Performance Center

Pritzker Pavilion

August 15, 2016/in Exterior Architecture Performance Center, Public Art, Urban Design Chicago--Illinois Frank Gehry Partners Silver L 2004 /by cmorris

Jay Pritzker Pavilion at Millennium Park

Pritzker Pavilion is a one-hundred-foot proscenium located at the North end of Millennium Park in Chicago. Designed by Frank Gehry Partners and manufactured with structural forms by Zahner.

The project consists of fourteen distinct forms, which visually appear as a cohesive whole. Each of these distinct forms is made using a straight stick steel primary structure. A secondary structure manufactured by Zahner attaches to the primary and is then clad in stainless steel by Zahner.

Each of these fourteen shapes serve to form the bandshell, providing protection from the elements while creating a focal point at the stage and orchestra pit of this dynamic outdoor amphitheater. Architects at Frank Gehry Partners began working with Zahner on this project in 1999, which was completed in 2004.

In total there were 697 prefabricated assemblies shipped to the jobsite. These assemblies were clad with over 3,000 stainless steel sheets measuring 2′ x 4′ on average. The sheets used for this project are 22ga Angel Hair finish on A316 stainless steel, a high performance stainless steel alloy containing molybdenum, a metal which provides high corrosion resistance for the metal.

The structure reaches a height of one-hundred twenty feet. In several areas, the structure curves back on itself, becoming nearly horizontal. The metal surface of this project is clad in stainless steel with a custom flat seam panel for dual curvature. The near-flat surface it creates, allowing the viewer to focus on the entirety of the shape rather than being drawn to the individual lines. According to an interview with the architect, the proscenium was inspired by Gehry’s 2001 flagship store for Issey Miyake in New York City, a sculptured titanium also made with Zahner.

Related System

Column Cover

Custom column cover systems provide decorative and functional aspects to both interior and exterior architectural design. Column cover manufacturing has been a mainstay of A. Zahner Company's production for several decades, producing both custom and standard systems for designers all over the world.

Zahner also completed all 24 of the 6′ diameter column covers. These enclose the green area of the park and provide support for the overhead lighting and sound cage over the park. These column covers consist of heavy-gauge stainless steel plate panels rolled to shape and attached with interior fastening system. The columns range in height from 12’ to over 24’ .

Each of the column covers is clad in a 10ga stainless steel, a heavier gauge than the 22ga stainless steel cladding the proscenium.

Point Pavilion

August 15, 2016/in Art & Sculpture Performance Center, Public Art, Sculpture Charleston--South Carolina BNIM Gold, Grey M 2004 /by cmorris

North Charleston Point Pavilion in North Charleston

The Point Pavilion at Riverfront Park in North Charleston, South Carolina is a fast-track work of public art designed by the architects at BNIM. Zahner design-engineered as well as fabricated and installed the entire system. This scope included the metal screens and hanging apparatus as well as the structural steel members which frame the artwork’s shape.

The client’s team used the Design Assist build method, meaning that Zahner played a collaborative role in the design’s development to reduce costs and improve the design’s efficiency and ease of construction. To facilitate structural analysis and fabrication constraints, Zahner developed a Building Information Model (BIM) which served as the entire project team’s BIM function for the duration of the project.

The main structure is made of 12” diameter galvanized steel pipe, rolled to a constant radius and cut to exact compound angles. The 3D model was utilized to produce templates of each cut. The welded frames were hot dipped galvanized post fabrication.

7/8” galvanized wire rope was strung between each frame to serve as a support for the perforated aluminum shading panels. The 3/16” aluminum panels were punched to a custom pattern as defined by the architect using custom perforation to reflect woven baskets that are indigenous to the region.

From initial concept to completed erection, the process took a total of six months. The entire process was streamlined to provide the maximum value to the client and to meet the project budget and schedule.

Detail of the Noisette metal panel system in North Charleston, SC.

Live performance at the Noisette Pavilion after completion.

Zahner's Tony Birchler and Wallace Engineering's Steve Huey test the structural load of the individual perforated panel mockup.

Weld inspection of the steel structure at Zahner headquarters in Kansas City.

Detail of the perforated aluminum plates on Noisette.

