Lusail (GRP)

Designed by AEB around the concept of a coral reef, the towers’ facade unfolds across 40,000 sqm of organic, non-repeating GRP pattern no two panels are alike, each shaped for its own place in the reef.

We produced and installed 1,200 lightweight GRP panels across both towers, each measuring 4 x 5 metres and mounted directly onto the glass envelope on brackets engineered to carry the panels’ full load. Spanning 8 elevations and 80 floors, the facade came together like a puzzle every panel and every bracket needed to align to millimetre accuracy, achieved through close coordination with the aluminium contractor throughout installation.

The scale of the project called for a different approach to production: rather than casting 1,200 individual moulds, our team engineered a reusable mould system that produced multiple panel variants from shared tooling eliminating the cost and lead time of conventional one-off moulds without compromising the organic, non-repeating pattern AEB’s design demanded. The result is a facade that reads less like construction and more like something grown along the coastline it stands on.