Performance Center

Scottsdale Civic Center

Lake|Flato and Dig Studio collaborated with the City of Scottsdale to transform the Civic Center into a vibrant, family-friendly green space and premier event destination in Scottsdale’s Historic Old Town. Zahner provided engineering, fabrication, and installation expertise for key architectural elements, enhancing the park’s artistic and structural identity.

Surrounded by significant cultural and civic institutions, the Civic Center’s design connects the city, the arts, and the community in a unified space. The Civic Center features multiple pavilions, including a new multifunctional 360-degree event structure. These purposefully designed spaces come together to create a cohesive and welcoming environment.

Aerial view of the Scottsdale Civic Center.

Lighting emphasizes the sculptural qualities of the pavilions at night.

The perforations in the pavilions create dappled shade.

Eaves made of the same panel material as the pavilions creates an cohesive aesthetic.

Detail view of the pavilion structure during the day.

Detail view of one of the pavilions at night.

Aerial view of the multifunction event space.

Preservation Plaza

February 9, 2023/in Art & Sculpture, Exterior Architecture Performance Center, Public Art, Sculpture Arnolds Park--Iowa RDG Planning & Design Silver, White M 2022 /by Jeneane Dunlap

The Preservation Plaza Stage offers a one-of-a-kind concert setting with the backdrop of West Lake Okoboji’s blue waters glistening in the background. The desire by the Historic Arnolds Park Incorporation (HAPI) and RDG Planning & Design to transform the area into a permanent event space has been realized from what was previously a green space frequented by lake goers for events.

Through a Zahner Assist engagement, Zahner worked with RDG to develop and refine the 6,400 square foot amphitheater that resembles the lake waves above and wooden boat hulls below. Nestled within the structural steel bays are Zahner’s patented aluminum ZEPPS. The structure finishes out with custom finished stainless steel flat seamroof panels, painted aluminum perimeter fascia, and columns covers.

Incorporated within Zahner’s work is the phenolic soffit system underneath which required intricate coordination with the provider. Apart from the structural steel and phenolic system, Zahner self-performed the installation over the course of six months and the project was completed in September of 2022. The Preservation Plaza Stage offers yet another unique experience to the charm and delight of the area and serves as a cornerstone anchoring the park for enjoyment by future generations.

The Preservation Plaza Stage in Arnolds Park, Iowa.

PHOTO © A. ZAHNER COMPANY.

The preservation plaza creates a permanent event space within Arnolds park.

PHOTO © A. ZAHNER COMPANY.

THE PRESERVATION PLAZA STAGE IN ARNOLDS PARK, IOWA.

PHOTO © A. ZAHNER COMPANY.

THE PRESERVATION PLAZA STAGE IN ARNOLDS PARK, IOWA.

PHOTO © A. ZAHNER COMPANY.

Mockup stainless steel skins were created to determine the best finish

Stainless steel skin mockup for THE PRESERVATION PLAZA.

PHOTO © A. ZAHNER COMPANY.

Custom finished stainless steel skins.

PHOTO © A. ZAHNER COMPANY.

210012_Preservation Plaza_Skin Option 2_Close

PHOTO © A. ZAHNER COMPANY.

210012_Preservation Plaza_Skin Option 1_Close

PHOTO © A. ZAHNER COMPANY.

The Preservation Plaza Stage lights up the night

The Preservation Plaza Stage offers a one-of-a-kind concert setting.

PHOTO © A. ZAHNER COMPANY.

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

Starlight Donor’s Circle

January 11, 2017/in Art & Sculpture Performance Center, Public Art Kansas City Gastinger Walker Harden Dierk Van Keppel Gold, Silver S 2007 /by cmorris

Donor’s Circle at Starlight Theatre

In 2007, the Starlight Theatre added a Donor’s Circle designed with local glass artist Dierk Van Keppel. The Donor’s Circle for the Starlight Theater features stainless steel, glass and lighting elements in both the ceiling and floor of the outdoor patio.

