Exterior Architecture

Dayton Residence

Dayton Residence in Vail, Colorado

The Dayton Residence is a private mountain home conceived by the architects at James Dayton Design in Minneapolis. Completed in 2009, the project began as a renovation of an existing 70’s ski lodge and expanded into a new construction.

Zahner developed details and provide Solanum Steel, Zahner’s exclusive darkened weathering steel panel system. The variegated material provides improved performance over Cor-ten steel, which has a tendency to stain adjacent surfaces. Zahner provided engineering, fabrication, delivery, and installation for the project.

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Dayton Residence

Serenity at the Dayton Residence in Vail, Colorado.

Snow falls at the Dayton Residence in Vail, Colorado.

Drawing diagram of the Dayton Residence in Vail, Colorado.

Daeyang Gallery

August 15, 2016/in Exterior Architecture Museum, Residential Asia, International, Seoul--South Korea E.Rae Architects, Steven Holl Architects Red M 2011 /by cmorris

WRNS Studio is an architecture and planning firm that provides sustainable design for education, healthcare, transportation, civic and urban mixed-use. The award-winning firm is recognized nationally, and is based in San Francisco with offices in New York City and Honolulu.

The firm has developed a growing number of works with Zahner, starting with the the Studio Libeskind-designed Contemporary Jewish Museum in which WRNS served as Architect of Record. Since then, Zahner has worked with WRNS on a number of projects, develop their unique design concepts into custom architectural systems, featured below.

Daeyang Gallery and House

Designed by Steven Holl Architects with architect of record E.Rae Architects of Seoul, this unique structure serves dual purposes, as both a residential guest house as well as an art gallery for visitors. JongSeo Lee of Steven Holl Architects was the associate in charge, and the project was completed in 2011.

The structure’s geometry is inspired by a John Cage sketch for a music score by the composer Istvan Anhalt, ‘Symphony of Modules,’ which Cage illustrated in an abstract form. The unusual shaped composition has now been reimagined as the plan layout of the Daeyang residence, continuing the chain from music, to art, to architecture.

This state of continued change and process informs many aspects of the building. Zahner worked closely with both the owner and the design team to develop a custom patina for the copper panel system that would match the desired coloration with natural warmth and texture.

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Daeyang Gallery

Because of the unique range of tones and the material’s rich aging process, copper holds a special significance in the hearts and minds of those at Zahner. The material’s tone and color is perpetually in a state of flux, changing with each location based on the temperature, moisture, and pollutants in its environment.

This constant state of change will add character and soul to the gallery’s surface. The custom deep red tone that was developed will likely darken over time, and eventually may even begin to green and blue. The difference between copper and other materials, is that this constant state of ‘corrosion’ is actually the process of forming a stunningly beautiful protective barrier which will outlast any sealer, paint, or protective coating.

View through the slats of the Daeyang Gallery entrance.

Architect's model of the Daeyang Gallery and House.

Front gates of the Daeyang Gallery and House.

Detail of the copper patina for the Daeyang Gallery and House.

Panoramic of the Daeyang Gallery and House during construction.

Bamboo form construction for Daeyang Gallery and House.

Copper wall panel for the Daeyang Gallery and House.

Daeyang Gallery and House during construction.

Installation of wall panel systems for Daeyang Gallery and House.

The custom panels were installed by local workers in Seoul, South Korea. Zahner supplied the pre-engineered panels which securely locked into the substructure. Photographs of the completed building can be viewed at Steven Holl Architects website.

Crosstown Substation

August 15, 2016/in Exterior Architecture Industrial Kansas City Pendulum James Woodfill Brown M 2013 /by cmorris

Crosstown Substation Renovation for the KCP&L

The architects at Pendulum developed a synthesizing design which combines elements of public art, architecture, and kinetic motion-based visual arts to create a low-profile barrier wall wrapping the KCP&L Substation.

Prior to the new design, the corner of 18th and Locust was deteriorating. KCP&L replaced the wall with a new design, including commissioned artwork, that would reflect the Crossroads’ artistic community spirit.
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The winning design by Pendulum included a space for the light artist James Woodfill to create a kinetic display. As the sun sets, an animated display of lights takes over: 10,500 color-changing LED lights alternate to create an illusion of motion, powered by 117 solar panels.

