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Wynwood Garage

March 5, 2021/in Exterior Architecture Parking Structure Miami--Florida Faulders Studio White L 2018 /by dsegard

The Wynwood Garage is a transformational mixed-use project that offers approximately 20,500 square feet of retail space, 428 parking spaces and 30,000 square feet of creative office space. The garage is also the first structured parking facility in Wynwood, at the center of the district.


The painted aluminum facade, designed by Faulders Studio, merges artistic unpredictability with the edgy neighborhood context and seamlessly blends the public benefit of parking with the commercial demands of Wynwood. According to Thom Faulders, “The facade and its shape-shifting patterns are “mega-subtle.” The perforated planes create multiple sight-lines that cascade around and envelop the structure in a way that is both highly specific and subdued. The wall is also designed to allow for additional artwork to be hung on the facade.

Custom perforated painted aluminum screen engineered and fabricated by Zahner.

Custom perforated painted aluminum screen engineered and fabricated by Zahner.

Photo by Tex Jernigan, ARKO | © A Zahner Company

Custom perforated painted aluminum screen engineered and fabricated by Zahner.

Custom perforated painted aluminum screen engineered and fabricated by Zahner.

Photo by Tex Jernigan, ARKO | © A Zahner Company
ZAHNER ENGINEERED AND FABRICATED OVER 54,000 SQUARE FEET OF FACADE PANELS.

ZAHNER ENGINEERED AND FABRICATED OVER 54,000 SQUARE FEET OF FACADE PANELS.

Photo by Tex Jernigan, ARKO | © A Zahner Company

The facade itself is constructed of a series of 1/8″ thick aluminum Drop & Lock panels, mounted to black painted aluminum mullions. A series of projected fin-like elements are mounted to the panels to provide depth to the design. The rounded corners appear to be free floating and utilize hot-dipped galvanized steel shapes to mount the mullions. These support points were design, fabricated and installed by Zahner.


Zahner was brought on to the project team early in the schematic design phase by Goldman Properties and Thom Faulders to develop his unique vison for the site in the Wynwood section of Miami. Zahner worked closely with the team, including the contractor, KVC Constructors, to design with the established budget in mind. This Zahner Assist approach yielded a series of tabletop mock-ups, and ultimately a large prototype, complete with the integrated lighting, was fabricated and installed at the Kansas City facility.

THE WALL IS DESIGNED TO ALLOW FOR ADDITIONAL ARTWORK TO BE HUNG ON THE FAÇADE.

THE WALL IS DESIGNED TO ALLOW FOR ADDITIONAL ARTWORK TO BE HUNG ON THE FACADE.

Photo by Tex Jernigan, ARKO | © A Zahner Company
Mockup created by Zahner with integrated lighting, fabricated and installed at the Kansas City facility.

Mockup created by Zahner with integrated lighting, fabricated and installed at the Kansas City facility.

© A. Zahner Company
Mockup created by Zahner through Zahner Assist process

Mockup created by Zahner through Zahner Assist process

© A. Zahner Company

Through Zahner Assist, we deliver enhanced value to the Design Assist phase by making it easier for owners, contractors, architects, and fabricators to communicate and work together towards project success. We have the experience and engineering capabilities all under one roof to develop system details, project budgets, and engineering specifications that create a general framework that the construction team can easily follow throughout the fabrication and installation phases.

Final installation of Zahner panels

Final installation of Zahner panels

Photo by Tex Jernigan, ARKO | © A Zahner Company
Final installation of Zahner panels

Final installation of Zahner panels

Photo by Tex Jernigan, ARKO | © A Zahner Company
https://e5awgs3wuhi.exactdn.com/wp-content/uploads/2021/03/10152158/wynwood-garage-arko-3403-2.jpg?strip=all&lossy=1&quality=92&webp=85&ssl=1 1702 2880 dsegard https://www.azahner.com/wp-content/uploads/2020/05/logo.svg dsegard2021-03-05 14:11:372025-03-12 09:50:10Wynwood Garage

Brickell Flatiron Parking Garage

November 4, 2020/in Exterior Architecture Parking Structure Miami--Florida Revuelta Architecture International Blue, Grey, Silver L, XL 2019 /by dsegard

Brickell Flatiron is a residential high-rise that towers above the Brickell district of Miami, Florida, at 736 ft. The name “flatiron” references the triangular lot that the 64-floor condominium sits on. Zahner worked closely with the architect, Luis Revuelta, and the developer, CMC Group, through the Zahner Assist process.

Zahner’s scope of work included design assist services, engineering, fabrication, and installation of the podium’s 13-story, 100,000 square foot parking garage façade. In total, the design team went through four façade design iterations before ultimately determining that the final design both creatively complimented the curvilinear forms of the architecture above and met the established budget.

Brickell flatiron is a 64-story residential high rise in Miami, Florida.

Brickell flatiron is a 64-story residential high rise in Miami, Florida.

Photo by Curtis Smith | ARKO © A. Zahner Company

Zahner engineered and fabricated a custom perforated-metal facade for the 13-story Brickell Flatiron Parking Garage.

Zahner engineered and fabricated a custom perforated-metal facade for the 13-story Brickell Flatiron Parking Garage.

Photo by Curtis Smith | ARKO © A. Zahner Company
Closeup of the custom metal facade for the Brickell Flatiron Parking Garage, produced by Zahner.

Closeup of the custom metal facade for the Brickell Flatiron Parking Garage, produced by Zahner.

