Sheybarah Hotel is a hyper luxury resort on Sheybarah Island on the Red Sea archipelago and was designed by Killa Design in Dubai and aims for a LEED-Platinum accreditation. It comprises a series of overwater and inland villas located on the uninhabited Sheybarah Island, 30-minutes by boat from the mainland. The island is home to a highly diverse environment with mangroves, sandy beach, and some of the most beautiful coral reefs in the world.
The goal of the project is to best preserve and enhance the surrounding biodiversity by minimising its environmental footprint.
Each overwater villa is lifted above the water surface reducing the ground foundation impact to the minimum and offers panoramic views to the sea, with sliding doors that open to a deck, a seating area, and an infinity pool with uninterrupted views of the sea and the horizon.
The approach to the façade design has been to minimise visual impact with each villa having polished stainless steel cladding that reflects the water, the sky, and the reef with the rich sea life below. This material is the key feature of the project and is used in various locations such as the lobby, dining areas, spa and beach villas.
Having previously successfully collaborated with Killa Design on the Museum of the Future in Dubai, GKI was first approached to resolve the detailing of the various mirrored stainless steel façade of this project.
The project’s geometry, particularly dealing with the complexity of the shape and the jointing, requires every detail to be modeled, analyzed and optimised in advance of fabrication. Through an extensive sample and mock-up process, GKI managed the removal of the originally engineered hairline joints between the panels achieving a seamless undistorted mirror stainless steel surface as per the design intent.
By providing various samples and mock-ups GKI was able to demonstrate the benefits of a jointless design to the Client as they were able to see the mock-up villa pod in person and gain confidence with the immaculate fabrication of the design. As a consequence GKI was then appointed a design and build contract for the structure and cladding based on the schematic design of the design team.
For the Sheybarah Hotel, GKI has developed a logistic plan in which the capsules will be prefabricated in GKI’s facilities in Dubai and will be shipped by sea to the final installation location.
Fabricating the villa pod off-site in our factory increases the quality due to the controlled factory environment. It enables achieving integrated, optimised solutions and coordination of all disciplines, further enhanced through the use of BIM to achieve good design coordination and clash detection between all trades at an early design stage, minimising the potential number of on-site changes as an outcome of the construction sequencing analysis.
Furthermore, the fabrication in our factory not only reduces the cost and time due to higher efficiencies, but also improves health and safety during construction.
A full new production unit has been created in our factory to accommodate the needs of this project and to ensure the maximum quality and accuracy is achieved for the stainless steel shell. The stainless steel panels are first received in our facilities once the production drawings have been coordinated with all trades.
The panels, which at this stage are oversized, are stretched and bent into shape using a custom-made set of molds created for each specific panel curvature. Once the panels have the required curvature, they are cut into the exact dimensions required. Following this, the edges of the panels are reworked in order to be prepared for the welding operations as part of the pre-assembly. Lastly, the panels are polished to achieve a perfect mirror finish, first using automatic machines and then by hand. To successfully perform these activities, we have developed our own machinery kits which don’t exist on the market.
When the pre-assembled panels are protected and ready to leave the factory, they are transported to our assembly yard. Once there, the panels are installed to the primary structure using a bespoke mechanical fixation detail which provides thermal and acoustic separation between the façade panels and the structural frame, also allowing for the designed movement depending on the lengths and directions of the panels. After a further control of the geometry, the pre-assembled panels are then welded together and the final polishing is done.