Charcoal | Zahner

Scene75

January 4, 2017/in Exterior Architecture Retail & Commerce Milford--Ohio RT Design Studio Charcoal, Red M 2015 /by cmorris

Scene75 Entertainment Center

Scene 75 is a retail renovation designed by RT Design Studio featuring a fin-based facade system developed by Zahner. The project entailed a conversion of a pre-existing box store into an indoor entertainment center in Milford, Ohio.

The project was an aggressive schedule. The entire process from design to fabrication was completed in less than four months. The building’s signage system integrates a marquee installation, made using CloudWall, a patented system developed by Zahner. The marquee overhangs the main entrance, and is made of red-painted aluminum profiles.

The design was made using parametric design of varying depth CNC cut aluminum fins, undulating to produce a smooth wave. The fully engineered system accommodates a 22’x16’ lighted sign in the middle. Programmable LED lights animate the exterior fin-based facade at night. Among other latest generation arcade gaming equipment and party rooms, the building features: Laser Maze, Go-Karts, mini golf, mini bowling, 4D Theater, Chaos Room, full bar, and a restaurant.

Related System

CloudWall®

CloudWall is a product system offered by Zahner to give designers a simple way to create facades and more. CloudWall provides a custom fin-based profile for facades, ceilings, fences, low-barriers and other applications.

Scene 75 facade entrance in Milford, Ohio.

Scene 75 facade at dusk in Milford, Ohio.

Gambucci Boutique

December 9, 2016/in Interior Architecture Retail & Commerce San Diego--California Luce et Studio Black, Blue-grey, Charcoal S 2015 /by cmorris

Laura Gambucci Boutique in La Jolla, California

Designed for Laura Gambucci by Luce et Studio, the retail boutique features a Zahner-manufactured perforated interior feature wall. Laura Gambucci, a former interior designer, worked with the design team to develop the custom interior architecture and features for her new boutique. The space presents a palette of silvers and golds, as well as blacks, greys and whites.

Working from custom options provided by Zahner, the team selected a material which would match the look and feel of the space. The material is a black Interference Stainless Steel with a mirror polish, a rich and reflective material used architecturally on major projects in the United States.

Custom furniture and fixtures can be fabricated with Zahner engineering for a variety of applications. These furnishings include both retail and exhibit design, as well as office, home, or exterior furniture.

Zahner engineers work with designers and contractors to develop integrated systems which meet a range of desired aesthetics. Below are a few examples of inspirational projects which include custom furniture designs fabricated by Zahner.

Related Project

Capitol Federal Hall

The building features various exterior and interior metalwork, design-engineered and manufactured by Zahner. The project was completed in 2015. Zahner worked with architects Gensler and Gastinger Walker, under the construction management of JE Dunn.

Upon entering the space, visitors are met with a reflective black perforated metal feature wall to their right. This wall system was designed using ImageWall provided by Zahner for making perforated metal systems. Using the online tool, designers developed a pattern, and further customized the system with a backlighting to create a unique perforated metal aesthetic

Detail of the interior screen wall with cross-seam perforation.

Black interference stainless steel used for the interior featurewall.

The Smithsonian NMAI

August 15, 2016/in Interior Architecture Exhibit, LEED, Museum Washington D.C. Jones & Jones, SmithGroup Ramona Sakiestewa Charcoal, Gold, Green L 2004 /by cmorris

THE SMITHSONIAN National Museum of the American Indian

Zahner was selected for the production of several decorative and artistic elements for the National Museum for the American Indian (NMAI). The Smithsonian-owned NMAI is dedicated to the preservation, study, and exhibition of the life, languages, literature, history, and arts of Native Americans.

The architectural design process included a number of designers and artists, including artist Ramona Sakiestewa, architects Jones & Jones with SmithGroup, and exhibition designers at Gerald Hilferty.

Zahner worked with Hopi artist Ramona Sakiestewa to produce a copper screen wall, a permanent installation in the court of the museum which lines a walkway down to the open space. Copper was chosen to acknowledge the antiquity of the Indian people who lived in the Northeast. It was a widely used material in Mound Builder cultures, which stretched from the Great Lakes to the Gulf of Mexico, east of the Mississippi, over 2000 years ago.

Photograph of Ramona Sakiestewa (Artist) and Ilze Jones (Architect) for the Smithsonian NMAI

Photograph of Ramona Sakiestewa (Artist) and Ilze Jones (Architect) for the Smithsonian National Museum of the American Indian in Washington D.C.

Photo © A. Zahner Company

Fabrication at Zahner HQ for the National Museum of the American Indian in Washington D.C.