Photo by Curtis Smith | ARKO © A. Zahner Company
Custom perforated-metal facade for Brickell Flatiron in Miami, produced by Zahner.

Custom perforated-metal facade for Brickell Flatiron in Miami, produced by Zahner.

Photo by Curtis Smith | ARKO © A. Zahner Company
Perspective view of the Brickell Flatiron parking facade.

Perspective view of the Brickell Flatiron parking facade.

Photo by Curtis Smith | ARKO © A. Zahner Company
Penthouse facade on top of Brickell Flatiron fabricated by Zahner.

Penthouse facade on top of Brickell Flatiron fabricated by Zahner.

Photo by Curtis Smith | ARKO © A. Zahner Company
Zahner also engineered and fabricated the penthouse facade.

Zahner provided an extra facade at the crown on a tight schedule.

Photo by Curtis Smith | ARKO © A. Zahner Company
https://e5awgs3wuhi.exactdn.com/wp-content/uploads/2020/11/05171558/brickell-flatiron-photo-curtis-smith-arko-0006-mono.jpg?strip=all&lossy=1&quality=92&webp=85&ssl=1 1665 2500 dsegard https://www.azahner.com/wp-content/uploads/2020/05/logo.svg dsegard2020-11-04 11:22:342021-11-04 10:01:50Brickell Flatiron Parking Garage

1401 Lawrence

June 2, 2017/in Exterior Architecture, Interior Architecture Highrise, LEED, Parking Structure Denver--Colorado Beck Group Brown, Gold, Orange L 2016 /by cmorris

ne1401 Lawrence in Denver, Colorado

1401 Lawrence is a Beck Group-designed building which features a Zahner-manufactured entry screen facade as well as an interior perforated art wall made using ImageWall by Zahner. The screenwall serves as a natural ventilation surface for the residential tower’s above ground parking.

The new highrise is located in the heart of downtown Denver. The design integrates the historic fabric of Denver’s LoDo district with a refined and contemporary facade. The project is pursuing LEED Gold certification. The building’s exterior entrances are framed by a custom perforated metal manufactured by Zahner. Beck Group has worked with Zahner on a number of projects which require curvilinear forms and perforated metal, including the Harim Headquarters in Seoul and the Irving Convention Center in Dallas.

Related Project

Harim Tower

The Harim Group wanted its new corporate headquarters to reflect its focus on sustainability and caring for its employees and the public. Beck provided a unique design solution which introduced 86,000 SF of mid-rise office tower on a small but high-value site. The project includes a boardroom for Harim Group, high-end restaurants, and a café in addition to a range of office spaces. 

Detail of the perforated and corrugated metal surface at 1401 Lawrence.

DETAIL OF THE PERFORATED AND CORRUGATED METAL SURFACE AT 1401 LAWRENCE.

PHOTOGRAPH BY MATT BRODEUR.

Interior perforated metal at the front desk for 1401 Lawrence.

INTERIOR PERFORATED METAL AT THE FRONT DESK FOR 1401 LAWRENCE.

PHOTOGRAPH BY MATT BRODEUR.

Elevation showing the perforated metal soffit entrance at the 1401 Lawrence building.

ELEVATION SHOWING THE PERFORATED METAL SOFFIT ENTRANCE AT THE 1401 LAWRENCE BUILDING.

PHOTOGRAPH BY MATT BRODEUR.

1401 Lawrence in Denver, Colorado.

1401 LAWRENCE IN DENVER, COLORADO.

PHOTOGRAPH BY MATT BRODEUR.

Detail of the perforated and corrugated metal surface.

DETAIL OF THE PERFORATED AND CORRUGATED METAL SURFACE.

PHOTOGRAPH BY MATT BRODEUR.

Two perforated metal entry facades for the 1401 Lawrence tower in Denver.

TWO PERFORATED METAL ENTRY FACADES FOR THE 1401 LAWRENCE TOWER IN DENVER.

PHOTOGRAPH BY MATT BRODEUR.

The building is a winner of the Design-Build Institute of America’s National Award of Merit in the Commercial Building Category and the NAIOP Colorado Office Development of the Year Award.

https://e5awgs3wuhi.exactdn.com/wp-content/uploads/2020/07/24135956/1_photo-of-1401-lawrence-in-denver-colorado.jpg?strip=all&lossy=1&quality=92&webp=85&ssl=1 1080 1920 cmorris https://www.azahner.com/wp-content/uploads/2020/05/logo.svg cmorris2017-06-02 20:47:342020-10-22 15:04:101401 Lawrence

Waiea at Ward Village

March 20, 2017/in Exterior Architecture Highrise, LEED, Parking Structure Hawaii, Honolulu--Hawaii James KM Cheng Architects, WCIT Architecture L 2017 Related Work /by cmorris

Waiea Tower Parking Structure at Ward Village, Honolulu

Waiea is a residential tower and parking garage located in Honolulu, Hawaii. The building is designed by James KM Cheng Architect with WCIT and includes a Zahner-manufactured parking structure facade clad in custom perforated metal.

The design for Waiea is part of the Ward Village development in Kaka‘ako, a commercial and residential district in Honolulu. Waiea is among the first of several building projects that are redeveloping the 60 acres included in the Ward Village Masterplan. The development includes designs led by Richard Meier, Bohlin Cywinski Jackson, Solomon Cordwell Buenz and AC Martin.

“Waiea,” which translates to “water of life,” is located on an existing surface parking lot makai (ocean side) of the existing Ward Entertainment Complex and represents the only immediate development opportunity along Ala Moana Boulevard within the approved Masterplan that would not impact or force relocation of existing tenants.

