Orange | Zahner

15 Renwick

15 Renwick Residential Development in Manhattan

Zahner provided exterior copper panels pre-patinated with a Dirty Penny finish.

15 Renwick is a 31-unit building, designed by ODA-Architecture, featuring a unique mix of 2- and 3-bedroom residences, three townhomes with private yards and four penthouse duplexes.

Sidra Medical Center

August 15, 2016/in Exterior Architecture Healthcare Asia, Doha--Qatar, International, Middle East Pelli Clarke Pelli Blue, Green, Orange XL 2014 /by cmorris

Sidra Medical and Research Center in Doha, Qatar

The Sidra Medical Center is designed by Cesar Pelli of Pelli Clarke Pelli with the executive architect Ellerbe Becket in Kansas City. The design is a massive Research and Medical Center which will serve both the science and health for local Qatari’s in Doha.

Zahner produced the three massive ‘wings’ which salute the sky using ZEPPS, Zahner’s process for designing and manufacturing complex structural forms. The subtle dual curvature required precise engineering and intelligent organization of components.

The Sidra project was unique for Zahner in a few different ways. Most projects produced using the ZEPPS Process feature a surface skinned with a durable metal such as stainless steel or copper. The client requested a terra cotta ceramic tile rather than a metal surface. While most environments will find stainless steel to be the highest performance materials, in environments such as a Doha, where sandstorms can blast silica into the surface, a harder, ceramic exterior facade was required.

The project was also unique for Zahner in that it was the first structure to use the Export ZEPPS. This means that instead of preassembling ZEPPS megapanels at Zahner, the ZEPPS components were fabricated and shipped in a disassembled state to Doha. There, instead of sending a field crew to Doha, local installers worked from a manual produced by Zahner. The local installers manual to produce the hundreds of unique panels in an on-site facility nearby the construction site. The panels were then crane-lifted and set by installers on each floor of the building.

Aerial photograph of Sidra, substantially completed.

Export ZEPPS for Sidra

Under normal circumstances, the ZEPPS Panels are fabricated and assembled in the Zahner shop. Each completed panel is shipped to the job site, and under ideal circumstances, installed by Zahner’s own field install team. In the case of Sidra, these ZEPPS Panels were fabricated as parts, packed, crated, and shipped in cargo containers to the site where the parts were re-assembled on site by local Qatari installers contracted by Alce Engineering. Below, a Zahner worker organizes parts for crating and shipment.

To organize this overseas project required the production of digital and paper instruction manuals particular to the Sidra Project’s Export ZEPPS. Zahner Engineers worked with the Marketing Department at Zahner to accurately convey all aspects of assembling Sidra’s Export ZEPPS Panels for prompt installation onto the structure.

Photograph of the paper version of the Export ZEPPS™ Manual for Sidra.

Assembly of an Export ZEPPS™ Panel in Doha.

About the Sidra Medical Center

Sidra is part of a new medical zone on the Education City campus. The Sidra Medical Center will also include residential accommodations for about 300 nurses, a car park and a pedestrian walkway to Weill Cornell Medical College. Sidra Medical Center houses over 500 beds for patients.

At full operation, Sidra will employ over 2,000 full time staff, including a team of highly talented and accomplished physicians and scientists to help establish the medical and research facility as a genuine center of excellence.

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.

McMurtry Building

August 15, 2016/in Exterior Architecture Education Stanford--California Bora Architects, Diller Scofidio + Renfro Brown, Orange L 2015 /by cmorris

McMurtry Building for the Department of Art and Art History

A work of architecture which both matches the surrounding aesthetics and yet stands out as an icon of its own, the McMurtry Building is a unique architectural project in Stanford, California. The structure features Zahner craftsmanship in both its custom patinated zinc facade and the courtyard’s grand stairway.

The McMurtry Building was designed by Diller Scofidio + Renfro whose design team worked with executive designers Boora Architects to bring this 100,000-square-foot project to fruition. The building was named for donors Burt & Deedee McMurtry who contributed over a third of the building’s costs. The campus building brings studio art, design, art history, film, and media studies together under a zinc roof.

Zahner’s scope required a unique warm-toned brown patinated zinc, which would encompass the roof, facades, soffit, and other areas of the building. Zahner developed this preweathered patina on zinc in multiple variations as part of the Design Assist process.