Photograph of the Crosstown Substation west facade at dusk.

Crosstown Substation designed by Pendulum, featuring Solanum weathering steel metalwork.

Custom cylinder sidewalk lights cast unique shadows through perforations.

The Crosstown Substation, featuring a prepatinated weathering steel custom wall system.

Detail of the Crosstown Substation during daylight.

Manufacturing the Weathering Steel Facade for Pendulum Architects

Zahner was brought on to provide a weathering steel surface that would endure all four seasons in Kansas City, as well as provide a worn steel aeshtetic with minimal corrosion and staining of adjacent surfaces. Using the Solanum Steel process, Zahner was able to provide a warm steel patina. Zahner also worked closely with the project team to provide all structural steel and fabrication required for the project.

Rendering of Crosstown Substation, designed by Pendulum Architects in Kansas City.

Mockup of Crosstown Substation, installed on-site at the previous park.

History of the Crosstown Substation

Originally the KCP&L station was the site of the Holmes Square Park. Designed by George Kessler, the park was originally opened in 1897, the same year A. Zahner Company was founded by Andrew Zahner. The park was directed by Elenore Canny, who was sworn in by the Kansas City Police Department in 1910, becoming the first woman to serve and protect as a police officer in Kansas City, Missouri, and also one of the first female police officers in America.

KCP&L has decided to place a plaque on the gate of the substation commemorating the Holmes Square Park and the accomplishments of Elenor Canny. The material and construction of the plaque was generously donated by A. Zahner Company.

Project Team

Architect/Designer: Pendulum
General Contractor: Turner Construction, Inc.
Lighting Consultant: Derek Porter Studio
Structural Engineer: Du Bois Consultants
Commissioned Artist: James Woodfill
Steel Contractor/Fabricator/Supplier: Zahner

Awards and Recognition

2014 EDC Cornerstone Award Winner for Energy
2014 Kansas City Chapter AGC Building Excellence Award

Cooper Union

August 15, 2016/in Exterior Architecture Education, LEED New York City Gruzen Samton, Morphosis Grey, Silver L 2011 /by cmorris

Cooper Union Academic Building at 41 Cooper Square

Cooper Union New Academic Building at 41 Cooper Square is a Morphosis designed educational facility which includes a custom-curving and perforated stainless steel facade, made by Zahner.

The University’s new building covers a full city block on Third Avenue from East 6th to East 7th in downtown Manhattan, bordering the East Village. The Morphosis design provides Cooper Union with a futuristic facade, strikingly different from its surrounding buildings.

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Emerson LA

Working with Zahner's Design Assist team of engineers, designers and fabricators, this generative design was developed for manufacturing. A team of Zahner installers completed the project in Los Angeles, providing the campus with a visually compelling, efficiently envisioned, and rapidly completed building envelope system.

Cooper Union New Academic Building in Manhattan.

From afar, small windows appear to be scattered across the building’s surface. Drawing nearer, it becomes clear that these windows are actually sheets of stainless steel. Perforated sheets, surfaced in a mechanically-applied Angel Hair finish, encompass the entire facade and offer a sustainable, energy saving solution. By controlling sunlight penetration during warm weather and acting as an insulating barrier in cold weather, the skin system promises a 50% reduction in heat load.

Timelapse of 41 Cooper Square in New York.

Fabricators at Zahner assemble the Cooper Union facade in Kansas City.

Design Assist for 41 Cooper Square

Morphosis Architects invited Zahner to join the project team early on in a Design Assist process. Zahner collaborated with the team to provide engineering-design and manufacturing for the building facade.

Many Zahner-manufactured projects begin in the Design Assist (DA) phase. During DA, Architects provide a general model or conceptual drawings, collaborating with Zahner engineers to define details. The goal of the process is to achieve efficient manufacturing, within a budget, while remaining true to the original vision. As the project moved into the production phase, parts were engineered, drafted, and fabricated as pre-assembled metal panels for quick installation. The completed panel assemblies were shipped to New York City where local installers completed construction.

Panels prepared for shipment to New York from Kansas City.

Cooper Union New Academic Building signage at Zahner shop.

Detail of the Cooper Union New Academic Building signage.

Interior vertical piazza of the Cooper Union New Academic Building.