Related System

Waiea at Ward Village

Waiea building parking structure facade in Honolulu, Hawaii.

WAIEA BUILDING PARKING STRUCTURE FACADE IN HONOLULU, HAWAII.

PHOTO © THAI & LU.

Waiea tower and building parking structure facade in Honolulu, Hawaii.

WAIEA TOWER AND BUILDING PARKING STRUCTURE FACADE IN HONOLULU, HAWAII.

PHOTO © THAI & LU.

Waiea building parking structure facade in Honolulu, Hawaii.

WAIEA BUILDING PARKING STRUCTURE FACADE IN HONOLULU, HAWAII.

PHOTO © THAI & LU.

The parking garage design uses ImageWall, a Zahner patented system for creating perforated metal. The designers developed a wave motif using the system, creating a perforated metal facade which pictures a wave across its surface. This motif is used throughout the building’s design, and repeated with the tower’s complex undulating glass facade.

The fabrication design also includes a custom embossed bump pattern across the surface. These indentations across the surface create both an appealing aesthetic as well as a rigidizing effect on the metal surface.

The building’s neighborhood of Kaka’ako has a deep history. It overlays elements of wahi pana (storied places), allowing the Waiea design to draw inspiration from time and place. Its design infuses cultural ideals and relationships between the ‘āina (land) and kānaka (people). The building introduces the stories of Hawaiian fishing gods Kū‘ulakai and his son ‘Ai‘ai, along with the genealogy of Kaka‘ako is woven throughout the building’s design. Its most prominent design feature is its sweeping glass facade. It is inspired by the essential life-giving role of water in Kaka‘ako’s landscape and the fishing nets used for sustenance by Hawaiians of both yesterday and today.

Detail of the Waiea facades.

DETAIL OF THE WAIEA FACADES.

PHOTO © THAI & LU.

Detail of the Waiea facade panel hardware.

Detail of the Waiea facade panel hardware.

PHOTO © THAI & LU.

Detail of the Waiea facade.

DETAIL OF THE WAIEA FACADES.

PHOTO © THAI & LU.

Waiea building parking structure facade in Honolulu, Hawaii.

DETAIL OF THE WAIEA FACADES.

PHOTO © THAI & LU.

Larger perforation for ventilation hardware.

DETAIL OF THE WAIEA FACADE PANEL HARDWARE.

PHOTO © THAI & LU.

Waiea building parking structure facade in Honolulu, Hawaii.

DETAIL OF THE WAIEA FACADE.

PHOTO © THAI & LU.

https://e5awgs3wuhi.exactdn.com/wp-content/uploads/2020/07/20083528/1_waiea-copr-thai-lu-3051-2.jpg?strip=all&lossy=1&quality=92&webp=85&ssl=1 1450 2880 cmorris https://www.azahner.com/wp-content/uploads/2020/05/logo.svg cmorris2017-03-20 15:39:242025-05-05 08:33:05Waiea at Ward Village

Museum Garage

January 19, 2017/in Exterior Architecture Parking Structure Miami--Florida Clavel Arquitectos, J. Mayer H. un Partner-- Architekten, K/R Architect-- PC, Nicolas Buffe, WORKac Black, Magenta, Rose L 2018 /by cmorris

The Museum Garage is a seven-story mixed-use retail and parking structure located in Dacra’s Miami Design District. Featuring five dramatically different architectural facades and a painted mural, the project celebrates diverse creativity in keeping with the development’s emphasis on innovative experiences in shopping and dining.

Terence Riley of K/R curated the project’s unique aesthetics recruiting designers from WORKac, J.MAYER.H, Clavel Arquitectos, Nicolas Buffe and K/R (Keenen/Riley). Each of these designers approached their part of the structure with a wholly unique vision, custom engineered and fabricated by Zahner.

Completed Museum Garage

COMPLETED MUSEUM GARAGE

PHOTO © GOLDEN DUSK PHOTOGRAPHY

Complex Projects Begin with Design Assist

Each facade began with the Zahner Assist solution, a methodology of working collaboratively with design teams to bring each unique vision to reality. This unique Design Assist process involves deep critical thinking of all project aspects, assuring constructability, safety, and aesthetic requirements are met. This step is crucial in discovering and solving issues that could arise in the shop and field, reducing the number of change orders and remaining within a project’s budgetary parameters.

Rendering for the Museum Garage

Rendering for the Museum Garage

Image courtesy of K/R Architects

WORKac : More Than a Facade

New York–based WORKac designed the east facade, which wraps the corner onto the north elevation. Meandering walkways are concealed and revealed through precisely placed perforated aluminum panels, themselves creating shapes from the resulting negative space. Each panel is painted white on the exterior and a vibrant pink on the interior. The concrete substructure, painted in the same pink hue, becomes part of the overall design. The intent is to reveal glimpses of the activities taking place behind the screens, including a DJ booth and street art space among others.

The project presented several design challenges, which Zahner and the WORKac team solved during the Zahner Assist process:

  • Complex geometry around the various radii and at the ground tier
  • Anchorage solutions for the complex structure
  • Solving for non-continuous mullions
  • Two color, double-sided painting on perforated aluminum

Related Surface

Museum Garage

Related System

Museum Garage

WORKac exterior facade painted aluminum detail.

WORKAC EXTERIOR FACADE PAINTED ALUMINUM DETAIL.

PHOTO © A. ZAHNER COMPANY

WORKac interior pink painted aluminum detail.

