The CST Tenero project comprises a series of membrane-covered shelters designed for longterm seasonal use. The architectural design features a geometrically complex form that posed significant challenges to both structural design and fabrication. To maintain the architectural intention while enabling feasible execution, the engineering team developed a hybrid approach combining standard aluminium profiles from modular tent systems with bespoke components and detailing. The primary structure consists of aluminium members connected by steel inserts. These inserts are not force-fitted but allow movement, introducing joint slip that affects the serviceability of the overall structure. To quantify this effect, full-scale load tests on complete portal frames were carried out in parallel with CAD-based modelling. The structural design and detailing evolved in an iterative process involving continuous refinement. Several system optimizations were achieved, including the elimination of diagonal braces, reduction of profile sections, and the development of a new tensioning system that integrates a ventilated ridge and perforated eaves. The textile envelope itself presented two major fabrication challenges: the geometrical complexity required a sophisticated panel layout and on-site welding, while the selected reflective membrane material could not be welded at the coated side, necessitating a redesign of conventional seam details. Further innovations included concealed cable routing for lighting and safety systems within the structural profiles, made possible by custom-designed inserts. A full-scale trial assembly was conducted to test the construction sequence and fine-tune the membrane fit. A second structural test validated deflection behaviour under load. Finally, a field-based environmental monitoring campaign confirmed the thermal performance benefits of the implemented system, demonstrating significantly reduced internal temperatures compared to standard solutions.