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Suzanne and Walter Scott Aquarium

November 1, 2021/in Exterior Architecture Entertainment, Renovation, Sculpture, Zoo Omaha--Nebraska Smith Bourne & Associates Blue, Green, Grey, Orange, Silver, White M 2019 Featured /by dsegard

Suzanne and Walter Scott Aquarium at Omaha’s Henry Doorly Zoo

Originally built in 1995, renovations for the Suzanne and Walter Scott Aquarium at the Omaha Zoo were completed in May 2020, featuring a redesigned facade, an updated outdoor cafeteria area, and new entrance features to the aquarium and aquarium conference center. As our third project in the Omaha metro area, Zahner provided various new design elements for this renovation, including the stainless steel wave facade on top of the building, the custom-cut metal coral features and column covers, the dimpled blue stainless steel cladding around the café, and the milled sea creatures that adorn the walls surrounding the space.

Completed Sea Turtle Cafe at the Suzanne and Walter Scott Aquarium.

Completed Sea Turtle Cafe at the Suzanne and Walter Scott Aquarium.

Photo by Alexandra Hoffman, ARKO | © A. Zahner Company
Completed entrance sign for the aquarium, fabricated utilizing Zahner's ZEPPS system.

Completed entrance sign for the aquarium, fabricated utilizing Zahner's ZEPPS system.

Photo by Alexandra Hoffman, ARKO | © A. Zahner Company
Suzanne and Walter Scott Aquarium exterior and Sea Turtle Cafe at Omaha's Henry Doorly Zoo at sunset.

Suzanne and Walter Scott Aquarium exterior and Sea Turtle Cafe at Omaha's Henry Doorly Zoo at sunset.

Photo by Alexandra Hoffman, ARKO | © A. Zahner Company

Zahner was brought on early in the concept development stage to provide Design Assist, which allowed us to work closely with the project team to refine the design intent, provide guidance on materials and finishes, and construct a comprehensive mockup for review before the project went into full fabrication. Due to this collaboration, there were zero change orders on the scope, and installation ran smoothly in cooperation with the contractor and the other trades’ schedules.

Original sketch for the Suzanne and Walter Scott Aquarium facade, by Mark Bourne.

Original sketch for the Suzanne and Walter Scott Aquarium facade, by Mark Bourne.

Photo courtesy of Henry Doorly Zoo
Visual mockup for the Suzanne and Walter Scott Aquarium facade, assembled in Zahner's Kansas City facility.

Visual mockup for the Suzanne and Walter Scott Aquarium facade, assembled in Zahner's Kansas City facility.

© A. Zahner Company
Night viewing of the mockup for the Suzanne and Walter Scott Aquarium facade.

Night viewing of the mockup for the Suzanne and Walter Scott Aquarium facade.

© A. Zahner Company

The freeform wave facade that sits atop the Sea Turtle Café was fabricated using Zahner’s ZEPPS™ technology, which combined the framing structure and the exterior skin into a complete curvilinear system. The individual wave units were pre-fabricated in our shop and shipped to the job site, where Zahner field technicians installed the full facade.

Zahner field workers install the wave facade on top of the Suzanne and Walter Scott Aquarium.

Zahner field workers install the wave facade on top of the Suzanne and Walter Scott Aquarium.

PHOTO © A. ZAHNER COMPANY
Profile of the completed wave facade on top of the Sea Turtle Cafe at Omaha's Henry Doorly Zoo.

Profile of the completed wave facade on top of the Sea Turtle Cafe at Omaha's Henry Doorly Zoo.

Photo by Alexandra Hoffman, ARKO | © A. Zahner Company
The face of the waves features a custom etched pattern that provides a reflective, rippling water effect.

The face of the waves features a custom etched pattern that provides a reflective, rippling water effect.

Photo by Alexandra Hoffman, ARKO | © A. Zahner Company
View of the Sea Turtle Cafe outdoor space at sunset with lighting.

View of the Sea Turtle Cafe outdoor space at sunset with lighting.

Photo by Alexandra Hoffman, ARKO | © A. Zahner Company
Various multi-color lighting systems were incorporated into the design to emphasize the aquatic theme at night.

Various multi-color lighting systems were incorporated into the design to emphasize the aquatic theme at night.

Photo by Alexandra Hoffman, ARKO | © A. Zahner Company

Decorative painted aluminum coral features adorn the edges of the café’s canopy and wrap the supporting columns. These were cut on our water jet before they were hand-rolled to the correct radius.