WORKAC INTERIOR PINK PAINTED ALUMINUM DETAIL.

PHOTO © A. ZAHNER COMPANY

Model for the initial WORKac design.

Model for the initial WORKac design.

Photo © WorkAC.

J. Mayer H. : XOX

The Berlin-based practice of J. Mayer H. created XOX, a facade that translates the voids created in the WORKac elevation into volumetric, puzzle-like shapes fabricated in aluminum with Zahner engineered structural forms. These shapes are painted with stripes of black, blue, and red patterns similar to those found in the far north facade designed by K/R. According to the K/R website, the collaborative nature of designing a facade alongside other creatives is “an exciting innovative design strategy to explore collaboration, adjacencies, and cross-referencing.” This portion of the project features embedded lighting on the perforated elements, imbuing the structure with an otherworldly glow.

During the Zahner Assist process, Zahner’s ZEPPS technology and Drop and Lock systems were combined to achieve the project’s aesthetic. The development of the system enabled pre-skinning of all elements which allowed for shop-level control of the curved, multi-colored painted artwork.

Related System

Museum Garage

Related System

Museum Garage

XOX by J. Mayer H.

XOX BY J. MAYER H.

PHOTO © A. ZAHNER COMPANY

Detail of XOX by J. Mayer H.

DETAIL OF XOX BY J. MAYER H.

PHOTO © A. ZAHNER COMPANY

Nicolas Buffe : Serious Play

Nicolas Buffe, a French artist based in Tokyo, designed Serious Play. The facade references Buffe’s studio practice, which is based on a
multi-faceted interpretation of erudite and popular culture. The
juxtaposition of classical and contemporary cultural references draw
upon the humanist notion of Serio Ludere, meaning ‘to play seriously,’ hence the work’s title.

Zahner fabricated the cartoon, baroque inspired images. Each section is cut from black and white layered HDPE and milled to reveal the artist’s signature drawing style. The shapes are attached in varying standoff dimensions, achieving the artist’s intent of visual depth.

Nicolas Buffe Facade

NICOLAS BUFFE FACADE

PHOTO © A. ZAHNER COMPANY

Through the Zahner Assist process, Zahner developed two custom systems that achieved the artist’s intent of visual depth. These standoff systems were integrated with the Drop & Lock panel system that acts as a white canvas for Buffe’s drawings. Many of the artwork elements have pre-attached luminaires behind them. Zahner solved for this by coordinating CNC cut paths on the reverse of the art pieces.

The kinetic lighting of the Nerman Museum, manufactured by Zahner for artist Leo Villareal.
Related System

Lighting

Zahner works with designers to develop custom lighting systems which integrate into a built facade or architectural detail.

Related System

Museum Garage

Overall view of Serious Play, a painted aluminum and milled black & white HDPE facade. by Nicolas Buffe.

OVERALL VIEW OF SERIOUS PLAY, A PAINTED ALUMINUM AND MILLED BLACK & WHITE HDPE FACADE. BY NICOLAS BUFFE.

PHOTO © A. ZAHNER COMPANY

Detail of Serious Play by Nicolas Buffe.

DETAIL OF SERIOUS PLAY BY NICOLAS BUFFE.

PHOTO © A. ZAHNER COMPANY

Clavel Arquitectos: Urban Jam

Clavel Arquitectos, based in Murcia and Miami, drew inspiration from the area’s urban growth with their facade, Urban Jam. The design features 36 car shells painted in silver and gold. The car shells were fabricated by Entech Innovative and engineered to attach securely to the facade by Zahner.

Urban Jam by Clavel Arquitectos.

URBAN JAM BY CLAVEL ARQUITECTOS.

PHOTO © A. ZAHNER COMPANY

Mock-up of Urban Jam by Clavel Arquitectos at Zahner Headquarters.

MOCK-UP OF URBAN JAM BY CLAVEL ARQUITECTOS AT ZAHNER HEADQUARTERS.

PHOTO © A. ZAHNER COMPANY

Keenan Riley (K/R) : Barricades

Keenan Riley (K/R) designed Barricades, a facade inspired by parking barricade stripes. The orange and white striped triangular extrusions, some perforated and illuminated, are disrupted by varying sizes of protruding painted concrete planter boxes. Each planter box is surrounded by a mirror polished, stainless steel “picture frame”.

Through the Zahner Assist process, the sloping slab of the parking structure was resolved with the rectilinear facade design through a secondary steel system that spans horizontally between concrete columns. This allowed the triangle extrusions to be shop-assembled, with mating head and sill extrusions, into units optimized for shipping and installation.

K/R's Barricades facade features painted aluminum extrusions.

K/R’S BARRICADES FACADE FEATURES PAINTED ALUMINUM EXTRUSIONS.

PHOTO © A. ZAHNER COMPANY

Detail of Barricades by K/R. Painted aluminum extrusions engineered and fabricated by Zahner.

Detail of Barricades by K/R. Painted aluminum extrusions engineered and fabricated by Zahner.

Photo © A. Zahner Company

Related Surface

Museum Garage

Related System

Museum Garage

Mockup sample for WorkAC.

Mockup sample for WorkAC.

Photo © A. Zahner Company.

J. Mayer H. mockup.

J. Mayer H. mockup.

Photo © A. Zahner Company.

Nicolas Buffe milled black & white HOPE aluminum.

Nicolas Buffe milled black & white HOPE aluminum.

Photo © A. Zahner Company.

Initial mockup for K/R Architects.