Basic structure beneath the Cooper Union's facade during construction.

Detail photograph of the less perforated rectangular sections.

Operable windows at Cooper Union New Academic Building.

Contemporary Jewish Museum

August 15, 2016/in Exterior Architecture Museum San Francisco Bay Studio Libeskind, WRNS Studio Blue L 2008 /by cmorris

The Contemporary Jewish Museum in San Francisco

Designed by Studio Daniel Libeskind with WRNS Studio, The Contemporary Jewish Museum in San Francisco features a facade and building envelope manufacture by Zahner. Originally founded in 1984 in San Francisco, California the museum’s mission was renovated with a new addition. The museum’s mission is to offer contemporary perspectives on Jewish culture, history, art, and ideas. The Museum reopened June 9, 2008.

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’.

Zahner was responsible for the design, engineering, fabrication, and installation of the facade and total building envelope, inclusive of the metal, glass, and substrate. The project uses the Inverted Seam roof and facade system, the most powerful roof and building envelope surface for water control, planar uniformity and long-term performance.

Zahner engineered the skylight windows to integrate into the Inverted Seam roof and building envelope system, inset with four-sided structural silicone glazing. The 36 custom skylights sit perfectly flush with the surface of the metal, giving the roof and siding a smooth, uniform facing.

Evening photograph of the Studio Daniel Libeskind-designed Contemporary Jewish Museum .

Cantilevered section of the Contemporary Jewish Museum in San Francisco.

Daniel Libeskind examines the light reflectivity of one of Zahner's panels.

The metal panels of the Contemporary Jewish Museum at mid-day.

Blue metal panels of the Contemporary Jewish Museum in San Francisco.

Contemporary Jewish Museum in San Francisco during construction.

At certain angles the metal panels reflect iridescent colors.

Aerial view of the blue metal panels on the Contemporary Jewish Museum in San Franicsco.

Aerial view of the blue metal panels on the Contemporary Jewish Museum in San Francisco.

Detail of the blue panels on the Contemporary Jewish Museum.

The subtle raised edges on the surface of the metal are a custom touch designed by Libeskind. The architect was able to design a custom raised indentation with Zahner design consultants and fabricators using the custom indentations for automated alteration of the metal surface.

This is the first major project whose facade was produced by Zahner for Daniel Libeskind. Since then Zahner has completed the Libeskind-designed 18.36.54 private residence and summer home in Connecticut, and in 2014, Zahner provided art fabrication on his design for the Ohio Holocaust and Liberators Memorial.

Columbus Museum of Art

August 15, 2016/in Exterior Architecture, Interior Architecture LEED, Museum Columbus--Ohio DesignGroup Green M 2013 /by cmorris

Margaret M. Walter Wing at the Columbus Museum of Art

The new Margaret M. Walter Wing of the Columbus Museum of Art is a contemporary work of architecture featuring both interior and exterior custom-patinated copper sheets manufactured by Zahner.

In 2013, the Columbus Museum of Art’s Board of Trustees unanimously voted in favor of beginning construction on a new expansion project which would enable the Museum to bring global exhibitions to the residents of Columbus, Ohio. The museum reached out to DesignGroup principal Michael Bongiorno whose design team, including Keoni Fleming, Annie Neumer, and Joseph Mayer, developed a strategy for the museum’s expansion. The expansion’s centerpiece, the Margaret M. Walter Wing, adds 50,000 square feet to the total square footage of the Museum’s available gallery space, and is expected to reach a LEED Silver certification.

Columbus Museum of Art in Columbus, Ohio.

Columbus Museum of Art, East facade, glass, and limestone.

Columbus Museum of Art, detail of the custom copper soffit.

Columbus Museum of Art, detail of the custom copper flashing and metalwork.

The architects worked with their client to develop a design which would pair the Museum’s rich history with its promising future. The designers achieved this balance in many ways, including aesthetics. The design of the building’s form is contemporary, featuring many modern architectural touches, while its surface is an antiqued copper, a rich material which would normally require decades of weathering to achieve.

Developing the Architectural Copper Panels with Custom Patina

Zahner has worked with patinated copper and copper-alloys since the company’s establishment in 1897, but it was only a recent advancement by Zahner’s research and development team that allowed the firm to match naturally aged copper.