Custom-embossed blue stainless steel clads the walls of the Sea Turtle Café and mimics the look of rippling water. Zahner fabricated a custom die to create this seemingly random emboss pattern. This feature is further highlighted by the lighting throughout the space, creating a fully immersive experience for visitors.


Zahner also provided the various metal sea creatures that decorate the walls of the café and the entrance sign. Each sea creature was individually milled out of aluminum on our CNC equipment.

The dual-layered coral feaures were waterjet cut out of aluminum to clad the edge of the canopy.

The dual-layered coral feaures were waterjet cut out of aluminum to clad the edge of the canopy.

Photo by Alexandra Hoffman, ARKO | © A. Zahner Company

Custom rippled blue stainless steel clads the ceiling of the outdoor cafe to create an underwater feel to the space.

Custom rippled blue stainless steel clads the ceiling of the outdoor cafe to create an underwater feel to the space.

Photo by Alexandra Hoffman, ARKO | © A. Zahner Company

Custom milled sea turtles and starfish against the rippled blue stainless steel cladding.

Custom milled sea turtles and starfish against the rippled blue stainless steel cladding.

Photo by Alexandra Hoffman, ARKO | © A. Zahner Company
Zahner millled out several different sea creatures to decorate the walls of the cafe, including sharks, jellyfish, turtles, stingrays, and starfish.

Zahner millled out several different sea creatures to decorate the walls of the cafe, including sharks, jellyfish, turtles, stingrays, and starfish.

Photo by Alexandra Hoffman, ARKO | © A. Zahner Company
All elements of Zahner's scope are further emphasized at night time.

All elements of Zahner's scope are further emphasized at night time.

Photo by Alexandra Hoffman, ARKO | © A. Zahner Company
https://e5awgs3wuhi.exactdn.com/wp-content/uploads/2021/11/04095716/omaha-aquarium-c-alexandra-hoffman-arko-3585-gradient.jpg?strip=all&lossy=1&quality=92&webp=85&ssl=1 1920 2880 dsegard https://www.azahner.com/wp-content/uploads/2020/05/logo.svg dsegard2021-11-01 16:15:442022-07-05 16:12:57Suzanne and Walter Scott Aquarium

In The Fold

September 27, 2021/in Sculpture Walnut Creek--California HKIT Architects Norie Sato Brown, Grey, Orange, Red, Silver M 2020 Featured /by dsegard

Viamonte at Walnut Creek Senior Living Folding Fence

This artwork entitled “In the Fold” was designed by renowned artist, Norie Sato, for the new Viamonte at Walnut Creek Senior Living Center in California. Zahner was brought on early in the design phase and provided design assist, engineering, and fabrication services for this project.

The fence is over 62 feet long, and over 7 feet tall at each peak. Inspired by the art of origami, the fence is comprised of dual-sided “Frost White” anodized aluminum and dual-sided Zahner Solanum™ weathering steel panels that are alternately folded to provide depth and an intricate profile. The branches pattern in the aluminum panels was waterjet cut while the leaves pattern on the Solanum panels was created using our ImageWall® custom-perforation technology.

"In the Fold" art fence at Viamonte Senior Living Center in Walnut Creek, CA.

"In the Fold" art fence at Viamonte Senior Living Center in Walnut Creek, CA.

Photo by Kevin Shea

The aluminum and steel panels are alternately folded to provide depth and an intricate profile.

The aluminum and steel panels are alternately folded to provide depth and an intricate profile.

Photo by Kevin Shea
Straight-on view of "In the Fold"

Straight-on view of "In the Fold"

Photo by Kevin Shea
The branches pattern in the aluminum panels were waterjet cut.

The branches pattern in the aluminum panels were waterjet cut.

Photo by Kevin Shea
The leaves pattern on the Solanum panels was created using our ImageWall® custom-perforation technology.

The leaves pattern on the Solanum panels was created using our ImageWall® custom-perforation technology.

Photo by Kevin Shea
"In the Fold" has no front or back, and is made to be viewed from all angles.

"In the Fold" has no front or back, and is made to be viewed from all angles.

Photo by Kevin Shea
The fence is comprised of dual-sided clear anodized aluminum and dual-sided Zahner Solanum™ weathering steel panels.

The fence is comprised of dual-sided clear anodized aluminum and dual-sided Zahner Solanum™ weathering steel panels.