Initial mockup for K/R Architects.

Photo © A. Zahner Company.

https://e5awgs3wuhi.exactdn.com/wp-content/uploads/2020/07/24134904/1_golden-dusk-photography-design-district-museum-garage-1.jpg?strip=all&lossy=1&quality=92&webp=85&ssl=1 1080 1920 cmorris https://www.azahner.com/wp-content/uploads/2020/05/logo.svg cmorris2017-01-19 17:28:272025-03-12 10:01:51Museum Garage

Children’s Hospital VCU

January 4, 2017/in Exterior Architecture Healthcare, LEED, Parking Structure Richmond--Virginia HKS, HKS Line Brown, Orange, Red L 2015 /by cmorris

Parking Structure for Children’s Hospital of Richmond Pavilion

The Children’s Hospital of Richmond Pavilion (CHoRP) is an HKS-designed building featuring Zahner perforated and patinated zinc throughout its exterior parking facade. The new building serves as a 15-story ambulatory pavilion built on East Broad Street between Tenth and Eleventh Street. The building consolidates existing pediatric clinics into a single urban location in downtown Richmond, Virginia. 

Zahner worked with the HKS Line team to provide a custom-perforated skin on three types of patinated zinc. The second, third, and fourth floors of this new building feature a perforated facade which provides airflow into the parking contained within. 

Related Project

Taubman Museum

Designed by Randall Stout Architects, the building includes a range of metal components manufactured and installed by Zahner engineers and artisans. Zahner was responsible for engineering, fabrication, and installation of the exterior secondary structure and facade. Zahner also provided interior metal surfaces for the project.

Custom patinated zinc and aluminum panels adorn the parking facade for Children's Hospital Richmond Pavilion.

Custom patinated zinc and aluminum panels adorn the parking facade for Children’s Hospital Richmond Pavilion.

Photo © A. Zahner Company.

Night photo of the Children's Hospital of Richmond Pavilion.

Night photo of the Children’s Hospital of Richmond Pavilion.

Photo © A. Zahner Company.

Dusk at the Children's Hospital of Richmond Pavilion.

Dusk at the Children’s Hospital of Richmond Pavilion.

Photo © A. Zahner Company.

Detail of the perforated metal facade for Children's Hospital.

Detail of the perforated metal facade for Children’s Hospital.

HKS Line perforation output renderings.

HKS Line perforation output renderings.

Diagram of the Children's Hospital Richmond.

Diagram of the Children’s Hospital Richmond.

Mockup panels for CHoRP.

Mockup panels for CHoRP.

Photo © A. Zahner Company.

https://e5awgs3wuhi.exactdn.com/wp-content/uploads/2020/07/24130808/1_childrens-hospital-richmond-chorp-copyright-zahner-tex-jernigan-5119.jpg?strip=all&lossy=1&quality=92&webp=85&ssl=1 1080 1920 cmorris https://www.azahner.com/wp-content/uploads/2020/05/logo.svg cmorris2017-01-04 16:00:432021-10-29 15:17:06Children’s Hospital VCU

Mission Bay Parking

December 30, 2016/in Exterior Architecture Parking Structure San Francisco Bay WRNS Studio L 2009 /by cmorris

Mission Bay Block 27 Parking Structure

Mission Bay Block 27 is a parking structure serving the UCSF community of San Francisco. Featuring a facade by Zahner, the WRNS Studio design is a noted work of architecture for parking structures.

Located in the Mission Bay Block 27 of San Francisco, this design by WRNS Studio for Alexandria Real Estate, houses 1,420 parking spaces on seven elevated levels. The structure features a metal screen with perforated imagery of California’s redwood forests. This facade was design-engineered by the Design Assist Group and produced by Zahner.

WRNS Studio desired an abstract pattern composed of four distinct oval cut-outs. They provided tree imagery and Zahner Design Engineers processed the imagery into the myriad of circular shapes to abstract the form. For the surface, the firm decided on a perforated bronze-anodized aluminum cladding, which covers the entirety of the metal scope for the garage.

Related Project

Contemporary Jewish Museum

3,028 sheets of blue iridescent cross-fire interference stainless steel clad the surface of the museum, which is formed in the shape modeled off of the Hebrew script for 'L'Chaim' which translates 'To Life'.

Mission Bay Block 27 Parking Structure at Alexandria.

MISSION BAY BLOCK 27 PARKING STRUCTURE AT ALEXANDRIA.

Detail of the perforated aluminum facade system from within the garage.

Detail of the perforated aluminum facade system from within the garage.

Engineering drawing of the perforated facade layout used on the San Francisco parking structure.

Engineering drawing of the perforated facade layout used on the San Francisco parking structure.

Detail of the perforated aluminum facade system from within the garage.

DETAIL OF THE PERFORATED ALUMINUM FACADE SYSTEM FROM WITHIN THE GARAGE.

How WRNS Created its Mosaic-Perforated Metal Facade

The aluminum’s punch-pattern was generated using a photograph of foliage. The image was run through several computer processes to rapidly produce the millions of custom perforated panels. Note: Zahner now offers an online tool for creating perforated metal panels at ImageWall for ShopFloor. This computer-to-machine language translation runs on the ZIRA™ Technology, a patented process (* Patent No. 7,212,688 B2 – May, 2007) for translating the architect’s imagery into pixelized metal, perforated and/or bumped panels.