Photo © A. Zahner Company

NATIONAL MUSEUM OF THE AMERICAN INDIAN IN WASHINGTON D.C.

PHOTO © A. ZAHNER COMPANY.

National Museum of the American Indian in Washington D.C.

Photo © A. Zahner Company

Potomac Room at the National Museum of the American Indian in Washington D.C.

Photo © A. Zahner Company

Copper screenwall for the National Museum for the American Indian in Washington D.C.

PHOTO © A. ZAHNER COMPANY.

Detail of the COPPER SCREENWALL

PHOTO © A. ZAHNER COMPANY.

National Museum of the American Indian in Washington D.C.

Photo © A. Zahner Company

PHOTO © A. ZAHNER COMPANY.

National Museum of the American Indian in Washington D.C.

Photo © A. Zahner Company

Oculus

August 15, 2016/in Art & Sculpture Sculpture Kansas City Reilly Hoffman Charcoal, Gold, Green S 2008 /by cmorris

Oculus Sculpture, KCAI Competition

Every other year, Zahner produces one or more artworks in conjunction with the Kansas City Art Institute’s Biennial Auction for Student Scholarships. In the 2007 year, artist Reilly Hoffman won the competition with a sculpture entitled, ‘Oculus’. Zahner manufactured the base form in aluminum, and water jet cut the parts for the sculpture. Hoffman then crafted copper and steel with his signature torch-carving techniques.

The design of the artwork is based on a smaller version of the artwork. The artwork’s concept is a sphere which has been cut into slices. Two of the slices are intertwined in a kiss. The sculpture’s exterior appearance is a rough steel, while its inner areas are clad in copper.

Although diminutive when compared to buildings, the sculpture is still quite large compared to the human scale. The large size required the use of a substructure to apply the metal surface.

To create the sculpture in its large form required making changes to the how the artwork is manufactured. Zahner engineers in the Design Assist team proposed using ZEPPS, the Zahner system developed for building curves. Using the this system enabled the team to make a light aluminum understructure to which the metal surface was attached.

This use of ZEPPS for manufacturing objects such as this one is somewhat atypical. The system is more commonly used to produce the large curved walls for uniquely shaped buildings. In situations where a rapid-installation process is required, or for installations at higher elevations, ZEPPS provides an efficient way to design, engineer, and install such unique forms.

The cad rendering above shows the effect of copper hammered through the mild steel plate. The mild steel has perforations in the side which allow for sections of the copper to show through, see below.

The project used three metals: a aluminum for its structure, copper for its core, and carbon-steel. The back and the inner sections of the sculpture are finished with the Star Blue patina on hammered copper. The sides of the sculpture are finished with water jet cut mild steel, backed by a sheet of sealed red copper, also hammered. The effect is a highly detailed and sculptural piece, which is now in a private collection.

Neiman Marcus

August 15, 2016/in Exterior Architecture, Interior Architecture Retail & Commerce Natick--Massachusetts Elkus Manfredi Charcoal, Gold, Orange, Silver L 2007 /by cmorris

Neiman Marcus Flagship Store by Elkus Manfredi

The Neiman Marcus in Natick, Massachusetts is the store’s Flagship property featuring a billowing facade designed by Elkus Manfredi Architects in Boston. The entire surface of the building is wrapped in a stainless steel curtain, a feature which flows throughout and into the building in the same style.

Elkus Manfredi Architects designed the facade’s undulations with perspective in mind. When travelers drive by, the structure appears animated and kinetic, an effect caused by the way the facade curves in and out. Zahner worked with the architects to design a curving facade panel system that is both aesthetically powerful as well as economically effective.

Related System

Neiman Marcus

Related Surface

Interference Stainless Steel

Light Interference Coatings (LIC) on stainless steel provide a broad range of color which changes in various lights. From a deep blacks to bold bright colors, the light interference process brings a whole spectrum to stainless steel. The fine coating adds an aesthetic layer to the metal without sacrificing the innate high-performance qualities of stainless steel.

The skin is actually three different tones of colored stainless steel. Two of these tones were formed by a electro-chemical process which permanently changes the tone of stainless steel. Zahner has used this process for several other projects, including the Contemporary Jewish Museum which has a dark blue interference coating and a cross-fire brushed pattern. Interference stainless steel was also used on the The EMP Museum, The Meyer Fletcher Residence, and the Royals Crown at Kauffman Stadium.

In addition to providing the exterior scope, Zahner also manufactured interior metalwork for the department store interior entrance. This interior wall uses a similar subtle curvature made in a lightweight ZEPPS framework. This scope included the ceiling area, made in a stainless steel with standard polish.

