Arena & Stadium

SoFi Stadium

June 11, 2021/in Exterior Architecture Arena & Stadium, Entertainment, Performance Center Inglewood--California HKS Silver, White XL 2020 Homepage Featured /by dsegard

SoFi Stadium is a sports and entertainment destination built in Inglewood, CA. Referred to as “unprecedented and unparalleled,” SoFi Stadium is the indoor/outdoor home of the Los Angeles Chargers and the Los Angeles Rams. SoFi will host a variety of events year-round, including Super Bowl LVI, the 2023 College Football Championship Game, and the 2028 Opening and Closing Ceremonies of the Olympic Games.

Designed by HKS, the 70,000-seat stadium also has a 6,000-seat venue and a 2.5-acre plaza, all of which are covered by a canopy of translucent ETFE membrane and 34,789 unique panels both in perforation and shape. Zahner’s expertise in perforated imagery (ImageWall®) was put to the test by HKS LINE and their image discretization algorithms/software. The panels were then manufactured by Zahner using a mass customization process developed in coordination with the architect.

THE INDEPENDENTLY-SUPPORTED CANOPY ALLOWS FOR WIND CIRCULATION, PROVIDES DIFFUSED LIGHTING, AND PROTECTS EVENT-GOERS FROM WEATHER.

HKS designed a unique canopy and skin for SoFi Stadium featuring custom-perforated anodized aluminum panels from Zahner.

PHOTO © NIC LEHOUX

ZAHNER PRODUCED 512 PANELS PER WEEK, OVER 67 WEEKS TO BE DELIVERED ON-SITE AND INSTALLED.

PHOTO © NIC LEHOUX

Zahner was brought on board to provide Zahner Assist, which allowed the architect to prove out their design and materials. As a result of the design team’s satisfaction, Zahner was ultimately chosen to furnish the outer shell scope of the stadium.

Drone view of the Frost White anodized aluminum front soffit of SoFi Stadium.

Photo by Jesse Pacheco, ARKO | © A Zahner Company

Drone Video

Custom Frost White Anodized Aluminum

During the Zahner Assist phase, Zahner was asked to develop an anodized finish with a white tint for the project, which did not exist in the market at that time. Using Zahner’s expertise in metallurgy, the Frost White anodized finish was developed specifically for SoFi Stadium. Due to its weight and strength, aluminum has a great benefit in many architectural applications. This finish was also applied to the 16 feet-long leading edge fascia of the canopy, which Zahner fabricated and supplied.

Closeup of Frost White anodized aluminum triskin panels.

The unique Frost White anodized finish on 1/8 inch thick aluminum panels has never been used before in any other project.

Photo by Jesse Pacheco, ARKO | © A Zahner Company

Drone view of the Frost White anodized aluminum front soffit of SoFi Stadium.

Photo by Jesse Pacheco, ARKO | © A Zahner Company

Mass Customization Through Digital Fabrication

Together with HKS, Zahner created a parametric design-to-fabrication workflow that streamlined production activities from the design model to the fabrication machine. On SoFi Stadium the promise of mass customization (part variation without additional cost) was realized through novel software automation and atypical project delivery methods.

A key to the production process was the transfer of design intent from the architect to Zahner. Instead of creating individual panel drawings (labor intensive to make and review), the architect provided ‘encoded’ text files with design intent for each unique panel. Zahner developed an automation script that automatically read each text file, nested each panel, and applied part specific fabrication parameters.

By virtue of this analysis, we were able to generate machine instructions directly from the design model, removing laborious tasks that traditionally add cost but not value. Ultimately this streamlined, collaborative process led to a drastic cut in the programming time for each panel from an unacceptable 15 min to an impressive 7 seconds per panel, managing the volume of unique panels efficiently and affordably.

Graphic showing the typical CNC fabrication method of one program producing 1000x parts.

Graphic showing Zahner's challenge of 10,000x programs producing one unique part per program.

This process fluidity is not typical in traditional production workflows where design and engineering tools are siloed from manufacturing tools. Here we wielded a computational dexterity common in the design/engineering software further downstream within the manufacturing process. The workflow allowed us to embed fabrication and sequence information directly into the CAD model during the design and engineering phase.

Included in the embedded information was an inscribed “dot code” on each panel, trackable via a custom app through the fabrication, shipping, and installation processes. This was a critical part of fabricating and shipping all 34,789 unique triskins under an expedited project schedule. Using this improved process, communication between architect, engineer, fabricator, and installer was seamless and the team was able to respond to project changes without incurring extra costs.