This project was an experimental use of the ZIRA™ Process, as the individual punched shapes were integral to the project. Instead of the typical round and square punches, the designer selected four elliptical punch patterns which were custom-manufactured to complete the surface of the screen-wall. The ZIRA™ Technology allows architects, designers, and engineers to transfer an image onto the surface of metal using physical processes such as perforation, bumped and dimpled surface patterns, as well as waterjet cut patterns and other physical alterations.

Mission Bay Block 27 Parking Structure at Alexandria.

Mission Bay Block 27 Parking Structure at Alexandria.

Mission Bay Block 27 Parking Structure at Alexandria.

Mission Bay Block 27 Parking Structure at Alexandria.

Mission Bay Block 27 Parking Structure at Alexandria.

Mission Bay Block 27 Parking Structure at Alexandria.

None
Mission Bay Block 27 Parking Structure at Alexandria.

Mission Bay Block 27 Parking Structure at Alexandria.

NonePHOTO © A. ZAHNER COMPANY.
Mockup of the WRNS concept, punched on aluminum plate metal.

Mockup of the WRNS concept, punched on aluminum plate metal.

PHOTO © A. ZAHNER COMPANY.

Detail of the perforated zigzag aluminum system used to cool and ventilate the school's parking garage.

DETAIL OF THE PERFORATED ZIGZAG ALUMINUM SYSTEM USED TO COOL AND VENTILATE THE SCHOOL’S PARKING GARAGE.

PHOTO © A. ZAHNER COMPANY.

Detail of the perforated zigzag aluminum system used to cool and ventilate the school's parking garage.

Detail of the perforated zigzag aluminum system used to cool and ventilate the school’s parking garage.

Photo © A. Zahner Company.

https://e5awgs3wuhi.exactdn.com/wp-content/uploads/2020/07/24122529/1_alexandria-img_3397-copyright-tex-jernigan-scaled.jpg?strip=all&lossy=1&quality=92&webp=85&ssl=1 2560 2048 cmorris https://www.azahner.com/wp-content/uploads/2020/05/logo.svg cmorris2016-12-30 21:46:452025-02-20 08:34:45Mission Bay Parking

DeBruce Center: Rules of Basketball

November 3, 2016/in Exterior Architecture, Interior Architecture Education, Museum, Parking Structure Lawrence--Kansas Gould Evans Associates Silver, White L 2016 /by cmorris

DeBruce Center and the KU Rules of Basketball

DeBruce Center is a Gould Evans-designed building featuring Zahner engineered metal systems throughout its interior and exterior. Zahner completed multiple scopes on the project, including the exterior and interior panels of bridge that connects to Allen Fieldhouse, guardrails, and the perforated scrim walls which enclose its adjoining parking structure.

The building complex was developed around a single piece of basketball history. The original Rules of Basketball, written in 1891 by James Naismith (the inventor of basketball and founder of the KU basketball program) were purchased and donated to the school, and have found their permanent home at DeBruce Center, a new facility adjoining the northeast corner of Allen Fieldhouse at KU.

The existing Allen Fieldhouse building at KU is now connected by a bridge to the Debruce Center. This connects the new exhibit and visitor center to historical Allen Fieldhouse, where the KU basketball team regularly plays their local games. This connection helps to physically explain the history of KU’s sports program. James Naismith (the ‘father’ of basketball) and Forrest “Phog” Allen (the ‘father’ of basketball coaching) each had an integral role in building this legacy. By physically connecting the two spaces, the designers at Gould Evans have built a literal link between the past and future of basketball at KU.

The bridge, which connects the DeBruce Center and Parking Garage to the Allen Fieldhouse.

THE BRIDGE, WHICH CONNECTS THE DEBRUCE CENTER AND PARKING GARAGE TO THE ALLEN FIELDHOUSE.

PHOTO © A. ZAHNER COMPANY.

Detail of the DeBruce Center bridge.

DETAIL OF THE DEBRUCE CENTER BRIDGE.

PHOTO © A. ZAHNER COMPANY.

Creating the Exterior Bridge at DeBruce Center

The Zahner team was tasked with creating large cut-out aluminum panels bearing the original rules for the game of basketball. The interior panels also contain a direct screenprint of text on aluminum, which maps out the visage of Naismith and Phog Allen.

The aluminum panels for the exterior bridge were milled from 3/8” aluminum, at a panel size of 6’ x 18’. Panels of this scale provide a unique challenge. Zahner both coordinated with the structural team to ensure that the plate attachment system was properly detailed out in order to take on such heavy loads (the panels weigh around 500 pounds each).

Zahner milled the complete text from the Rules of Basketball, cutting stenciled text into each of the panels. The panels are backlit at night by LED lights that were installed by the lighting designer. During the day, the Angel Hair finish applied to the panels disperses sunlight and softens the natural reflectivity of the aluminum.

The Allen Fieldhouse (left) is connected to the DeBruce Center via an aluminum clad pedestrian bridge.

THE ALLEN FIELDHOUSE (LEFT) IS CONNECTED TO THE DEBRUCE CENTER VIA AN ALUMINUM CLAD PEDESTRIAN BRIDGE.

PHOTO © A. ZAHNER COMPANY.

Milling and Etching Interior Metal Wall Panels to Tell a Story.

The interior bridge continues the exterior bridge’s aesthetic of text milled out from Angel Hair aluminum, and also adds an additional silkscreened visual element. Rather than the rules of basketball, the milled aluminum panels on the east wall contain quotes from both Naismith and Phog Allen. Because these panels are interior and don’t have windloads to contend with, the designers were able to go with a thinner sheet, at 3/16” x 5’ x 10’ each.