Photo by Kevin Shea
The detailed cutouts and patterns make for interesting and ever-changing shadows as the sun rises and sets.

The detailed cutouts and patterns make for interesting and ever-changing shadows as the sun rises and sets.

Photo by Kevin Shea
Designed by Norie Sato, "In the Fold" is more than 62 feet in total length, and over 7 feet tall.

Designed by Norie Sato, "In the Fold" is more than 62 feet in total length, and over 7 feet tall.

Photo by Kevin Shea
https://e5awgs3wuhi.exactdn.com/wp-content/uploads/2021/09/13111227/170180_Walnut-Creek-Folding-Fence-30-gradient.jpg?strip=all&lossy=1&quality=92&webp=85&ssl=1 483 864 dsegard https://www.azahner.com/wp-content/uploads/2020/05/logo.svg dsegard2021-09-27 12:57:362025-05-05 07:59:14In The Fold

Barnard College

July 21, 2020/in Exterior Architecture Education New York City SOM Brown L 2018 Featured /by Winifred Wright

Barnard College; New York, NY

Prominent in its upper westside location in Manhattan, The Cheryl and Philip Milstein Teaching and Learning Center is a new academic hub in the heart of the Barnard College campus. Designed by Skidmore, Owings & Merrill LLP (SOM), the 128,000 square foot building features a five-floor base plinth which transitions into a slim eleven floor tower that is aligned with the existing STEM facility of Altschul Hall.

Zahner supplied custom Baroque™ patinated zinc sheets, one of our custom-developed patinas available in the Zahner Surfaces collection. As Barnard looks to the future, the Baroque surfaces will age elegantly as the College continues in its role as a premier institution for women of intellect, ambition, and vision.

Facade for 178 North Eleventh with antique copper patina in Brooklyn, New York.

Barnard College Exterior Facade

ARKO

Facade for 178 North Eleventh with antique copper patina in Brooklyn, New York.

Barnard College Exterior Facade

ARKO

Facade for 178 North Eleventh with antique copper patina in Brooklyn, New York.

Barnard College Exterior Facade

ARKO

Facade for 178 North Eleventh with antique copper patina in Brooklyn, New York. ARKO
https://e5awgs3wuhi.exactdn.com/wp-content/uploads/2020/07/23154344/barnard-college-c-zahner-arko-9556-grayscale.jpg?strip=all&lossy=1&quality=92&webp=85&ssl=1 1666 2500 Winifred Wright https://www.azahner.com/wp-content/uploads/2020/05/logo.svg Winifred Wright2020-07-21 19:04:312021-06-23 14:28:14Barnard College

Bloomberg Center

December 30, 2016/in Exterior Architecture Education, LEED New York City Morphosis Gold, Green L 2017 Featured /by cmorris

Bloomberg Center at Cornell Tech

Bloomberg Center is the flagship building on Cornell Tech’s Roosevelt Campus in New York City. The Morphosis-designed building features a louver-perforated skin manufactured by Zahner. The double-skin facade fits into the building’s Net Zero energy plan to operate as a self-sufficient and energy-efficient building. The center is also targeting LEED Platinum Certification.

Related Post

Hacking a Robot to make Louvered Facades

In the Summer of 2015, Zahner’s ShopFloor team was tasked with developing several methods for louvered perforations to create picotage-effects for architectural metal.

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NonePhoto © A. Zahner Company.
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Detail of the louvered perforation patterns on color-shift iridescent painted aluminum panels.
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Perforation patterns on color-shift iridescent painted aluminum panels.
Image-perforated metal with color-shift iridescent painted aluminum.
Detail of the perforated metal facade during construction.
Color-shifting painted aluminum moves between bronze and green color-tones.
Color-shifting painted aluminum moves between bronze and green color-tones.
New Campus at Cornell.
Related Project

Gates Hall at Cornell

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.

https://e5awgs3wuhi.exactdn.com/wp-content/uploads/2020/07/24122132/1_cornell-roosevelt-island-courtesy-zahner-7378.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 cmorris2016-12-30 22:07:152021-07-26 10:46:53Bloomberg Center

The Petersen

August 15, 2016/in Exterior Architecture Automotive, Museum, Parking Structure Los Angeles--California Kohn Pedersen Fox Red, Silver L, XL 2015 Featured, Related Work /by cmorris

The Petersen Automotive Museum in Los Angeles, California:

Situated on Los Angeles’ famous Miracle Mile, the newly renovated Petersen Automotive Museum has achieved an iconic status while creating open spaces which invite community engagement. The design encases the building in a red-painted corrugated aluminum rainscreen system which acts as the backdrop for a series of stainless steel structural ribbons. These scopes were engineered, manufactured, and installed by Zahner.