View of the shadows created by perforations from the aluminum panels overhead.

Structure of Noisette Pavilion, also designed-engineered and fabricated by Zahner.

Construction of Noisette as it nears completion.

View of the sky through Noisette's perforated aluminum panels.

Awards and Recognition

2005 — IPA Award for outstanding perforated metal
2006 — Illuminating Engineering Society of North America – International Illuminations Design Awards, Capital Section Award
2005 — AIA Young Architect’s Forum – Monsters of Design, Merit Award

New World Symphony

August 15, 2016/in Interior Architecture Performance Center Miami--Florida Frank Gehry Partners Blue, Green M /by cmorris

New World Symphony Bar Canopy

Designed by Frank Gehry Partners for the New World Symphony Orchestra, Gehry’s office was brought in by the client for their past work on musical venues such as the Walt Disney Concert Hall in Los Angeles for which Zahner provided Design Assist consultation.

The New World Center signified a transition for Gehry’s firm. While elements of his signature style can be found in various elements throughout, around, and even on top of the new building, the structure itself is simple.

Zahner’s involvement with the New World Symphony is particular to a architectural metal accent in the atrium of the new building. Zahner used a similar interference metal surface on projects such as Antoine Predock’s Tampa Museum of Science and Industry or Frank Gehry’s Experience Music Project.

However, neither of these projects has quite the blue-green tonality of the architectural canopy produced for the New World Symphony. This is because the material selected for the project is an unusual architectural metal. The project’s interior canopy is made in titanium, a surface which is known for both its expense, and its difficult workability.

Related Surface

New World Symphony

Creating the Curves of the New World Symphony Bar

This iridescent canopy presents a good example of how ZEPPS can be used to construct smaller architectural elements as well as art and sculpture. ZEPPS enables quick installation because the entire project is pre-engineered for smart installation, and it also provides the architects and artists with a digital model, allowing changes to be made via international conference meetings on the internet.

The New World Symphony Bar Canopy was broken down into buildable sections. Each of these sections is a ZEPPS Assembly, and these sections were small enough that installers could handle assemblies without the use of cranes.

Each of the ZEPPS assemblies was built and pre-connected in the Zahner shop. The ZEPPS forms are pre-skinned with an aluminum sub-surface, and then finished with Titanium skins and sealed in plastic to protect the surface from fingerprints.

CAD Image showing the totality of the bar canopy, viewed from above. ZEPPS&trades; Assembly sub-structure.

Fabricator in the Zahner shop grinds aligns ZEPPS® Panels.

Pre-assembled canopy, prior to skinning the titanium surface.

Two ZEPPS assemblies await installation.

Installing the New World Symphony Bar Canopy

The entire bar was pre-assembled at Zahner to test the connections and fit the blue-titanium skin surface. Then the ZEPPS assemblies where separated, packaged, and shipped to the New World Symphony Center construction site in Miami, Florida.

Related System

New World Symphony

The ZEPPS assemblies were designed to be small enough that interior installers could manage each section without the use of cranes. These assemblies are also lightweight due to the aluminum construction.

Zahner installers ensure the wiring is prepared for light fixtures.

New World Symphony Bar detail of irridescent titanium surface.

Zahner installers finish the titanium edges.

Detail of the finished titanium surface.

After installing the panels, field operators finish edges and connect gaps with additional smaller ZEPPS assemblies with the titanium skins.

Although Zahner was only involved in creating the interior metalwork, one of the most intriguing aspects of the symphony hall is the ongoing outdoor wallcasts, projected videos of performances for the general public. These outdoor events are free to the public, and have created a sense of community among Miami residents.

Kauffman Center

August 15, 2016/in Exterior Architecture Performance Center Kansas City BNIM, Safdie Architects Silver L 2011 Homepage Featured /by cmorris

KAUFFMAN CENTER FOR THE PERFORMING ARTS

The Kauffman Center for the Performing Arts is a project designed by Safdie Architects located in Kansas City. Zahner provided the stainless steel and substructure, which wraps the entirety of the facade and roof. This included the engineering, fabrication, and installation. Zahner also provided interior metalwork in key areas such as staircases and other architectural detailing on the building’s interior.