Zahner engineers and artisans worked with Gastinger Walker Harden, with Bob Rohlf and the Starlight Theatre Association of Kansas City to engineer, fabricate, and install the artwork. The surface features glass cast by local Kansas City artist Dierk Van Keppel.

Related Project

Starlight Theater

In the late 1990s, they theatre company recognized a need to fortify For the Theatre's centennial, a new building was completed to improve that quality of productions which could be performed at Starlight. In 2000, Zahner was responsible for manufacturing the new roof system for the amphitheater. Named the Jeannette and Jerome Cohen Community Stage, the new stage also included a roof for Starlight theatre, and increased its technical capability, making it one of the largest roadhouses in the country.

Zahner manufactured the stainless steel memorial ceiling pieces as well as the inset floor and framework for the glass floor system. The stainless steel and floor medallions are etched with the inscription of “Anita B. Gordon Honorary Court”.

Detail of the metal ceiling system made for the Starlight Theatre Donor's Circle

Starlight Theatre Donor's Circle, featuring inset glass with floor and ceiling metalwork.

The metal base for the inset glass at Zahner HQ in Kansas City

Memorial ceiling before peeling the protective film from the stainless steel

NMSU Theatre

December 26, 2016/in Exterior Architecture, Interior Architecture Education, LEED, Performance Center Las Cruces--New Mexico Holzman Moss Bottino Architecture Silver M 2014 /by cmorris

Center for the Arts at New Mexico State University THEATRE

The Center for the Arts at NMSU Theatre is a design by Malcolm Holzman which includes a series of Zahner-manufactured custom railings. The new building is located at the corner of University Avenue and Espina Street.

The project, lead by Malcolm Holzman of Holzman Moss Bottino Architecture includes an earth-toned aesthetic with custom guardrail designs developed and manufactured by Zahner for the new performance and rehearsal center.

The three-story state of the art academic building is 59,000 gross square feet with a large performance space for theater and dance, which has an orchestra pit and trap room, orchestra level, two balconies and fly tower. The building also features a large rehearsal room, classrooms, office and back-of-the-house supporting areas.

Detail of the custom undulated steel curtains used on the Center for the Arts at NMSU.

Interior of the theater at NMSU Center for the Arts.

THE MARK AND STEPHANIE MEDOFF THEATRE

The building’s main auditorium, The Mark and Stephanie Medoff Theatre, is a 466-seat theater lined by 4 levels of balcony seating. These balconies were outfitted by Zahner using a metal curtain system developed for creating billowing aesthetics on a small scale.

INTERIOR BALCONY CUSTOM RAILINGS

Lining each of the theater’s balconies are a series of artistic guardrails developed with Zahner. These artistic guardrails served as a creative solution referencing the theater curtain. The design was developed with Zahner using the custom zinc-plated mesh, which was formed by hand and then stiffened using a galvanic cladding process.

EXTERIOR TERRACES CUSTOM RAILINGS

The building’s three exterior terraces are lined with the same custom guardrail design used for the interior balconies.

The building received a LEED Gold Certification. The New Mexico State University Center for the Arts was completed in 2012 for the New Mexico State Centennial.

Midland Theatre

December 15, 2016/in Art & Sculpture, Exterior Architecture Historic, Performance Center, Renovation, Restoration Kansas City BNIM Tom Corbin Gold, Orange S 1987 /by cmorris

Arvest Bank Theatre at the Midland

Midland Theatre is a historic 3,573-seat theater located in the Power & Light District of Kansas City, Missouri. The building was originally designed by Boller Bros, and has at various states been restored and renovated.

In 1987, Zahner was brought in by BNIM and and artist Tom Corbin to develop the custom architectural metal for the historic theater’s restoration.
Working from historic photographs, Zahner worked to carefully detail new fabricated components for the building’s metal marquee. Zahner artisans fabricated these parts in sheet brass and muntz, working to integrate the molded brass features cast by Tom Corbin in his foundry.
The end result is a golden marquee which resonates with the building’s original 1927 appearance.