Typically, architectural copper panels are installed as raw or ‘red’ copper sheets, and while this color will quickly morph from reflective reflective pinks and reds to a matte brown surface, it will still take another few decades before the metal fully patinates into the blues and greens.

An example of this slow patination process is the de Young Museum in California, which Zahner manufactured and installed in 2003-2005 as unpatinated copper panel system. Ten years later, the surface is now starting to show signs of green along the panel seams, but the overall tone is still a deep matte burnt umber tone. It is likely another ten to twenty years before the de Young will take on a green hue.

For the new CMA building, Zahner sped up the process. Zahner engineers manufactured pre-weathered custom blue-green copper using a rapid patina process. A process that normally takes twenty to thirty years was achieved in the span of a few weeks.

Zahner fabricated the building’s custom flashing and standing seam roof and supplied the pre-patinated copper sheets for the copper wall panels. Keith Panel Systems (KPS) engineered and fabricated the wall panels on their KPS System ‘A’ which provides a compartmentalized and pressure-equalized rainscreen. Phinney Industrial Roofing coordinated the work with KPS and successfully completed the installation as the sub-contractor to Corna Kokosing Construction.

Columbus Museum of Art, view from the main entrance.

Columbus Museum of Art, detail of the custom metalwork.

Columbia University

August 15, 2016/in Exterior Architecture Education, Highrise, LEED New York City Moneo Brock Studio Grey L /by cmorris

Columbia University Northwest Corner Building

Completed in 2010, the Northwest Corner Building was developed by Columbia University for the beginning of their campus expansion on the upper-west side of Manhattan, New York. The design by architect Rafael Moneo features an extruded aluminum facade, a system that was designed-engineered and fabricated by Zahner for the cladding of the structure.

The building’s engineering is a bold feat of structure and construction. Its design called for a 125′ span across the existing gymnasium on ground level. Because Columbia opted to build around an existing gymnasium, the building design was modeled after a high-rise bridge. The construction process took place during the school’s basketball season, and due to this, many aspects of the construction process required surgical precision.

The angularity of the facade is designed to express both the building’s randomized structural bracing, as well as the tailored building systems. The architects and engineers faced many unique layout challenges and the building required long-term flexibility. The extruded aluminum facade is an engineering-intensive surface designed and fabricated to evoke the same unified precision as the building itself.

Detail of the Columbia University Northwest Corner Building.

Columbia University Northwest Corner Building.

Detail of the aluminum facade system used on Columbia University Northwest Corner Building.

Creating the Energy-Efficient Aluminum Facade System

The new university building is certified LEED Gold. Integrating into the the building’s LEED aspirations was a simple process for A. Zahner Company because the operations and manufacturing of the plant is already well-suited for LEED applications.

Zahner delivered the aluminum system for this project under a design assist mode of production. Using this method enabled Zahner’s engineering and design team to reduce the construction waste for the facade down to a fraction of the building’s footprint.

Columbia University's first installed aluminum panels.

Zahner-produced mockup for wind-testing the Columbia facade system.

Detail of the aluminum extrusion system facade used on Columbia University.

Columbia University Northwest Corner Building: in the Press

“The building is a gleaming physical expression of the university’s desire to bridge the divide between the insular world of the campus and the community beyond its walls.”

—Nicolai Ouroussoff, New York Times

The New Columbia University Sciences building has attracted many news outlets and media interest due to its unique facade and intelligent engineering by the architectural team lead by Rafael Moneo. Learn more about the project via both internal and external links below.

Metals in Construction Columbia University (PDF) by Adam Friedberg, p22-31 (Columbia)
New York Times A Building Forms a Bridge by Nicolai Ouroussoff February 2011

Chihuly Bridge of Glass

August 15, 2016/in Exterior Architecture, Landscape Architecture Bridge, Exhibit, Museum, Pedestrian Bridge Tacoma--Washington Andersson-Wise Architects Dale Chihuly Blue, Grey M 2002 /by cmorris

Chihuly Bridge at the Museum of Glass in Tacoma, Washington

The Chihuly Bridge is a destination feature for Tacoma, Washington. Designed by Andersson-Wise Architects as an addition to the Tacoma Museum of Glass, the project provides a pedestrian bridge to downtown Tacoma. Made possible by a donation from Jim and Carolyn Milgard, the bridge crosses over major rail lines and links the Museum of Glass to Union Station and the State History Museum.

