s lead engineer stated that this is “a piece of art that Tecman Industry is erecting on our project.” A new facility was erected swiftly to cater to the envelop works. It was dedicated to the production of the structure and equipped with a new set of digitized machinery, including precision CNC cutting platforms, continuous welding stations, compact versatile tapering machines, and bending and cutting machines, among others. The aim was to produce all the components of the project under one roof with high accuracy and within a very limited time frame.

Once this goal was achieved, an elaborate sophisticated labeling /shipment process was put in place to allow the transportation of the parts in sequence to be hot dip-galvanized in Qatar prior to erection on site (such processes resulted in preserving the quality of the galvanization).

THE CHAOTIC FAÇADE The chaotic envelop is the main feature of the rectangular building spanning 290 meters in length, 145 meters in width, and 15.7 meters in height, topped by a cantilever canopy 7 meters wide all around the façade. This chaotic façade pattern covers an area of 24,000 m2 composed of 3 layers totaling an area of 72,000 m2. It is composed of hollow square aluminum sections manufactured specifically for the project with an anodized brushed finish. This masterpiece is composed of more than 950,000 members to be assembled into patterns. The members were cut with high precision over very accurate templates in the factory, then shipped and assembled onsite using dedicated assembly platforms for each type of pattern using concealed inner sleeve connectors. This particular assembly method resulted in a high level of accuracy and precision.

ENGINEERING AND MANUFACTURING STRATEGY The façade screen was subdivided into construction modules of 720*720 cm elements in 17 different types of patterns, with each composed of three sub-patterns forming the triple layer modules. Once the accuracy and quality control was achieved over the assembly platforms, the module was then lifted to its final location on the façade and mounted within the structure over movement pads designed to cope with the structural deflection of the steel frame. This construction methodology was initially conceived to respond to the following criteria: 1- Factory chain production manufacturing 2- Tight time frame for site assembly and erection 3-High accuracy (0 deviation in dimensions) for 850 linear meters of envelop

SHIPMENT AND DELIVERY The decision to manufacture the façade components in Tecman’s facility in Beirut was made for accuracy purposes, involving an elaborate labeling and shipping process. 350 land trucks were shipped following a delicate sequence of delivery in synchronization with the site assembly progress to avoid an out of sequence erection process on site.