KAUFFMAN CENTER FOR THE PERFORMING ARTS CLAD IN GB-60 STAINLESS STEEL.

PHOTO © DRONE & FILM STUDIOS.

Zahner worked closely with the design team to develop the surface systems. The entire roof and metal wall-surface is clad in GB-60 stainless steel. Zahner developed this product to provide a muted reflectivity and resilience to the elements.

The internationally recognized design team assembled includes Moshe Safdie & Associates, BNIM Architects, JeDunn Construction, Theatre Projects Consultants, and Nagata Acoustics. Their design incorporates the very latest in architectural innovation and technology to create virtually perfect acoustics and optimal sightlines in both performance halls.

KAUFFMAN CENTER FOR THE PERFORMING ARTS CLAD IN GB-60 STAINLESS STEEL.

PHOTO © DRONE & FILM STUDIOS.

KAUFFMAN CENTER FOR THE PERFORMING ARTS.

PHOTO © DRONE & FILM STUDIOS.

Related Project

Fisher Center

The performance center was completed in 2003, designed by Frank Gehry Partners. Zahner has been involved with Gehry's firm since the beginning, and has been involved in a number of featured Gehry projects over the years. The Bard College was finished a year after Weatherhead at Case Western, and a year prior to the Pritzker Pavilion in Millennium Park, Chicago. All three were built using Zahner engineering-design, fabrication, and installation.

The design provides a 285,000-square-foot hall with two performance venues: the 1,800-seat Muriel Kauffman Theatre and the 1,600-seat Helzberg Hall. The first stainless steel panels were installed at the Kauffman Center the week of August 2nd, 2010, and the project was inaugurated September 16th 2011.

KAUFFMAN CENTER FOR THE PERFORMING ARTS.

PHOTO © DRONE & FILM STUDIOS.

Zahner installers set panels at Kauffman Center.

Photo © A. Zahner Company.

Installation of Kauffman Center interior metalwork by Zahner field operators.

Photo © A. Zahner Company.

Field operators install the ZEPPS™ Panels on the South roof of Kauffman Center.

Photo © A. Zahner Company.

A single ZEPPS panel for the roof system is hung at Kauffman Center.

Photo © A. Zahner Company.

Kauffman Center architectural paneling.

Photo © A. Zahner Company.

KAUFFMAN CENTER FOR THE PERFORMING ARTS.

PHOTO © DRONE & FILM STUDIOS

KAUFFMAN CENTER FOR THE PERFORMING ARTS.

PHOTO © DRONE & FILM STUDIOS.

Fisher Center

August 15, 2016/in Exterior Architecture Performance Center Kingston--New York Frank Gehry Partners Silver L 2003 /by cmorris

Richard B. Fisher Center for the Performing Arts at Bard College

The Richard B. Fisher Center for the Performing Arts is the latest addition to the Bard College campus. Featuring a curving roof and structure manufactured by Zahner, the building is nestled amongst the foothills of the Catskill Mountains.

The performance center was completed in 2003, designed by Frank Gehry Partners. Zahner has been involved with Gehry’s firm since the beginning, and has been involved in a number of featured Gehry projects over the years. The Bard College was finished a year after Weatherhead at Case Western, and a year prior to the Pritzker Pavilion in Millennium Park, Chicago. All three were built using Zahner engineering-design, fabrication, and installation.

Related Project

Weatherhead School

The 22 ga stainless steel surface resembles an undulating, unbroken ribbon. Finished in #4 satin, the surface is more reflective than Angel Hair or GB-60 but less diffuse than a mirror-finish.

Photograph of the setting sun on the Fisher Center at Bard College.

Creating the Surface of Fisher Center

Angel Hair stainless steel clads the entire surface of the secondary structure (which was also produced by Zahner, explained below). The stainless steel skins were lapped and fastened using a custom-engineered counter-sunk fastener. The finish of this surface is unlike any other surface in its ability to create muted tones, ambiently reflecting its surroundings.

The Richard B. Fisher Center Performing Arts Center at Bard College.

Detail of the Angel Hair stainless steel surface on the Fisher Center at Bard College.

Photographs of the Fisher Center at Bard College.

Photograph of the western entrance to the Fisher Center at Bard College.