Designed by Kohn Pedersen Fox (KPF) in New York with the construction management by Matt Construction in Los Angeles, Zahner was brought onto the project early on in the planning and development process. Starting under a Zahner Assist (Design Assist) contract, the construction team developed a fabrication and installation strategy with the engineers at Zahner.

This is the second project completed by Zahner with KPF. The two teams worked together prior on the IBM Headquarters in Armonk, New York.

IBM Headquarters at Armonk, New York. IBM Headquarters at Armonk, New York.
Related Project

IBM Headquarters

Nestled within a landscape of 450 wooded, rocky acres some 50 miles from Manhattan, the IBM World Headquarters exemplifies KPF’s demonstrated ability to respond to the natural context and produce an innovative work of architecture. Completed in 1997, the headquarters is the centerpiece of an existing corporate campus in this wooded setting with deep ravines slicing through the landscape.

Petersen Automotive Museum in Los Angeles, California.

PETERSEN AUTOMOTIVE MUSEUM IN LOS ANGELES, CALIFORNIA.

PHOTO © A. ZAHNER COMPANY.

Making the Petersen Automotive Museum

Design development for the Petersen Automotive Museum began in 2012. Principal Trent Tesch knew that the complex shapes would be best defined under a Design Assist contract with Zahner. Examining the forms gave the team an opportunity to approach their design with as much information as possible. Zahner Assist enabled KPF to bring the client into a conversation with Zahner.

Sharing models and preliminary drawings while the design was still conceptual allowed for conversations regarding costs and aesthetics to remain transparent, assisting the client during the decision making process.

The project made use of several Zahner technologies and methodologies: the ZEPPS Process for designing and manufacturing the building’s curved forms; the Angel Hair non-directional surfacing applied to each of the stainless steel skins attached to the curved forms; and Zahner Assist, Zahner’s method for developing complex projects into factory-produced realities. The project also includes an ImageWall custom perforated metal screen which continues the architect’s design, mimicking the stainless ribbons in a perforated metal graphic across the building’s parking structure. The Petersen Automotive Museum is the direct result of a design team confidently departing from convention.

Perforated metal screenwall by Zahner continues the Petersen Automotive Museum's sculptural motif.

PERFORATED METAL SCREENWALL BY ZAHNER CONTINUES THE PETERSEN AUTOMOTIVE MUSEUM’S SCULPTURAL MOTIF.

PHOTO © A. ZAHNER COMPANY.

Underneath the undulating ribbon facade of the Petersen Automotive Museum.

UNDERNEATH THE UNDULATING RIBBON FACADE OF THE PETERSEN AUTOMOTIVE MUSEUM.

PHOTO © A. ZAHNER COMPANY.

A perforated parking garage facade continues the stainless steel ribbon motif.

A PERFORATED PARKING GARAGE FACADE CONTINUES THE STAINLESS STEEL RIBBON MOTIF.

PHOTO © A. ZAHNER COMPANY.

Detail of the facade of the Petersen Automotive Museum.

DETAIL OF THE FACADE OF THE PETERSEN AUTOMOTIVE MUSEUM.

PHOTO © A. ZAHNER COMPANY.

Petersen Automotive Museum

PETERSEN AUTOMOTIVE MUSEUM

PHOTO © A. ZAHNER COMPANY.

Design Assist Mockup for the Petersen Automotive Museum.

Design Assist Mockup for the Petersen Automotive Museum.

Photo © A. Zahner Company.

Design Assist Mockup at dusk for the Petersen Automotive Museum.

Design Assist Mockup at dusk for the Petersen Automotive Museum.

Photo © A. Zahner Company.

The Mock Up as a Design Catalyst

As part of the Zahner Assist contract, we included a to-scale visual mockup. Mockups are included as part of this process in order to aid in design decision making and determine the best method for building any given form. The team selected the lower northeast corner of the building’s design to fabricate as a mockup section. This empowered the design team to determine how the ribbons would wrap around the corner, an integral aspect of the building’s design.