NonePHOTO © A. ZAHNER COMPANY.

The adjacent west wall contains direct screenprinted text on aluminum. This text utilizes a similar visual trope to ZIRA in that it uses letterforms to map out the image of Naismith and Phog Allen, drawing yet another visual parallel between these founding fathers and the legacy of basketball at KU.

NonePHOTO © A. ZAHNER COMPANY.
NonePHOTO © A. ZAHNER COMPANY.
NonePHOTO © A. ZAHNER COMPANY.
NonePHOTO © A. ZAHNER COMPANY.
NonePHOTO © A. ZAHNER COMPANY.
NonePHOTO © A. ZAHNER COMPANY.
NonePHOTO © A. ZAHNER COMPANY.

Interior Aluminum Plate Guardrails and Staircase Ramps

Zahner also completed a series of interior guardrails from 5/8” aluminum, in an Angel Hair finish to match the surrounding walls. These were made from solid plates connected only at the floor level, stairs, and ramp.

To achieve a uniform planar surface with minimal fasteners, custom connections were developed by Zahner engineers to create the massive guardrails which wind up and down the interior of DeBruce Center.

NonePHOTO © A. ZAHNER COMPANY.
NonePHOTO © A. ZAHNER COMPANY.
NonePHOTO © A. ZAHNER COMPANY.
NonePHOTO © A. ZAHNER COMPANY.
NonePHOTO © A. ZAHNER COMPANY.
NonePHOTO © A. ZAHNER COMPANY.

Using ImageWall to generate Perforated Imagery on Metal

The final piece of Zahner’s scope on DeBruce Center was a custom ZIRA perforated image of wheat, comprising around 7,250 square feet of space. At 243 total 3’ x 10’ 16ga panels, this was our largest scope item and required coordination with multiple trades, such as existing site and new steel. The engineers and fabricators at Zahner provided a system for drop and lock attachment that allowed for a smooth installation.

NonePHOTO © A. ZAHNER COMPANY.

The perforations cross between panels, allowing imagery to continue seamlessly across the wall, without the distraction of edges. This was achieved by examining the pattern’s parametric relationship of visual elements to the larger surface. The resulting image emulates a field of wheat, hearkening back to symbols of Kansas, and the history of KU.

NonePHOTO © A. ZAHNER COMPANY.
NonePHOTO © A. ZAHNER COMPANY.
NonePHOTO © A. ZAHNER COMPANY.
https://e5awgs3wuhi.exactdn.com/wp-content/uploads/2020/07/24120150/1_debruce-copyright-zahner-2431.jpg?strip=all&lossy=1&quality=92&webp=85&ssl=1 1080 1920 cmorris https://www.azahner.com/wp-content/uploads/2020/05/logo.svg cmorris2016-11-03 17:28:312025-05-05 08:19:54DeBruce Center: Rules of Basketball

Zahner Headquarters

August 15, 2016/in Exterior Architecture Parking Structure, Renovation Kansas City Crawford Architects L. William Zahner Silver M 2011 /by cmorris

The North Dock Expansion at the Zahner Campus

Designed by Crawford Architects, the Zahner Headquarters façade features undulating ZEPPS assemblies. ZEPPS, the Zahner process used to create custom curving surfaces, are used in projects around the world. Typically, ZEPPS assemblies consist of structural aluminum fins and ribs which are then clad in stainless steel, zinc, or any other building skin material.

The design of the Zahner Headquarters, however, was inspired from examining the ZEPPS understructure; the assemblies were intentionally left exposed, revealing the beauty of the engineering behind what is usually covered over. Zahner engineered and produced the exterior façade, naming it ‘Cloud Wall,’ and subsequently developed an app for designers to easily create similar custom façade iterations online.

The billowing curtain wall features glass inset between each fin. Part of the Inverted Seam system, Zahner developed a patented Drop & Lock method for engineering and installing panelized dry-set glass. Installation is quick and easy via male and female connections.

With a nearly 40-foot high ceiling 10,000-square feet of added space, the expansion allows Union Sheet Metal Workers to easily fabricate large-scale ZEPPS and other assemblies.

None PHOTOGRAPHY © MIKE SINCLAIR
A crane is used to hoist each panel into place.

A CRANE IS USED TO HOIST EACH PANEL INTO PLACE.

PHOTO © A. ZAHNER COMPANY.

Zahner Installers install the glass panels.

Zahner Installers install the glass panels.

Photo © A. Zahner Company

Zahner Headquarters viewed from the North.

Zahner Headquarters viewed from the North.

Photo © A. Zahner Company

Zahner Headquarters viewed from the East.

Zahner Headquarters viewed from the East.

Photo © A. Zahner Company

Photograph of the Cloud Wall during construction.

Photograph of the Cloud Wall during construction.

Photo courtesy of Crawford Architects

Zahner employees have a safety lunch in the shop prior to the Cloudwall Installation.

Zahner employees have a safety lunch in the shop prior to the Cloudwall Installation.

Photo © A. Zahner Company

Liverpool Interlomas.</a

Liverpool Interlomas.

Photo © Mike Sinclair.

Photograph of the shop interior during the production of MIC.

Photograph of the shop interior during the production of MIC.

Photo © A. Zahner Company

Zahner Expansion nears completion.

Zahner Expansion nears completion.