Detail of the Angel Hair Stainless Steel and structural steel for Fisher Center.

Designing, Fabricating, and Installing with ZEPPS Technology

Working in CATIA and Pro-Engineer and utilizing Gehry Partners master model, Zahner developed a workable surface using the ZEPPS Technology to form the walls and roof of this dynamic set of structures.

Using the dual-curving panels made possible by ZEPPS eliminates several construction steps because it requires no additional supports or finishing due to its exclusively structural aluminum components. Over 3,200 stainless sheets were installed on top of 710 unique ZEPPS assemblies — each panel interlocks with the next to form the dynamic but uniform surface of the roof and sides.

Using the ZEPPS assemblies allowed the entire EIFS (Exterior Insulation Finishing Systems) wall and glazing to be embedded in the dual curving forms. This provided options for the interior wall surfaces of the building to closely mirror the exterior of the building. Along with EIFS walls and glazing, Zahner’s system formed the entire roof, wall and much of the building envelope for the performing arts center.

The panels consist of a high strength aluminum frame structure profiled to form the shape desired by the architect. Per the architect’s request, the interior side of the panel was left uncovered to expose the intricate framing members.

Fabricating the Fisher Center stainless steel and aluminum panels at A. Zahner Company in Kansas City.

History of Fisher Center: The Design Team looks at the dual curvature metal panel system at A. Zahner Company Headquarters | Bard College student sign 'Make huge silver crumpled buildings, not war.'

A. Zahner Company field crew install the panels at Bard College.

Construction photo of the south entrance of the Richard B. Fisher Center at Bard College.

Photo of the south entrance of the Richard B. Fisher Center at Bard College.

Photographs of the Fisher Center building and landscape.

Interior and exterior of Fisher Center, viewed through the massive glazing system on the front entrance.

The Bard College canopy is the first design by Frank Gehry Partners to leave the ZEPPS understructure exposed, a decision made to celebrate the complex construction that goes into buildings.

The engineers at Zahner and the architects at Gehry’s office enjoy a dynamic working relationship that continues to evolve and push the boundaries of what is possible to design and build. Learn more about how Gehry’s team works with Zahner to build complex buildings.

Festival of Arts

August 15, 2016/in Exterior Architecture Museum, Performance Center Laguna Beach--California, Los Angeles--California Bauer Architects Brown, Red, Violet M 2015 /by cmorris

Festival of Arts and Pageant of the Masters, Laguna Beach

Combining both natural and built elements from the surrounding environment, the Festival of Arts renovations link both the City of Laguna Beach with its surrounding canyon landscape. Zahner’s scope consisted of fabricating a series of five stand-alone wall sections, the tallest of which rises to nearly 20’. These act as both a decorative feature wall and a place-holder for signage regarding various events and exhibitions.

The existing concrete signage wall was demolished as part of the proposed renovation. Bauer Architects sought to reimagine the wall as art. They started with the image of tree branches, a link to the forested setting using the words of the philosopher Seneca, “All art is but an imitation of nature”.

For the perforations, a standard circular punch shape was used to create imagery of trees on the form’s copper surface. These shapes were then cut from the metal using a punch. When assembled in unison, the panels read as an entire image. To create additional texture and add rigidity to the panels, a series of embossed and debossed bumps were applied to the surface.

Related Surface

Festival of Arts

Growing a Stable Patina on Architectural Copper

The architects wanted to use a natural material with an aged look. Zahner’s Dirty Penny patinated copper was selected as the base material. This oxidized copper material was developed by Zahner to expedite the natural weathering process of copper. Rather than taking years to develop a rich, dark patina, the Dirty Penny process results in a stable patinated surface using a rapid chemical-based treatment. The panels for Festival of Arts were pre-patinated and shipped directly to the jobsite for installation.

The unsealed patinated panels will continue to age with time. The metal’s surface acts as a living protective barrier, similar to the way moss grows on stone. Unlike paint or anodization, which will deteriorate with time, the custom copper patina will continue to grow stronger as the surface oxidizes.