The mockup process provided Zahner crucial insight into how to best develop the red-painted structural steel armatures which are used throughout the project. The mockup also helped the design team establish the ideal color for the painted corrugated aluminum surface.

Zahner installers hang a ZEPPS Ribbon Assembly at the Petersen Automotive Museum.

Zahner installers hang a ZEPPS Ribbon Assembly at the Petersen Automotive Museum.

Photo © A. Zahner Company.

Zahner fabricators create the ZEPPS Ribbon assemblies for the Petersen Automotive Museum.

Zahner fabricators create the ZEPPS Ribbon assemblies for the Petersen Automotive Museum.

Photo © A. Zahner Company.

3D Model of a single ZEPPS Assembly for the Petersen Automotive Museum.

3D Model of a single ZEPPS Assembly for the Petersen Automotive Museum.

Photo © A. Zahner Company.

Zahner field installers at the construction site for the Petersen Automotive Museum.

Zahner field installers at the construction site for the Petersen Automotive Museum.

Photo © A. Zahner Company.

Creating the new Petersen Automotive Museum facade

The existing building, purchased by the Petersen Automotive Museum in 1994, was rectilinear and fairly straightforward in form. It was originally a department store. Six years after the store closed, museum founder Robert Petersen chose the site to house his automotive museum. Since the Museum is nearly devoid of windows, the site was ideal for safely housing Mr. Petersen’s collection without harmful exposure to sunlight.

Because the existing building contained very little glass and was box-like in form, it acted as a blank canvas for the design team. ZEPPS, the Zahner system for developing sculptural forms, was used to build curving stainless steel ‘ribbons’ which wrap the building, giving it a feeling of rapid motion. The result looks similar to the aerodynamic flow diagrams drawn in wind tunnel tests by automotive designers.

Using ZEPPS to Create Dual-Curving Forms

To build complex dual curving forms with the lightest structural loads, Zahner uses the ZEPPS process. ZEPPS stands for Zahner Engineered Profiled Panel Systems, and comprises Zahner’s approach to building complex, curvilinear forms. The crux of the system is the paring down of a complex design into manageable parts for manufacturing.

Using an architect’s 3D model, Zahner’s engineers examine geometry with a manufacturing mindset. Each curve is analyzed and developed into a series of patented aluminum structural components. These components are pre-assembled at the shop and compose the structural form for each ZEPPS Asssembly. Using aluminum extrusions rather than steel allows for a lighter load on the structure of the façade, and also allows for more economical fabrication methods.

The final step in creating with ZEPPS is to clad it in surface material. For the Petersen Automotive Museum, Zahner’s Angel Hair Stainless Steel surface was selected. After the structure is built, each ZEPPS is clad in the desired metal, and loaded onto a truck for field install. By breaking dual curves into units, ZEPPS creates precision within the manufacturing process, and allows for much quicker field installation.

Detail of the Petersen Automotive Museum's Angel Hair Stainless steel.

Detail of the Petersen Automotive Museum’s Angel Hair Stainless steel.

Photo © A. Zahner Co.

Petersen Automotive Museum in Los Angeles, California.

PETERSEN AUTOMOTIVE MUSEUM IN LOS ANGELES, CALIFORNIA.

PHOTO © A. ZAHNER COMPANY.

Roof of the Petersen Automotive Museum.

ROOF OF THE PETERSEN AUTOMOTIVE MUSEUM.

PHOTO © A. ZAHNER COMPANY.

View of Wilshire Blvd during the construction of the Petersen.

View of Wilshire Blvd during the construction of the Petersen.

Photo © A. Zahner Company.

Screenwall at the Petersen Automotive Museum in Los Angeles, California.

SCREENWALL AT THE PETERSEN AUTOMOTIVE MUSEUM IN LOS ANGELES, CALIFORNIA.

PHOTO © A. ZAHNER COMPANY.

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Underneath the Roof of the Petersen Automotive Museum.

UNDERNEATH THE ROOF OF THE PETERSEN AUTOMOTIVE MUSEUM.

PHOTO © A. ZAHNER COMPANY.

Structural Steel

A new structural steel exoskeleton was needed to carry the loads from the red corrugated rainscreen as well as the cantilevered stainless steel ribbons which arch over the rooftop to provide shading for a private event space.