During the development of details, three final ‘color’ options were presented in mockup form. The architect then narrowed the selection down to the finalized stable patina option. The chosen patina has a rich brown hue, interspersed with variegated grey and umber. The tone defines the McMurtry Building.

McMurtry Building in Stanford, California, designed by Diller Scofidio + Renfro.

McMurtry Building interior gathering area for students.

About the McMurtry Building’s Design

The building’s design includes stacking cantilevered forms, broken by a sloping diagonal on both the east and west sides. This balanced criss-crossing of elements divides the various disciplines within its space.

In a speech delivered at the McMurtry Building groundbreaking, principal-in-charge Charles Renfro expounded on the building’s unique design approach. He describes how the two interwoven ‘strands’ influence the building’s form. The strands divide as well as unite the building’s two wings. At one end, classrooms serve as a clean learning space, and at the other, artist studios provide a work area. The strands come together the building’s rooftop communal space, and again the spaces are united at the ground floor library for art and architecture.

The strand of the southern wing is clad in preweathered zinc. Zahner performed the design-engineering and manufacture of the zinc aspects of the McMurtry Building. Zahner also performed the installation of zinc panels and metalwork, working to ensure a high-quality product for the architect and client.

McMurtry Building for the Department of Art and Art History.

Detail of the Zinc panels on-site at the McMurtry Building in California.

Detail of the custom zinc ceiling corner and facade for the McMurtry Building in Stanford, California.

The soffit area is detailed with a preweatehred custom zinc with custom panel-patterns.

Detail of the cantilevered facade with custom-patinated zinc metalwork, on the McMurtry Building in Stanford, California.

Creating a custom roof and facade with Design Assist

Before making the actual facade and roof panels, Zahner was selected to design-engineer the exterior cladding systems. Hiring Zahner through a separate Design Assist contract, the architects were able to solidify the design details before building the actual project.

As part of the Design Assist contract, Zahner also provided multiple mockups for the zinc rain screen. The final mockup was installed just North of the actual McMurtry Building on the University campus. This mockup focused on many of the most difficult and complex aspects of the facade, soffit, and roof. By creating a mockup, the entire project team was able to predict and better develop the final product.

The McMurtry mockup was installed on-site in Stanford, California.

Patina technicians in the Zahner Dallas facility create the custom patina on zinc.

The building's cantilevered form highlights the rooftop area's custom patina on zinc.

Detailed of the corner where the zinc facade meets the zinc soffit.

Custom zinc ceiling soffits and staircase at the McMurtry Building in Stanford, California.

The McMurtry Building's cantilevered forms (zinc panels across the top).

Detail of the custom zinc interior atrium staircase at the McMurtry Building in Stanford, California.

Custom zinc ceiling soffit for the McMurtry Building in Stanford, California.

Detail of the zinc ceiling soffit and recessed lighting.

Detailed metalwork uses Zahner's preweathered custom zinc patina.

West side of the McMurtry Building, detail of the copper-toned patina on zinc.

Detail of the east utility area. The zinc provides an alternative to cor-ten weathering steel.

Cafe on the east side of the McMurtry Building in Stanford, California.

Utility area of the McMurtry Building in Stanford, California.

Detail of the corner edge of the zinc facade and soffit.

Zinc roof with a custom patina, McMurtry Building in California.

The McMurtry project is among several projects featuring Zahner manufacturing at the University campus. Zahner also worked on the WRNS-designed Hoover Garage which is located just a few minutes from the the McMurtry Building.

Gulf Islands

August 15, 2016/in Exterior Architecture, Interior Architecture Residential Vancouver BC AA Robins Brown, Orange, Red M 2012 /by cmorris

Gulf Islands Residence, Pacific Northwest

With jutting lines of burnt umber flying across the horizon, this remote single-family house is situated in rocky southern shores of the Pacific Ocean near Vancouver, British Colombia. Tony Robins of AA Robins Architect took on this 6,500 sq ft cladded challenge as lead architect and gave this hidden gem a contemporary style reminiscent of the modern sculptor Alexander Calder.

The exterior and interior cladding of the home is done primarily with A. Zahner Company’s trademarked patina, Solanum Steel weathering steel. This pre-weathered steel surface provides a vibrant and warm color to complement the surrounding blue ocean and sky. Comparative to raw weathering steel, Solanum Steel offers a stable surface which reduces runoff from the natural patina on its surface.