Project Timeline showing the reduction of computation and the growth of costs as a project progresses.

Single panel design with fabrication details and instructions.

Closeup of panel design details.

Closeup of the inscribed "dot code" used to track the panel through the fabrication, shipping, and installation processes.

Fabrication Process

The panels attach to a steel space frame, which attaches to the steel superstructure surrounding the stadium; along with the roof, this makes up the canopy. The independently supported canopy (separate from the stadium bowl structure) covers the stadium, allowing for wind circulation, diffused lighting, and protection from the elements.

Custom tooling was designed by Zahner for creating the softened edges around the perforations.

Underside of the support structure that forms the SoFi Stadium canopy.

The triangular panels attach to a support system, which attaches to the steel structure surrounding the stadium.

Pre-fabricated mega panel being installed into place on-site.

Zahner worker on site for the construction of SoFi Stadium.

Underside of the support structure that forms the SoFi Stadium canopy.

PHOTO © NIC LEHOUX

Rogers Place Arena

July 20, 2020/in Exterior Architecture Arena & Stadium Edmonton--Alberta HOK Silver L 2016 /by Winifred Wright

Rogers Place Arena; Edmonton, Alberta

Located in the heart of downtown Edmonton, Alberta, the Rogers Place arena is Canada’s first certified LEED Silver National Hockey League arena. Designed by sports architecture experts, HOK, the facility is home of the Edmonton Oilers and the Edmonton Oil Kings.

Zahner supplied 212,000 square feet of custom Angel Hair® stainless steel panels. Zahner also fabricated and supplied 380+ ZEPPS panels to form the geometric controlled edges of the curvilinear structure.

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

Okie Blanchard

December 9, 2016/in Exterior Architecture Arena & Stadium, Passive Security Cheyenne--Wyoming Davis Partnership Architects Silver M 2015 /by cmorris

Okie Blanchard Sports Complex

Designed by Davis Partnership Architects, the new stadium at Okie Blanchard Sports Complex features a unique metal panel system made by Zahner. The architects used the Zahner-patented ImageWall to generate and detail custom image-perf which form custom imagery of football motifs.

The custom system required a number of changes to the base ImageWall system, so the designers worked with ImageWall design team to develop their project. Using the ImageWall System, the architects were able to quickly iterate through a number of unique panel designs for the stadium.

Related System

Okie Blanchard

Additional Features of the Okie Blanchard System

One of the features of ImageWall which greatly increased the image quality across panels is the project’s use of Cross-Seam Perf. This is an innovation Zahner developed through the use of parametric design. Cross-Seam Perf comes standard with most ImageWall applications.

Most manufacturers of perforated metal don’t have a system capable of perforating across the seams, which means that each panel will have a picture-frame around the image. Punching the metal surface on both sides of the panels reveal gives the illusion of a continuous perforation across the metal surface without breaking each panel into picture frames.

The custom screen walls function as both passive security measures serving to prevent access under the bleachers while also providing a sports theme for stadium visitors.

Detail of the Okie Blanchard privacy screens.

Cross-seam perforation is a standard feature of ImageWall perforated metal.

In an effort to make room for a future junior high school on the campus, the sports and athletics program at East High School required re-planning and consolidation. Per master planning recommendations the much beloved original Okie-Blanchard stadium would need to be razed and replaced with a much-needed new facility. AVI, Inc. with Davis Partnership Architects was selected for the project encompassing 26-acres due to the team’s experience in outdoor athletics facilities and skill in incorporating natural topography into its designs.

Image output for the perforated metal used by ImageWall.

Cowboys Stadium

August 15, 2016/in Exterior Architecture Arena & Stadium Dallas--Texas HKS Silver XL 2009 /by cmorris

Dallas Cowboys Stadium

Designed by HKS, the Dallas Cowboys Stadium is among the largest in the world, seating 100,000 people. Zahner produced the stainless steel perimeter metalwork on the exterior and the interior of the stadium.

Due to the geometric complexities of these areas, HKS selected Zahner to produce the custom finished steel work. Zahner design-engineered the HKS entrance archway using ZEPPS, a system created for creating and manufacturing complex forms. Using the ZEPPS system allowed for fabricating structural sections that were easily installed.

“

HKS’s spirit of cooperation in providing leadership, design innovation, delivery and execution to our project superseded even my high expectations and helped bring our dreams to life. AT&T Stadium has proven itself not only as a football stadium, but as a venue for other sports and large entertainment events. It has been an instant hit – recognizable worldwide.

