More Projects

News & Updates

The North American Copper Awards has recognized Zahner's copper metal-work for the Waipolu Gallery in Oahu, Hawaii. Waipolu Gallery and Studio in Hawaii

Zahner completed the New Academic Building at Cooper Union in New York City. See the time-lapse construction video at Videos & Downloads.

President and CEO Bill Zahner is featured in the August Issue of Wired Magazine, where he has now been dubbed, the "Alpha Geek" of Metal. Read Article

Alpha Geek Bill Zahner holding Metal Sheets

The NASCAR Hall of Fame project reached 1,000,000 man-hours without a "lost-time" accident milestone recently. In recognition for Zahner's achievement TBEKD presented a plaque to Zahner
See more awards

Bill Zahner named an Honorary Member of the American Institute of Architects.

Introducing the Hands of the Artistâ„¢ division, where Zahner engineers and craftsmen produce projects for artists.
Visit Zahner's Hands of the Artist website

Dallas Fort Worth Airport

Dallas Fort Worth Airport, Terminal D

The new Terminal D at the Dallas Fort Worth Airport is the largest square-foot project completed to date using the Inverted Seam™ Roofing System.  The new terminal was built to give international travelers a lasting positive impression of their arrival and departure from the United States.   Zahner worked with lead design architect HNTB as well as architect of record Corgan Associates, and HKS, Inc the managing architect to complete this vast project.

Aerial view of Terminal D while landing Original photograph by Justin CozartZahner digitally defined and developed a custom-designed structural system to maintain the exact shape of the architect’s model. The corrugated metal decking system installed under our roof could only provided a facetted form. The owner and the architect wanted a torrus shape. The entire roof was then clad with 22 ga stainless steel, Inverted Seam™roof panels. Zahner custom fabricated and installed all of the gutter and fascia systems that were incorporated into the surface.

 

The project features approximately 500,000 square feet of surface covered with 11 acres of stainless steel roofing. Just over two miles of gutter and 5 miles of fascia panels were also part of Zahner’s scope.

Energy Efficiency

The Zahner Inverted Seam™ Roof is part of the total low-energy solution for the project, reducing the cooling costs by more than 90 percent during peak electrical demand hours.

Zahner field workers during construction

The Terminal D development program includes design of the airport’s central thermal storage tank, a structure that utilizes less expensive electricity at night to create a store of ice to cool the terminal during daytime hours when rates are higher. The project was reviewed by the Clean Airport Initiative team of experts to evaluate incorporated features of sustainable design and to use it as a case study for upcoming guidelines for sustainable airport design.