Midtown Theatre Marquee restored to its 1927 appearance.

Restored Midland Theatre in the early 1990's.

Zahner fabricators put the finishing touches on the Midtown canopy

Detail of the cast bronze, brass and sheet Muntz Metal fabrication.

The Chrysalis

November 17, 2016/in Art & Sculpture, Exterior Architecture Performance Center, Public Art, Sculpture Columbia--Maryland Living Design Lab, Marc Fornes / THEVERYMANY Marc Fornes Green L 2017 /by cmorris

The Chrysalis Amphitheatre at Symphony Woods park

The Chrysalis is a multi-purpose pavilion, sculpture, and performance center designed by Marc Fornes with Living Design Lab. Zahner manufactured and installed the exterior structure and skin system.

The Chrysalis is made of tubular steel knit together to form a structure that houses a pavilion and stage for performances. It broke ground in September 2015 and was completed and opened to the public April 22, 2017.

With its name, The Chrysalis pays homage to the larval transitionary stage of a butterfly. With its form, The Chrysalis references the low-lying cypress tree seen in the eastern United States marshland. Its enormous roots provide the structural capability for a sweeping array of performances and events. As a building, the venue will attract larger productions while also providing an intimate space for smaller gatherings.

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Film of The Chrysalis at Merriweather Post Pavilion.

The Chrysalis at Merriweather Park in Symphony Woods.

Marc Fornes’ design for The Chrysalis was brought to life by a team which architects of record Living Design Lab and landscape designer Mahan Rykiel. included Whiting Turner, ARUP, Walters Group, and Zahner.

Located in the city of Columbia in Maryland, the sculptural work is nestled in the Merriweather Park at Symphony Woods. The new construction is placed adjacent to the Merriweather Post Pavilion, a performance center in Symphony Woods Park.

Aerial photo of The Chrysalis in Columbia, Maryland.

Detail of the painted aluminum shingles and structure of The Chrysalis.

Detail of the painted aluminum shingles at grade.

Stage of The Chrysalis in Columbia, Maryland.

Rear stairway at The Chrysalis in Columbia, Maryland.

Detail of the structural aluminum and curved steel pipe.

Engraved design and construction credits at The Chrysalis in Columbia, Maryland.

East elevation of The Chrysalis in Columbia, Maryland.

The Chrysalis nearing completion in Columbia, Maryland.

3D buildup of components for The Chrysalis.

Structural system for The Chrysalis during construction.

Wyly Theater

August 15, 2016/in Exterior Architecture LEED, Performance Center Dallas--Texas Kendall Heaton Associates, OMA, REX Architecture Silver L 2008 /by cmorris

Dee & Charles Wyly Theatre

Situated in the arts district of downtown Dallas, the critically acclaimed Wyly Theatre was designed by REX Architecture and Rem Koolhaas OMA. Heralded as one of the most intelligently conceived performance centers in the world, the Wyly is designed to accommodate traditional and experimental performances of music, dance, and cinema in a uniquely rigged space that rapidly transforms to meet various performance requirements.

Such a unique interior space called for a similarly unique exterior. Zahner provided the design, engineering, fabrication, and installation of the extruded anodized aluminum facade.

Related Project

Winspear Opera House

Zahner produced the canopy which covers the Winspear as well as the Strauss Square and Sammons Park. These two venues offer outdoor performances and projected shows.

Detail of the perforated aluminum lighting system for Wyly Theatre.

Wyly Theatre by REX Architecture & Rem Koolhaus OMA

Designing the Facade for Wyly Theatre

The architects contracted Zahner in a Design Assist process to develop a solution for the building façade. The process enables both the design and fabrication teams to solidify a clear design concept, increasing efficiencies before moving to the fabrication phase.

The concept for the Wyly façade began with an idea that, through design iteration and charrette, culminated in taking the idea one step further. The result is an extruded aluminum façade that emulates the billowing fabric of a closed curtain. Perforations in key areas allow for elegant lighting of the building’s signage.