Jerry JonesOwner, President and General Manager, Dallas Cowboys.at

Ticketing & Giftshop at the Dallas Cowboys Stadium.

Detail of the stainless steel metalwork on the Dallas Cowboys Stadium.

Royals Crown

August 15, 2016/in Art & Sculpture, Exterior Architecture Arena & Stadium, Flagship Kansas City Populous Gold L /by cmorris

Royals Crown at Kauffman Stadium

The new Royals Crown at the Royals Ballpark was designed by Populous in two stages for the Kauffman Stadium. The golden structure was designed to crown the new vertical screen at the stadium, one of the largest screens of its kind in the world.

Zahner was responsible for engineering, fabricating, and installing the Kauffman Stadium Crown using gold interference-coated stainless steel. The metal skin of the interference coating is nearly iridescent, and gives the surface an additional bright sparkle.

This stainless steel also features a machine-indented surface. Imperceptible from a distance, this fine-bumped surface reduces the oil-canned appearance common among thin-gauged metal. Each of the spheres at the peaks of the crown are outfitted with hundreds of LED lights that light up for various effects and illuminate the night sky.

Related Project

Kauffman Stadium

The new structure at the Royals stadium features two sections which use selective perforations in stainless steel to create the image of the Royals logo on the surface of the metal. This perforated surface wraps the entire building, yielding a mesh facade which provides light, air control, and a visually intriguing artistic aesthetic.

Zahner has produced several projects using the interference-coated metal surface, including 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 Experience Music Project, The Meyer Fletcher Residence, and the Neiman Marcus in Natick, Masssachusetts.

Building the Kauffman Crown

The shop photos and CAD images above show the substructure used to build each of the spheres. These were produced using the ZEPPS Process, a system which uses an extruded aluminum substructure to assist in the creation of curving shapes and forms. The ZEPPS Process was developed to simplify the construction of curves on complex curvilinear buildings such as those designed by Frank Gehry and Randall Stout. The physical components used in this process can also be seen on the surface of the Zahner Headquarters building in Kansas City, which intentionally was designed to leave this substructure exposed.

The video below was produced by The Royals to show the way in which Zahner was involved in the production of the Royals Crown a massive Stainless Steel Crown which sits atop the new digital scoreboard and video screen.

The first stage of the Crown was completed in 2008. In 2010, Zahner added a reverse section to the Kauffman Stadium Crown, so that the substructural components would not be visible from the I-70 Highway which runs to the North of the Stadium. Zahner was also responsible for producing the perforated stainless steel Royal Logo facade at Kauffman Stadium. This section wraps around the sides of the stadium, and provides an additional visual aesthetic to the Royals Ballpark.

BOK Center

August 15, 2016/in Exterior Architecture Arena & Stadium, Performance Center Tulsa--Oklahoma Pelli Clarke Pelli Grey, Silver XL 2008 /by cmorris

Bank of Oklahoma Center in Tulsa, Oklahoma

BOK Center (Bank of Oklahoma) in Tulsa, Oklahoma is a nearly 20,000 seat multi-purpose arena for sports, concerts, and massive events. The project involved Zahner’s production and installation of several thousand Angel Hair stainless steel panels, each installed on a ZEPPS framework, the building block for complex architectural curves and highly efficient and accurate installations in architecture. The project called for 350,000 square feet of exterior metal panels.

Designed by César Pelli of Pelli Clarke Pelli, the project was managed by Flintco and Manhattan Construction, who called the BOK Center “one of the best architectural designs in their 100-year history of building projects.”

The city officials in Tulsa hired the architects to develop an arena that would be an architectural icon. Pelli Clarke Pelli used architectural themes of the city, developing a swirling aesthetic for the exterior and interior aspects of the building.

Stainless steel facade detail of BOK Center in Oklahoma.

Interior metalwork for BOK Center in Oklahoma.

Photograph of BOK Center during construction.

Basrah Sports City

August 15, 2016/in Exterior Architecture Arena & Stadium Asia, Basra--Iraq, International, Middle East HOK Brown L, XL 2012 /by cmorris

Sports City Stadium in Basra, Iraq

Designed by 360 Architecture (now HOK), the new Basrah Sport City Center is part of a larger sports complex that aims to boost the city as a sporting center in the Middle East. Zahner provided the perforated weathering steel exterior panels. Zahner also provided a number of interior metal surfaces.

The perforated steel was a pre-weathered Solanum Steel, a Zahner-manufactured weathering steel (corten) product. The product was designed for architectural projects requiring a stable finish and patina with minimal staining of adjacent surfaces.