Zahner served as both the sole contractor and manufacturer in the production of the Chihuly Bridge of Glass. This construction included all structural steel, glazing and cladding elements as well as fiber optics and vacuum HVAC system within the cases.

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Museum of Glass

Zahner produced the metalwork for the glass bridge as well as the massive cone which can be identified throughout the downtown area. The cone was manufactured in stainless steel diamond panel system which was attached to a ZEPPS structural framework, each made by Zahner.

The system that Zahner used for the glass encasement of the artworks is the Drop Lock glass installation system, which allows for easy installation and sustainable maintenance. The system builds on Zahner’s patented Inverted Seam system for creating co-planar metal facades and roofs. The assembled panels provide rapid installation, require no silicone, and result in a visually clean edge with a dry look.

Visitors who walk across the bridge get a closer look at the work of artist Dale Chihuly. The bridge is divided into three sections:

— Seaform Pavilion: a glass ceiling and canopy system showcasing 2,364 works of Chihuly glass from his Seaform and Persian series.
— Crystal Towers: a permanent art installation by Chihuly, rising 40 feet above the bridge deck and serve as beacons of light.
— Venetian Wall: an eighty-foot long installation displaying 109 sculptures from three of Chihuly’s series: Venetians, Ikebana, and Putti.

Venetian Wall for the Chihuly Bridge of Glass, with Museum of Glass in the background

Pedestrians cross the Chihuly Bridge of Glass

Venetian Wall at the Chihuly Bridge of Glass

Seaform Pavilion at the Chihuly Bridge of Glass

Chihuly Bridge Seaform Pavilion, designed by Andersson Wise

Zahner field construction crew delivers the Seaform Pavilion for the Chihuly Bridge of Glass

Zahner field construction crew installs the Seaform Pavilion for the Chihuly Bridge of Glass

Plaque for the Venetian Wall at the Chihuly Bridge of Glass

Chihuly Bridge designed by Andersson Wise.

Press

US Glass Magazine – Chihuly Connections: New Bridge Creates A Link to Museum of Glass.
ArchNewsNow – Chihuly Bridge of Glass By Arthur W. Andersson, AIA/Andersson-Wise Architects

Cerner Headquarters

August 15, 2016/in Art & Sculpture, Exterior Architecture Flagship, Workplace Kansas City Gould Evans Associates Silver M, S 2005 /by cmorris

Signage for Cerner Headquarters Vision Center Forum Portals

The Cerner Corporation World Headquarters is designed by Gould Evans and features Zahner-manfufactured signage systems. Zahner produced this uniquely perforated stainless steel sculpture and sign for the Cerner Corporation in North Kansas City.

Two sculptural navigational displays were built: a small corner entrance sign adjacent to the building’s main entrance, and a large signage system visible from the nearby highway. This larger sign features an illuminated Cerner logo mounted on the perforated stainless steel screen wall.

Each of the displays were fabricated by Zahner using ZIRA, a patented technology developed by Zahner creating perforated imagery. The architects and client designed a non-repeating pattern of 1’s and 0’s, binary code in a non-repeating pattern. Zahner developed a process to rapidly punch the numbers using multiple dies.

Detail of the perforated metal signage system at Cerner Headquarters.

Cerner signage wall at the Cerner World Headquarters.

Detail of the perforated metal system used for Cerner Headquarters.

Detail of the Cerner World Headquarters signage wall.

The larger of the two displays, visible from the end of 210 Highway in North Kansas City, was produced with lighting systems embedded in the aluminum and stainless steel framework. Pictured above and below are photos of the signage at night, and during the day. As cars drive by, it appears to flash and animate due to the lights parallactic relationship with the perforations.

The complete system for the 61′ long sign structure comprises 72 panels supported vertically by stainless steel structural fins of varying depth and shape. Each panel is constructed from 18-gauge stainless steel, with a perforation pattern generated from a random sequence of binary code.

The display closest to the building features a DNA strand within the sign, visible as an orange tube. The structure was built with 1/4″ aluminum fins, attached to square tubes which create the sign’s profile. The face of the fins were installed with 14 gauge Angel Hair Stainless steel panels.