Photo © A. Zahner Company

Learn more about the Zahner Headquarters Expansion

  • Green Building & Design Magazine Crawford Architects June 2012.
  • Architect Magazine Zahner Cloud Wall September 2011.
  • Archdaily Zahner Factory Expansion September 2011.
  • Zahner Product: GlassFin™ Curtainwall
  • Zahner Product: Drop & Lock™ Metal Panel Systems
https://e5awgs3wuhi.exactdn.com/wp-content/uploads/2020/07/24113851/1_zahner-hq.jpg?strip=all&lossy=1&quality=92&webp=85&ssl=1 1080 1920 cmorris https://www.azahner.com/wp-content/uploads/2020/05/logo.svg cmorris2016-08-15 23:32:152025-02-20 07:34:53Zahner Headquarters

Winds of Aphrodite

August 15, 2016/in Exterior Architecture Parking Structure, Transportation Kansas City Crawford Architects Suikang Zhao Grey, Silver L 2008 /by cmorris

Bartle Hall Convention Center Loading Dock Remodel

Working with artist Suikang Zhao, Crawford Architects led a redesign of the Bartle Hall Loading Dock to provide both a face-lift and a functionality-lift. The new design features an expanded aluminum screen wall developed by Zahner, offering a uniquely artistic first-impression of downtown Kansas City. The project aluminum screen skin connects to a galvanized steel superstructure, and as night falls, thousands of computer-color-controlled LEDS light up the mesh screen.

Working collaboratively with Crawford Architects, I designed art that is integrated into architect and the north and west facade of the screen-covered loading dock. The basic design idea is about soften monolithic monstrous design of 70’s into tangible / feminine touch as if a piece of giant fabric flying from sky and happen to catch up the corner of the Convention Center. Layers of steel meshes creates changing moment of mystical appearance depending on weather and time of day, and is lit up by computer-color-controlled LED light in the evening.

Completed in 2008, the project required the transformation of a 70’s brutalist structure into a softened and tangible work, as if it were a giant strip of fabric flying from the sky which happened to catch the corners of the convention center. Because of the way that downtown Kansas City highways are organized, when visitors first exited the highway, they would see the Bartle Hall Convention Center’s loading docks, replete with overflowing dumpsters and big trucks unloading for the upcoming show.

Dusk photograph of the Winds of Aphrodite artwork on Bartle Hall Loading Dock.

DUSK PHOTOGRAPH OF THE WINDS OF APHRODITE ARTWORK ON BARTLE HALL LOADING DOCK.

None
NonePHOTO © A. ZAHNER COMPANY.
None
Moire patterns on the expanded aluminum facade and artwork at Bartle Hall

MOIRE PATTERNS ON THE EXPANDED ALUMINUM FACADE AND ARTWORK AT BARTLE HALL

PHOTO © A. ZAHNER COMPANY.

Light filters through the Winds of Aphrodite's aluminum surface on Bartle Hall Loading Dock.

Light filters through the Winds of Aphrodite’s aluminum surface on Bartle Hall Loading Dock.

The formed expanded aluminum surface allows light to filter into the Bartle Hall Loading Dock.

The formed expanded aluminum surface allows light to filter into the Bartle Hall Loading Dock.

The corner of the Bartle Hall Loading Dock renovation.

The corner of the Bartle Hall Loading Dock renovation.

The other part of the problem was that it was hard for the large trucks to enter the space because the original space wasn’t well thought-out. Architects at Crawford re-designed the framework and brought in Chinese artist Suikang Zhao to bring a flowing perforated aluminum screen, produced, fabricated, and installed by Zahner. Zahner was also integral in the Design Assist Process, where the artists, architects and Zahner engineering directors and designers work to maximize and refine the end design.

Drawing of the semi-truck pathways taken at Bartle Hall's loading dock.

Drawing of the semi-truck pathways taken at Bartle Hall’s loading dock.

The result of all this preparation is a new Bartle Hall Convention Center that works. The triangular screens appear as sails flowing in the wind, allowing light to enter and disguising the view of the docks. The previously underused loading docks are now used by every big truck that unloads at Bartle Hall.

The architects’ redesign of the Bartle Hall Loading Dock included looking at the paths that a truck takes, making it more efficient for semi-trucks to pull in, unload, and depart from the loading bay.

Light filters through the Winds of Aphrodite's aluminum surface on Bartle Hall Loading Dock.

Light filters through the Winds of Aphrodite’s aluminum surface on Bartle Hall Loading Dock.

Winds of Aphrodite by Suikang Zhao and Crawford Architects.

Winds of Aphrodite by Suikang Zhao and Crawford Architects.

Entrance to the Bartle Hall Loading Dock in Kansas City.

Entrance to the Bartle Hall Loading Dock in Kansas City.

Winds of Aphrodite by Suikang Zhao and Crawford Architects.

Winds of Aphrodite by Suikang Zhao and Crawford Architects.

Winds of Aphrodite by Suikang Zhao and Crawford Architects.

Winds of Aphrodite by Suikang Zhao and Crawford Architects.

Zahner installers during the renovation of the Bartle Hall Loading Dock.

Zahner installers during the renovation of the Bartle Hall Loading Dock.

None
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Winner: 2008 Kansas City Capstone Award

https://e5awgs3wuhi.exactdn.com/wp-content/uploads/2020/07/24120214/2_bartle-hall-garage-dock.jpg?strip=all&lossy=1&quality=92&webp=85&ssl=1 1080 1920 cmorris https://www.azahner.com/wp-content/uploads/2020/05/logo.svg cmorris2016-08-15 23:32:132020-10-23 16:19:11Winds of Aphrodite
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