Our system design process is a multidisciplinary approach involving the system design department, engineering department, shop drawings department full time, and feedback design meetings are held frequently with the participation of the Manufacturing Coordinator, R&D Department, the Laboratory and of course the Project Management Team and the Site Chief. Thanks to use of the most advanced 3D modeling computer programs the design is verified easily by the design team and easily conveyed and communicated to the related departments. The designers are always guided by the engineering department with support of engineering calculations of any sort of façade physics issues according to the relevant norms of the country of the project.

The developments in the Computer Aided Design programs leading to more complex envelopes and continuous improvement architectural cladding materials, combined with increased tendency towards hightech façades made façade engineering an important discipline in the construction industry...

The department is equipped with the world’s newest technological equipment and the latest state of the art computer simulation models incorporating the most sophisticated methods from finite elements (FE) up to Computational Fluid Dynamics (CFD) methods, transient as well as steady state analysis, three dimensional as well as two dimensional modeling.

After the system design is approved the aluminum and gasket extrusion dies and components dies and molds are produced and a visual mock-up with original components glass and infill materials is produced for general review of the client and the architect. This stage is also very utile for the manufacturing department to verify as a last review before the mass production of the materials starts. The last stage of the system design phase is the tests in the laboratory which is described in detail in the testing chapter of this book.

We also produce another set of drawings which are prepared for the shop level and these are called production drawings. Production drawings is the translation of the shop drawings into machining language and these are internal drawings for the use of factory, quality management department and the site installation team and not submitted to the architects. Metal Yapı employs 50 architects, engineers and technicians in both detailing processes, all equipped with the latest versions of the most advanced ACAD and Solid modeling software. Besides software found in the market Metal Yapı has in house computer software development team which creates special custom software to be used to speed up, improve the capacity of the detailed design process and to eliminate human errors.

Metal Yapı can design 30 unique and different projects at the same time through the same process regardless of the size, the type or the location of the project and this is secured with the ISO 9000 Quality Management System which has been applied since 2002. All the design process is tracked in an online automatic tracking and tracing system which reports the current status of each piece of drawing file as well as the time spent so that the time planning schedule is controlled by the project design chief and the project manager. The transfer of shop drawings to the production drawings department and the transfer of production drawings to the CNC machines are realized through the internet and intranet networks.

Metal Yapı’s production capacity is supported by three strategically located and fully integrated manufacturing facilities, enabling us to deliver large-scale and technically demanding façade, stainless steel, and steel construction projects with unmatched precision and efficiency. Çatalca Plant: Serving as the group’s main production hub, the Çatalca Plant spans 75,000 m² of open area and 27,500 m² of enclosed space, housing advanced fabrication technologies for façade and structural systems. Çatalca Free Zone Plant: With 20,000 m² of enclosed production space, this facility is the group’s second largest and plays a key role in international projects thanks to its location within a free trade zone, enhancing global logistics and export capabilities. Tuzla Plant: The third facility includes 5,000 m² of enclosed space within a 10,500 m² open area, focusing on specialized components and high-precision assemblies to support our diversified production pipeline. Across all facilities, in-line testing is integrated into every stage of production, allowing real-time monitoring of performance criteria and material integrity. This is reinforced by our proactive quality management system, which emphasizes prevention over correction, ensures full traceability, and maintains strict compliance with international standards. Each plant is equipped with modern machinery and staffed by highly skilled teams, enabling Metal Yapı to execute complex architectural projects with excellence. Our integrated production model guarantees that all systems from bespoke façades to structural and stainless steel elements are delivered with consistency, quality, and confidence.

The installation teams in various geographies are mainly local manpower trained by supervisors sent from Metal Yapı and loyal to the company. In case of emergency there is always the opportunity to send installers from Metal Yapı.

Before starting a project we prepare a specific quality plan based on analysis that identifies and accounts for any unique aspect of the project whether it be the panel size and types, site condition, performance requirement or design detail. Alike a specific safety plan is made analyzing all the risks incorporated due to the specific conditions of the site.