The exterior scope included various metal details, including the soffit at the Neiman Marcus entrance and the throughout areas underneath the facade’s curtain. Providing these standard details for the facade and other areas is typical of Zahner scope. The company routinely handles interior and exterior standard metalwork on a variety of projects.

Related System

Soffit Systems

Soffit systems engineered and manufactured by Zahner are the result of innovative architects, designers, and artists who challenged the norms of what to expect in the built environment. Working with Zahner to develop a custom metal soffit system begins with your design.

Designing the complex curtain system for the Neiman Marcus facade was made possible through Design Assist. Zahner worked with the architects at Elkus Manfredi to develop a design, mockup, and manufacturing process to efficiently fabricate, deliver, and install the exterior metal facade.

Building a dual-curved facade with pre-fabricated panels.

The building’s 570-foot-long undulating stainless steel façade, in tones of bronze, champagne and silver, “waves in and out and top to bottom almost as if someone was wearing a dress and walking,” said Elkus.

Morimoto

August 15, 2016/in Exterior Architecture Restaurant New York City Stephanie Goto, Tadao Ando Charcoal, Grey S 2006 /by cmorris

Morimoto in New York City

A red curtain displaying traditional Japanese noren hangs in the custom entrance for the Morimoto, a Japanese restaurant in the Chelsea neighborhood of Manhattan. The facade, manufactured by Zahner in Kansas City, brings a custom touch to an otherwise standard shingle. Its blackened zinc patina on galvanized steel is both classic and modern, as is its corrugated facade.

The restaurant, named for and run by Iron Chef Masaharu Morimoto, is designed by Stephanie Goto and Tadao Ando. This upscale Chelsea bar and restaurant is just a few steps from the South end of the High Line Park in lower Manhattan.

Zahner produced the exterior, a blackened galvanized steel corrugating wall with a wide opening for its entrance. The facade’s matte appearance is a feature of its natural patina. The system that Zahner designed with the architecture team uses a face-fastener which add an industrial aesthetic.

Related Surface

Oscura™ Blackened Steel

Oscura is a Zahner blackened patina on steel that has been developed for interior use. Activated steel surfaces create a mottled and artistic ambiance that varies from sheet to sheet. The primary surface is sealed with a clear coat to mitigate rusting due to the effects of the ambient interior environment.

Instructional Centre

August 15, 2016/in Exterior Architecture, Interior Architecture Education, LEED Toronto--Canada Perkins + Will Blue, Charcoal, Green L 2011 /by cmorris

University of Toronto Mississauga Instructional Centre

The University of Toronto at Mississauga (UTM) has developed a number of unique buildings to serve the students on its campus. The Instructional Centre at UTM is no different. Clad in a Zahner pre-patinated copper surface, this custom blue patina on copper was developed specifically for the project.

The patina was an inspired decision by the architects at Perkins + Will whose design required a number of unique aspects for both the interior and exterior of the building.

The architects wanted a facade with an artistic patina, revealing the bare copper in some areas, and hitting dark points in others. This mottled appearance appears natural, but it is manufactured by Zahner.

The award-winning University of Toronto Instruction Centre’s new building is certified LEED Silver, and was completed in 2011.

Related Surface

Star Blue™

Star Blue copper is a preweathered surface patina on copper offered by A. Zahner Company. The custom copper sheet product provides a range of unique visual color textures on authentic copper surfaces.

Under normal circumstances, raw copper sheet will develop a copper patina after ten to twenty years. In the case of the UTM Instructional Centre, this patina was developed in a matter of weeks by chemically oxidizing the metal in a controlled environment.

Zahner patina technicians developed a custom Star Blue patina on the copper, modifying its application technique for artistic effect. Zahner cultivates and trains patination experts for both their scientific prowess as well as their artistic vision, because many clients require a high-performance artistic patinated panel rather than a uniform machine-produced surface.

These copper sheets were then formed by Zahner into a panels. The prefabricated panels were crated and shipped to the job site in Toronto, where the pre-patinated panels were installed.

Students walking at dawn amidst the blue copper facade.

Students walk up and down the main staircase.

Overhead view of the new building at UTM.

Interior view showing the variance of brown and green copper.

The mood of the patinated copper interior walls changes during the evening.

The Instructional Centre is built just northwest of the recently completed Hazel McCallion Academic Learning Centre. The new building features a cafe in the main entrance and lobby underneath the main staircase.

The Instructional Centre’s design includes two lecture halls stacked vertically and organized into three towers, each clad in the pre-patinated copper. Each of these solid volumes enclose smaller perimeter lounges, enticing students to gather before and after lectures.