Related Surface

Protected: Solanum Steel™

Solanum Steel is a pre-oxidized weathering steel (Corten) surface developed by Zahner. The surface is produced by accelerating the natural weathering process and stabilizing the result. Solanum Steel provides artists, architects, and designers with a range of resonant tones on an enduring surface.

Photograph of the Gulf Islands Residence designed by AA Robins.

Detail of the facade design, Gulf Islands Residence designed by Tony Robins of AA Robins architects.

The Solanum Steel exterior of the Gulf Islands Residence appears bright umber in the afternoon light.

Photo of the interior Solanum Steel application. Light flows through the perforations on metal's surface.

Zahner engineered a CAD layout of the panels on the Gulf Islands Residence.

Fabricating the Weathered Steel Facade

The only way to reach this island is by taking a ferry directly from Vancouver, traveling through the narrow passage separating Mayne Island and Galiano Island. Because traveling to the house is an adventure of itself, the structural modules that make up the house had to be prefabricated, shipped over by ferry, and driven up the site on 23 trucks. Zahner provided the Solanum Steel pre-weathered sheets to local fabricators.

The design has many interior elements that bring the modern edge inside such as skylights framed with red steel beams, giant glass walls, and high windows hidden by the perforated Solanum Steel surface. The high windows are hidden so the rock-shaped perforations can cast light onto the adjacent wall adding a playful pattern to the room throughout the day. This same perforated pattern can be seen with the powder-coated aluminum on the edge of the infinity pool that is equipped with a waterslide.

This residence at Gulf Islands evokes the ebb and flow of its surrounding landscape. To learn more about Zahner’s custom patinas, see the surfaces page of the website, or contact Zahner about developing a custom patina to fit the needs of your project.

Gates Hall at Cornell

August 15, 2016/in Exterior Architecture, Interior Architecture Education, LEED Ithaca--New York Morphosis Orange, Silver L 2014 /by cmorris

Bill & Melinda Gates Hall at Cornell University

Gates Hall is a new computer science building for students of Cornell in Ithaca, New York. Designed by Morphosis Architects, the building features Zahner custom systems for the soffit, interior entry foyer, and exterior facade. The building, named for Bill & Melinda Gates, is a dedicated building for Cornell University’s Computing and Information Science (CIS) program.

The project’s facade is designed using generative processes developed by Morphosis. Its unique appearance also serves the building’s environment performance, reducing heat gain while providing natural light into the offices and classrooms.

The complex facade appears to be made up of unique parts, but there are several typical forms which are cleverly spaced to give the appearance that each part is unique. This technique of using the negative space to create complex visuals is a hallmark of the architecture firm’s genius, and can be seen on other Morphosis projects such as Emerson College LA and Bloomberg Center.

Related Project

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.

Zahner worked with Morphosis to optimize the frame panel system, reducing it to the fewest number of components. By switching from bulky hollow frames to a combination of angles and plates, Zahner minimized the leading edges and simplified its compound joint conditions, resulting in sharper lines and cleaner forms at a reduced cost.

Photograph of the Gates Hall main entrance and soffit system.

Metal panel system provide the building's offices with natural light and shading.

Field time and layout were reduced immensely by using a three-point attachment scheme and coordinating anchor locations beforehand, which were fabricated into the mullions. There are 450 total framed panels using 90 panel types, fabricated by Zahner for the facade. Each panel was pre-designated and automatically numbered with its specific location and pre-installed mullion incorporated anchor-tabs awaiting their arrival.

The facade project team included Zahner working directly with glass installer W&W to optimize the panel system. Thornton Tomasetti provided the structure’s engineering, and Welliver was the construction manager that coordinated and ensured the project’s success. The project team’s delivery of the angular sunshades should contribute to the building’s expected LEED Gold certification.

Reducing the cost of the Gates Hall facade with Design Assist

Because Zahner not only fabricates but also engineers its facades, Design Assist is often employed for complex facades such as Gates Hall at Cornell. By managing the project under a Design Assist contract, Zahner was able to refine the façade elements with Morphosis to arrive at a system that achieved the aesthetic intent and was streamlined for fabrication and installation.

Interior foyer with stainless steel entrance metalwork.

Detail of the exterior galvanized steel facade connection.

Detail of the orange-painted aluminum soffit system used on Gates Hall at Cornell University.

The design team members examine the Zahner mockup as part of the Design Assist contract.

Detail of the interior metalwork on the Gates Hall at Cornell.