Additional metal signage at Cerner Headquarters.

Fabricating the Cerner Signs

The sculptural sign was custom perforated from stainless steel plates using binary code to create the pattern. The surface is an array of 1’s and 0’s randomly placed across the plates of stainless steel.

Below are photos from the Zahner shop in Kansas City, where the material for each display was formed. Each panel was perforated using dies custom-made for the project. Together with the automated punches allowed the fabricators on the shop floor to quickly assemble components after being produced on the computer-controlled punch.

Backlit perforated metal system at Cerner Headquarters.

Cerner signage during fabrication at Zahner .

Cedar & Kettner

August 15, 2016/in Exterior Architecture Parking Structure San Diego--California IPD: International Parking Design Silver L 2015 /by cmorris

Cedar & Kettner Development, Little Italy Parking Structure

Cedar & Kettner Development Parking Structure is located in downtown San Diego and features a Zahner-manufactured CloudWall facade system. The striking new parking garage anchors the corner of Cedar Street and Kettner Boulevard in the Little Italy area of downtown San Diego.

The series of vertical facade fins were made using the Zahner-patented CloudWall™ system. These fins were installed using custom extruded channel embeds which were set in concrete. Zahner worked with McCarthy to coordinate the location for each embed. Bassett Construction was the installer, and came to the project with experience on several other Zahner jobs.

The 240,000 SF design-build garage provides 650 spaces with three levels below grade and six levels above, serving as both a work garage for employees of the County of San Diego, as well as night parking for events in the downtown area.

Cedar Kettner Parking Structure in San Diego, California.

PHOTO © CHANY PHOTOGRAPHY.

The design team visited Zahner’s Headquarters prior to working on the job, and experienced the CloudWall system installed on the building’s facade. The project was led by IPD, who served as the architect of record. The team worked with construction manager McCarthy Builders in San Diego, and Bassett in San Diego led the install team.

The CloudWall fins were designed and shaped using 3-D computer-generated studies which resulted in an undulating façade that visually changes based on the point of view and sun angle. This new structure promises more than just additional spaces to park.

The Cedar & Kettner Parking Structure improves the commuter experience, offering a canopy over the adjacent trolley platform. The hope is that by offering more space for visitors, the already vibrant tourism within Little Italy will have room to increase. The new parking building is a key structure towards bringing more construction for additional projects in San Diego.

Cedar Kettner Parking Structure in San Diego, California.

PHOTO © CHANY PHOTOGRAPHY.

Cedar Kettner Parking Structure in San Diego, California.

PHOTO © CHANY PHOTOGRAPHY.

Completed in 2015, this new building provides much needed parking for visitors in a bustling area of tourism. 645 new spaces to park give the county the ability to accommodate greater amounts of tourism, bolster the local economy, and look great while doing so.

Reminiscent of ripples in the San Diego Bay, the CloudWall surface follows the recently completed waterfront park. The facade encompasses the building’s seven above-ground levels. Three additional levels exist underground.

Cedar Kettner Parking Structure in San Diego, California.

PHOTO © CHANY PHOTOGRAPHY.

Switching from Phenolic Plastic to Aluminum Plate

The wave-like fins were originally designed as a phenolic plank system. Design authorities determined some environmental and combustion concerns with the phenolic material. In the interest of public safety and longevity of the surface, all parties agreed that the design needed to be revisited in another material.

Following initial discussions with the group, Zahner visited onsite with the city and county officials, architects, and general contractors. The team reviewed the design and determined the specifics for providing the desired aesthetic.

Clear anodized aluminum was selected for both the fins and the cross bracing. The aluminum’s light material weight allowed for the phenolic system to easily be replaced with metal, without any structural redesign. The economical cost of aluminum also helped to lighten any budgetary concerns.

Scaling the CloudWall System

Prior to the Cedar & Kettner project, the CloudWall system was limited to one or two-story buildings. This was due to limitations of material lengths for the aluminum hardware. The CloudWall system was modified and custom-engineered for the project to span the six-story Cedar & Kettner building. This was accomplished by dividing the metal components into two lengths.

Zahner built a mockup to test how the new components would fit together, and also to test lighting and color options for the client.