As part of the Design Assist process, a mockup is produced to further aid in downstream planning. The mockup serves a critical function in each project, often revealing previously unknown insights and methodologies for efficient fabrication and installation.

Winspear Opera House

August 15, 2016/in Exterior Architecture, Interior Architecture Performance Center Dallas--Texas Foster & Partners, Kendall Heaton Associates Grey, Red, Silver L 2009 /by cmorris

Margot and Bill Winspear Opera House

The Winspear Opera House is one of five venues comprising the new Dallas Center for the Performing Arts. Zahner worked on several of them. Zahner was also responsible for the Wyly Theatre, directly across the street from the Winspear Opera House.

Zahner produced the canopy which covers the Winspear as well as the Strauss Square and Sammons Park. These two venues offer outdoor performances and projected shows.

Designing the Canopy

Zahner worked closely with the architect to develop a high-quality engineered surface that is easily installed and provides long-term performance. The Winspear Opera House canopy was designed as a solar shade by the architects at Foster.

Photograph of the Winspear Opera House at night in Dallas, Texas

The angles of the massive fins were determined by following the path of the sun. The design intent was to eliminate most of the direct sunlight on the Winspear Opera House and surrounding park, while increasing the ambient light underneath the canopy. Foster’s design creates a cooler microclimate around the building, and the canopy significantly reduces the energy requirements of the Winspear Opera House.

Winspear Opera House and Strauss Square outdoor performance space.

The Arts in all their many exciting forms are a bridge between people – Annette Strauss.

Detail of the Winspear Opera House aluminum canopy

Detail of the Winspear Opera House Canopy

The high-craft aluminum canopy has aircraft-grade connections and is engineered and fabricated with the highest design standards. The photographs show above show the artful design layout of the fins integrating into the canopy framework.

Interior Metalwork

In addition to producing the canopy which shades the entire campus of the Winspear, Zahner also engineered and fabricated the entrance desks in the theater’s lobby and atrium. These desks are produced using half-inch thick anodized aluminum.

Zahner fabricated three desks for the interior atrium, which serve as ticketing booths and winebars. Each of the desks feature high-quality connections that are completely hidden from plane view. The design is a slight curve which matches the general curvature of the interior layout.

The Winspear Opera House is adjacent to the Wyly Theatre in Dallas whose exterior surface was also engineered and produced by Zahner.

Suzanne Roberts Theatre

August 15, 2016/in Art & Sculpture, Exterior Architecture Performance Center, Sculpture Philadelphia--Pennsylvania Kieran Timberlake Gold, Red, Violet M 2007 /by cmorris

The Philadelphia Theatre Company’s dynamic Marquee signage

Completed in 2007, the Suzanne Roberts Theatre was designed by KieranTimberlake and features signage manufactured by Zahner.

Named for the former actress, playwright, and director, Suzanne Roberts Theatre is part of the initiative to enhance Philadelphia’s Avenue of the Arts. The building’s new marquee signage provides a striking statement about the quality of the arts program while maintaining the existing building and providing cover as an entrance soffit.

Related Project

Kieran Timberlake Office Stair

For the firm’s 63,000 ft² office, Zahner created a custom floating stairway. Connecting the entrance lobby and lab area with the office and meeting spaces, the painted red steel stairway is a feat of form and function.

Suzanne Roberts Theatre in Philadelphia.

KieranTimberlake contracted Zahner to provide engineering and fabrication for the dynamic shape of the facade signage. Working through an intitial Design Assist phase, the project was developed for digital fabrication.

To produce the sculptural form, the marquee was engineered and fabricated using ZEPPS Technology, the Zahner system for building complex, curving sculptural forms. The technology enables fast installation, installed in just a few assemblies. Each assembly is made up of structural aluminum fins and ribs which are prefabricated in the Zahner facility offsite. These assemblies were then clad in a number of sheet metal skinned surfaces. KieranTimberlake worked with Zahner to select a iridescent stainless steel surface which provides the sign’s unique coloring.