Manufacturing Accurately-Curved Architectural Forms

Creating the curvature for the panels proved to be a unique challenge. Some of the walls were derived from a single radius, while other sections included more than one radius in a single wall. All of these were tangent to one another. Due to the embossed and debossed bump pattern, the usual method of processing the entire sheet through a roll former could not be used. This compression would damage the bumps. Zahner’s solution was to crimp roll the top and bottom legs of each panel.

Crimp rolling the edges gave the sheets a gentle curve, but the process is not entirely precise. So to increase precision, Zahner also created a series of aluminum templates at the desired radius. Zahner was able to match the copper panels to the aluminum templates during the crimping process, resulting in a highly accurate architectural form.

The resulting geometry matches identically to the each of the radii provided in the architect’s model.

Simplifying the Concealed Attachments

Copper rolled angles were used as attachment hardware on the backs of each panel and fastened to existing mullions. In order to fit the curvature, these angles were also stretched to the appropriate radius. Coordination of fasteners to the copper rolled angles became key.

To disguise fasteners, Zahner assisted with coordinating the location for a series of aluminum “hats” on the mullions. Each piece of hat hardware lines up with a perforated hole. Fasteners were run through the perforations, to the back hardware. This allows for panels to be removed with ease, so that signage could be easily installed, and maintenance remains uncomplicated.

Designing concealed hardware is one of the advantages of using Zahner’s engineering and design team for projects like this. Contact Zahner to see what kinds of assistance we can provide for your project, or learn about how you can get your team started early with Zahner using Design Assist.

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.

Starlight Theater

October 21, 2010/in Art & Sculpture, Exterior Architecture, Interior Architecture, Landscape Architecture Historic, Performance Center Kansas City Gastinger Walker Harden Blue, Brown, Green, Red L 2000 /by cmorris

Starlight Theatre and Stagehouse in Kansas City

Zahner has been involved in a range of scopes for the Starlight Theatre in Kansas City, ranging from the roof and cupola turrets, as well as the Donor’s Circle completed with artist Dierk Van Keppel.

Starlight Theatre has a rich history, which dates back to 1925, when a Romanian Queen visited Kansas City. The city’s Federation of Music worked to bring a musical showcase which raised nearly ten thousand dollars, which began the movement for an outdoor theatre space. In 1951, construction was completed.

Building the Stagehouse for Starlight Theatre

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.

Starlight Theatre in Kansas City.

Photo courtesy of America’s Roof.

Photos of Starlight Theatre during construction.

Photo A. Zahner Company.

In addition to producing their own shows, Starlight began presenting major national tours in 2000 so they could bring more recent and contemporary Broadway musicals to Kansas City as well as share their productions with indoor theaters around the country. This increased production versatility has continued to make Starlight Theatre a summer favorite for residents and visitors alike.

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

Related Project

Starlight Donor’s Circle

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.

Zahner manufactured the roof, cupolas, and turret towers in raw unpatinated copper, also known as “red copper”. This material quickly went from the golden-orange tones above into a warm darker tone. This material will continue to patina, and one day develop into a green verdigris patina on the building’s roof.

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Jay Pritzker Pavilion at Millennium Park

Related System

Column Cover

North Charleston Point Pavilion in North Charleston

Awards and Recognition

New World Symphony Bar Canopy

Related Surface

New World Symphony

Creating the Curves of the New World Symphony Bar

Installing the New World Symphony Bar Canopy

Related System

New World Symphony

KAUFFMAN CENTER FOR THE PERFORMING ARTS

Related Project

Fisher Center

Richard B. Fisher Center for the Performing Arts at Bard College

Related Project

Weatherhead School

Creating the Surface of Fisher Center

Designing, Fabricating, and Installing with ZEPPS Technology

Festival of Arts and Pageant of the Masters, Laguna Beach

Related Surface

Festival of Arts

Growing a Stable Patina on Architectural Copper

Manufacturing Accurately-Curved Architectural Forms

Simplifying the Concealed Attachments

Bank of Oklahoma Center in Tulsa, Oklahoma

Starlight Theatre and Stagehouse in Kansas City

Zahner has been involved in a range of scopes for the Starlight Theatre in Kansas City, ranging from the roof and cupola turrets, as well as the Donor’s Circle completed with artist Dierk Van Keppel.

Building the Stagehouse for Starlight Theatre

Related Project

Starlight Donor’s Circle

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