The UTM Instructional Centre is located at the north end of campus in place of a parking lot.Read more about the pre-patinated Star Blue patina used on the surface of the building, or Contact Zahner to request custom samples for your project.

El Paso Courthouse

August 15, 2016/in Exterior Architecture Government, LEED El Paso--Texas Antoine Predock Architect PC Black, Charcoal, Gold, Violet L 2010 /by cmorris

El Paso United States Federal Courthouse

Designed by Antoine Predock Architects, the award-winning courthouse in El Paso features a Zahner-manufactured copper facade. Officially dedicated in early September of 2010, the construction of the courthouse was made possible by American Recovery and Reinvestment Act investments by GSA.

The courthouse has been recognized around the United States for both its architectural qualities and its environmentally innovative design.

The building won the Texas Downtown Association’s President’s Award for Best New Construction, which recognizes construction excellence in downtown or commercial districts. Judges were impressed by the use of materials, which paid homage to the copper industry of El Paso and how the design of the building connected with the surrounding downtown.

North elevation of the El Paso Federal Courthouse.

Detail of the Special Proceedings Court at El Paso's Federal Courthouse.

El Paso Courthouse viewed from the northwest.

The building’s mass is largely composed of two materials. Limestone, quarried locally in Texas, and copper, a material which references the local smelter. Zahner provided engineering-design, as well as fabrication and installation of the copper panels.

The building was certified as LEED Silver by the U.S. Green Building Council. Its design makes use of innovative ventilation and air conditioning; computerized heating systems; lighting and utility metering to conserve energy; window glazing; energy-efficient Energy Star products; as well as interior and exterior elements made from recycled materials.

Building the El Paso Federal Courthouse

Zahner was was responsible for the custom cladding of the El Paso Courthouse. This included the engineering, fabrication, and installation of the red copper facade.

As the installers began cladding the building, the material began to blacken in areas as intended. This is caused by the oxidation of the surface, the natural process of patination on copper.

El Paso Federal Courthouse during construction.

The patina begins to form on the surface of the recently completed courthouse.

As the metal oxidizes, the material will go through the stages of copper weathering. After a year, the appearance matches the Dirty Penny patina, and the surface will continue to age, evolve, and change in color.

Clyde Frazier NYC

August 15, 2016/in Interior Architecture Restaurant New York City Morphosis Black, Blue, Blue-grey, Brown, Charcoal, Gold, Green, Grey, Indigo, Light blue, Magenta, Orange, Red, Silver, Violet, White, Yellow M 2012 /by cmorris

Clyde Frazier’s Wine & Dine in New York City

Clyde Frazier’s Wine & Dine is a new construction high-end sports bar and eatery designed by Morphosis. The space features a Zahner-manufactured ceiling, made using generative design and automated fabrication.

Designed by Morphosis for NBA Champion and former New York Knicks Player Walt Clyde Frazier, this New York City restaurant expands a full city block in the Hell’s Kitchen neighborhood. A swarm of suit jackets dominates the central corridor of Clyde Frazier’s Wine and Dine, a 10,000 square foot experience which mixes American and Asian cuisines.

Zahner provided the ceiling architectural feature. This ceiling is made up of custom cut and folded aluminum plates, 544 in total. The aluminum plates are printed from photographs of Mr. Frazier’s suit jackets. These parts are segmented into six unique shapes, where are placed at intervals of increasing distance. This interval placement creates the illusion that every part is unique.

Clyde Frazier's Wine & Dine in New York City.

The colors in the model categorize the panels according to breaks and sizes. Between the differing anchor placements, prints, panel sizes, and panel shapes, all 544 aluminum panels ended up being unique.

Even more complex were the ribs which held them in place. Because the panels were anchored at different angles, every drill hole had to be custom placed. Thus, each of the 69 ribs had 6 segments for a total of 463 segments, each with 3 unique faces.

3D model for Clyde Frazier's Wine and Dine.

“The transformative feature in the room, however, is suspended from the ceiling, where a 170-foot-long assemblage of colorful, patterned, flat and folded aluminum fins floats over the dining area, bar, and lounge. Morphosis found the stripes, plaids, and prints for this polychromatic sculptural reef in Frazier’s closets.

The architects photographed their contents and, working with Zahner’s metal fabricators, digitally printed images for a film adhesive applied to 544 aluminum panels of six shapes. The palette varies from blue to brown-gold to charcoal, with red painted undersides enhancing the gestalt. ‘It’s mesmerizing,’ says Frazier.” — Suzanne Stephens, Architectural Record.