Working with the designers’ 3D models, Zahner’s team of engineers developed a series of tree-like forms in structural steel to support the ZEPPS Ribbon assemblies. The structural steel skeleton was inspired by hot rod manifolds to serve the dual purpose of providing aesthetic cohesiveness as well as functional support for cantilevered elements of the design. The structural ‘trees’ support the ribbons that flow over the roof area, as well as the Fairfax Ave ground level ribbons.

The ZEPPS ribbons required custom curved structural steel within each unit. Zahner mapped out each curved radius using the 3D model, allowing for fabrication in the shop to be handled quickly and precisely.

Custom Corrugated Aluminum

Painted aluminum acts as the backdrop for the stainless steel ZEPPS forms, echoing the concept of a sports car in bright red intensity. The aluminum was completely custom, and unlike any standard corrugated pattern. The corrugated profile formed an exact 90 degree angle, versus the typical sine wave that is commonly seen in corrugated metals.

To accommodate for the custom nature of this design element, Zahner formed each of the corrugated panels in house, utilizing a custom die within the press brake.

ImageWall Screenwall for the Petersen Parking Enclosure

As a continuation of the stainless steel ribbons, the design team also selected a painted red aluminum ImageWall for the Museum’s Parking Garage. Using Zahner’s patented technology, ImageWall uses perforated holes to map an image across multiple panels. In this case, the image provides cohesiveness, and ties the parking garage in with the larger facade.

ImageWall Screenwall enclosing the Parking Structure of the Petersen Automotive Museum.

IMAGEWALL SCREENWALL ENCLOSING THE PARKING STRUCTURE OF THE PETERSEN AUTOMOTIVE MUSEUM.

PHOTO © A. ZAHNER COMPANY.

Detail of the screenwall facade of the Petersen Automotive Museum.

DETAIL OF THE SCREENWALL FACADE OF THE PETERSEN AUTOMOTIVE MUSEUM.

PHOTO © A. ZAHNER COMPANY.

Parking Structure Screenwall at the Petersen Automotive Museum in Los Angeles, California.

PARKING STRUCTURE SCREENWALL AT THE PETERSEN AUTOMOTIVE MUSEUM IN LOS ANGELES, CALIFORNIA.

PHOTO © A. ZAHNER COMPANY.

https://e5awgs3wuhi.exactdn.com/wp-content/uploads/2020/07/24112219/1_petersen-museum-c-zahner-tex-jernigan-8531.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 23:31:532025-05-05 08:14:56The Petersen

Grace Farms

August 15, 2016/in Exterior Architecture LEED, Worship Center New Canaan--Connecticut, Northeastern United States Handel Architects, SANAA Silver L 2015 Featured /by cmorris

The River at Grace Farms in New Canaan, Connecticut

Descending into a valley at Grace Farms in New Canaan Connecticut, The River consists of five volumes linked together by a single curving roof. SANAA designed the project with Handel Architects serving as the executive architect. The new building provides a sanctuary, library, court, commons, and pavilion, all under an aluminum roof by Zahner.

Zahner’s Design Assist team was brought into the project for their expertise in engineering and manufacturing systems for custom building envelopes. The panel system provides a subtle dual curvature, and yet consists of standard-sized sheets of exterior anodized aluminum. Zahner developed the roof in close collaboration with the architects, who provided feedback and requirements for its aesthetic performance.

“Our goal with the River is to make the architecture become part of the landscape. We hope that those who are on the property will have a greater enjoyment of the beautiful environment and changing seasons through the spaces and experience created by the River.”
— Sharon Prince, Grace Farms Foundation President.

The River at Grace Farms, in New Canaan, Connecticut

The River at Grace Farms, in New Canaan, Connecticut

PHOTO © A. ZAHNER COMPANY.

The building's reflective roof appears as a river below the feet of visitors on the hill.

The building’s reflective roof appears as a river below the feet of visitors on the hill.

PHOTO © A. ZAHNER COMPANY.

Roof detail for Grace Farms, designed by SANAA.

Roof detail for Grace Farms, designed by SANAA.

PHOTO © A. ZAHNER COMPANY.

The River at Grace Farms, exterior anodized aluminum.

The River at Grace Farms, exterior anodized aluminum.

PHOTO © A. ZAHNER COMPANY.

Wood panel ceiling provides a canopy for The River at Grace Farms

Wood panel ceiling provides a canopy for The River at Grace Farms

PHOTO © A. ZAHNER COMPANY.

A landscape painter at Grace Farms in New Canaan, Connecticut.