Engineering rendering and construction photograph of the completed facade.

Using Zahner’s Design Assist process allowed Morphosis to hone the costs of their design while meeting its visual requirements. Once the design intent was solidified, Zahner clarified the forms, both aesthetically and functionally. This resulted in reduced waste and construction delays, as well as a reduction in the overall cost.

The facade was designed to create the illusion of movement through a series of rigid forms. By varying the shape and angle that panels integrated into the panel system, Morphosis was able to create smooth transitions across the surface. Each panel is mounted on a staggered galvanized steel frame, and skinned with perforated stainless steel.

The design team members overlook the window unit integration of the completed facade.

Gates Hall facade seen from the adjacent baseball field parking structure.

Photograph of students entering the overhanging panel at Gates Hall.

Detail of the custom metal panels used on Gates Hall at Cornell.

Building the Entrance Soffit

In addition to the building’s generative facade, Zahner also engineered and manufactured the bright orange soffit under the main entrance. The sloping curves of the painted aluminum soffit contrast against the angularities of its framed panels.

Zahner used the ZEPPS assemblies on the soffit to achieve this flowing surface. Systematic production of seven internal fin members per panel created the continuous curves and minimized the number of joints. Support members follow the profile of the soffit to ensure the efficiency of the final surface and optimal installation.

Zahner's soffit layout and design for the main entrance.

Photograph of orange-coated aluminum soffit panel system at Gates Hall.

Atrium at Gates Hall, shows the interior feature wall installed and fabricated by Zahner.

Detail of the shaded perforated metal panel system at Cornell's Science Center.

Student Lounge at Gates Hall, shaded by the perforated panel system by Zahner.

Building with Morphosis

Zahner has worked with Morphosis on several projects including Cooper Union and Clyde’s Wine and Dine in New York City, and the Eugene Federal Courthouse in Oregon, and Emerson LA in California. Because of these successful collaborations, Morphosis brought Zahner onboard during the planning stages to provide Design Assist.

Dome on the Plaza

August 15, 2016/in Exterior Architecture Historic Kansas City Gastinger Walker Harden Brown, Orange, Red, Yellow M 2008 /by cmorris

The Dome on the Country Club Plaza

Working with Gastinger Walker Harden Architects and Highwood Properties, Zahner produced the subtly spiraling domed roof for Baja 600 Restaurant on the Country Club Plaza in Kansas City. Zahner designed, engineered, fabricated, and installed the Dome using zinc with custom patina.

The Dome on The Plaza uses Roano Zinc, a preweathered zinc with custom patina. The Roano Zinc surface is an aged patina whose variegated tones vary from panel to panel, creating an aged aesthetic suitable for both contemporary and historic architecture.

Domed roofs are complex feats of engineering, and this one is no different. Constructing the dome’s cladding required sophisticated planning and layout. Each row of panels is characterized by a unique panel shape, requiring over twenty panel types. Zahner engineers mapped the thirty foot diameter dome so that the complex surface would be easily installed.

Roano Zinc patina featured as part of the Dome on the Plaza.

Photograph of the Dome on the Plaza after decade of aging.

Roano Zinc-clad Dome on the Country Club Plaza during installation.

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.

Five threaded rods support each rib. The central columns do not hold the weight of the panels.

Aluminum fabricated-metal forms with custom printed and mounted graphics.

Installation process at Clyde Frazier's Wine and Dine

Installation of the printed aluminum fabrications.

Arkansas House

August 15, 2016/in Exterior Architecture, Interior Architecture Residential Northwest Arkansas Marlon Blackwell Architects Brown, Orange, Red M 2004 /by cmorris

Private Residence in Northwest Arkansas

This major home renovation in Northwestern Arkansas by architect Marlon Blackwell Architects is clad in an accelerated weathering steel facade system manufactured by Zahner.

The residential project’s interior wood and metal surfaces act as an interior liner to the building’s rough-to-the-touch Solanum Steel exterior architectural monitors. Flooring of rift-sawn cherry and walnut also act to form an interior liner. Taut and highly crafted, this refined surface acts as an interior liner to the exterior monitors clad in weathering steel shingles.

The architect’s challenge for the project was to reassemble a fire-damaged home while introducing possibilities for the transformation of the house’s spatial character. The design was defined in three weeks and the details were settled after construction began. The architect could work only in areas damaged by the fire, leaving the rest untouched for insurance purposes.