A landscape painter at Grace Farms in New Canaan, Connecticut.

PHOTO © A. ZAHNER COMPANY.

The Sanctuary at Grace Farms in New Canaan, Connecticut.

The Sanctuary at Grace Farms in New Canaan, Connecticut.

PHOTO © A. ZAHNER COMPANY.

Building at Grace Farms.

Building at Grace Farms.

PHOTO © A. ZAHNER COMPANY.

The River at Grace Farms, New Canaan, Connecticut

The River at Grace Farms, New Canaan, Connecticut.

PHOTO © A. ZAHNER COMPANY.

Profile of the roof detail at Grace Farms.

Profile of the roof detail at Grace Farms.

PHOTO © A. ZAHNER COMPANY.

The building's wooden soffit provides a contrast to its reflective aluminum roof.

The building’s wooden soffit provides a contrast to its reflective aluminum roof.

PHOTO © A. ZAHNER COMPANY.

Grace Farms roof winds its way up the hill.

Grace Farms roof winds its way up the hill.

PHOTO © A. ZAHNER COMPANY.

Grace Farms, designed by SANAA.

Grace Farms, designed by SANAA.

PHOTO © A. ZAHNER COMPANY.


Grace Farms, designed by SANAA.

Grace Farms, designed by SANAA.

PHOTO © A. ZAHNER COMPANY.

Grace Farms roof has a warm soffit manufactured in wood.

Grace Farms roof has a warm soffit manufactured in wood.

PHOTO © A. ZAHNER COMPANY.

Grace Farms, designed by SANAA.

Grace Farms, designed by SANAA.

PHOTO © A. ZAHNER COMPANY.

Creating the Grace Farms dual-curving serpentine Roof

To achieve dual curvatures and other complex shapes, many roof systems use ZEPPS, a Zahner system for achieving sculptural forms in architecture. However, for the Grace Farms project, the dual curvatures of the roof were subtle and didn’t require dramatic curves. So the engineering team at Zahner developed a light-weight system to achieve the shape, without the need for a custom ZEPPS specification.

The roof system was made by the use of several custom aluminum extrusions. These form a channel system between the aluminum skins. Within this channel, a floating aluminum plate snaps into place, which provides a smooth visual transition between the aluminum panels.


Details of the Grace Farms roof system during construction

Details of the Grace Farms roof system during construction

Photos © A. Zahner Company

None

One of the economic advantages of this custom roof system, is that it allowed for the use of a standard-sized aluminum plate, 20′ in length. The only custom roof panels required are along the roof’s edge, which were cut at custom angles to provide the roof’s contoured edge.

Zahner field installers were also involved in putting together the system, and provided feedback to the engineering team in Kansas City. The system was also simple to install, and provided flexibility for the field operators who put it together — flexibility without sacrificing aesthetics.

Detail of the panels to create the dual curve roof on Grace Farms.

Detail of the panels to create the dual curve roof on Grace Farms.

Photo © A. Zahner Co.

Installers place the structural steel supports for the Grace Farms roof.

Installers place the structural steel supports for the Grace Farms roof.

Photo © A. Zahner Co.

Roof detail for Grace Farms, designed by SANAA.

Roof detail for Grace Farms, designed by SANAA.

PHOTO © A. ZAHNER COMPANY.

The decision to allow the the aluminum roof panels to overhang the building’s edge created an intriguing aesthetic effect. Because of the way that the aluminum interfaces with the building’s edge, the spacing between panels becomes visible against the sky above. This void between panels is further accentuated by the shadows that they cast along the soffit. The shadow provides a kind of sun dial, creating diagonal marks across the building’s profile, visible in many of the photographs of the building.

The sliver of light which passes between the panel’s void provides a unique aesthetic effect, appearing as a sharp diagonal line between the shadows. This sunbeam’s angle changes as the sun passes across the sky.

Installers lay the panels to create the dual curve roof on Grace Farms.

Installers lay the panels to create the dual curve roof on Grace Farms.

Photo © A. Zahner Company.

Installers lay the panels to create the dual curve roof on Grace Farms.

Installers lay the panels to create the dual curve roof on Grace Farms.

Photo © A. Zahner Company.

Grace Farms was designed by SANAA with Handel Architects as its architect of record. Sciame managed the project, and Zahner engineering and manufactured the exterior roof system, coordinating the enclosure system with Dahill who provided the waterproofing for the roofing components.

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