Exterior Architecture

NASCAR Hall of Fame

NASCAR Hall of Fame in Charlotte, North Carolina

A twisting stainless steel ribbon races around the perimeter of the NASCAR Hall of Fame in Charlotte, North Carolina. Zahner was brought into the project to build the structural form which wraps its facade. The building opened in May 2010, and it serves as a sprawling museum dedicated to racing and NASCAR history.

The building’s design was lead by architect Pei, Cobb, Freed. The firm envisioned a möbius strip-styled stainless steel roadway racing around the perimeter of the main building. The design of a möbius entails the concept of infinity, indicating a sort of infinite path for racing.

To create the building’s möbius required the design of a unique curvilinear shape. To produce this, Zahner engineers implemented the ZEPPS, the Zahner system for building unique architectural forms. Using ZEPPS enabled the architects to design and manufacture the building’s facade efficiently and within budget. It also enabled simple and straight-forward construction of an otherwise immensely complex shape.

The möbius is clad in Angel Hair stainless steel, a product developed by Zahner to reduce the glare and bright spots while providing a satin finish. Even in bright sunlight, the surface has significantly less glare than mill finishes on stainless steel.

Manufacturing the Unique Facade for NASCAR

The Museum went from design to completion in just over two years. The project’s expedient construction was due to good management by Turner BE&K, as well as a smooth design process.

The design and manufacture of the structural form of the stainless steel was provided by Zahner. Zahner engineers employed a Design Assist method to design the details of the ZEPPS forms.

These ZEPPS forms contain not only the shape and facade, but also electrical, lighting, insulation, and water-proofing. The intelligence of ZEPPS is twofold: you decrease the amount of rigid structural steel which doesn’t like to curve, and you automate aspects of the production of the aluminum forms. In the field, the construction crew receives numbered and pre-assembled parts.

The wall system that makes up the ribbon is constructed from aluminum panels that are approximately 8 foot in width. Wall heights vary with the tallest being in the region of 45 feet. By shipping these forms as preassembled units, the team was able to maximize efficiency in the shop, and maximize efficiency of installing the parts in the field.

“

“Zahner held to our budget, schedule, safety, and quality standards… The ribbon will indeed be the feature remembered by all who visit the NASCAR Hall of Fame. I highly recommend A. Zahner Company for any project which demands the qualities referenced above.”

Tom BarnettConstruction Manager at BE&K Turner Construction.at

A step-by-step process employed by Zahner included the method of splicing plates into specific dimensions and then joined together. Each panel is individually numbered, so construction knows exactly what spliced plate goes between designated panels.

CAD View of the moebius structure Zahner designed compared with the installed view.

Hanging a single NASCAR Hall of Fame ZEPPS Panel.

Detail of the metalwork also provided on the doors for the NASCAR Hall of Fame.

ZEPPS structure that Zahner designed and built for the NASCAR Hall of Fame.

Museum of Science and Industry

August 15, 2016/in Exterior Architecture Museum Tampa--Florida Antoine Predock Architect PC Blue, Silver L 1995 /by cmorris

The Museum of Science and Industry (MOSI) in Florida

Completed in 1995, this spherical theater is the key organizing element of the entire facility. Zahner was involved in the design-engineering, fabrication, and installation of several interior and exterior elements within the complex, including the lush blue reflective dome itself. Antoine Predock, the architect who designed MOSI, began working with Zahner design engineers early in the schematic phase to develop a curvilinear system that would support the project.

MOSI was the first project Zahner produced by Antoine Predock, and the first project by Zahner to include dual curvatures. This marked a turning point in the way that Zahner produces its metal surfaces. Zahner had just completed the Weisman Museum with Frank Gehry, one of the earliest projects with Gehry and Zahner. The demands on the metal surface were many, but none of compared to what the Tampa dome would require.

Aerial imagery of Tampa Museum of Science and Industry.

Detail of the MOSI dual curvature roof panel system during installation.

Manufacturing the complex facade for MOSI

The Museum of Science and Industry in Tampa introduced new hurdles for the performance of sheet metal on curvilinear buildings. The dome of the spherical shape of the dome would require the metal surface to curve in two directions at once, which is the definition of dual curvatures. Similar to a sheet of paper, metal sheets do not want curve in both directions.

To overcome this obstacle, Zahner and Predock developed a triangulated panel system which would allow smooth dual-curving of the metal surface. This project was completed a few years before Zahner would go on to influence the Zahner ZEPPS technology. This system provides both the structure and the surface. However, this project was pre-ZEPPS, and as such, the project was accomplished using a more rudimentary aluminum substructure.

Roof of the MOSI Dome in Tampa — Dual Curvatures.

Detail of the MOSI dual curvature roof panel system.

Detailed drawings of the dual-curving MOSI facade were made.

Detail of the MOSI dual-curvature dome panel system in Tampa, Florida.

The mirror-polish stainless steel used for the project was chosen by the architects to evoke the sky and waters of Tampa Bay, less than twenty miles from the museum. The reflective finish creates unexpected lush colors reflected from both the green grounds surrounding the building, as well as the range of tones seen in the skies.

The mirror surface of the museum creates opportunities for luscious sunset tones across the surface of the metal, as seen above. In this case, the triangular panelization of the metal creates visual interest by dividing up the reflected planes, much like pillowed glass or the oil-canning of metal.

Zahner’s expertise was also required for a few other aspects of the museum, including the perforated drop ceiling systems, the aluminum peepholes in the south elevation, and the museum shop which is clad in a reflective stainless steel surface.

Morimoto

August 15, 2016/in Exterior Architecture Restaurant New York City Stephanie Goto, Tadao Ando Charcoal, Grey S 2006 /by cmorris

Morimoto in New York City

A red curtain displaying traditional Japanese noren hangs in the custom entrance for the Morimoto, a Japanese restaurant in the Chelsea neighborhood of Manhattan. The facade, manufactured by Zahner in Kansas City, brings a custom touch to an otherwise standard shingle. Its blackened zinc patina on galvanized steel is both classic and modern, as is its corrugated facade.

The restaurant, named for and run by Iron Chef Masaharu Morimoto, is designed by Stephanie Goto and Tadao Ando. This upscale Chelsea bar and restaurant is just a few steps from the South end of the High Line Park in lower Manhattan.

Zahner produced the exterior, a blackened galvanized steel corrugating wall with a wide opening for its entrance. The facade’s matte appearance is a feature of its natural patina. The system that Zahner designed with the architecture team uses a face-fastener which add an industrial aesthetic.

Related Surface

Morimoto

MOCA Cleveland

August 15, 2016/in Exterior Architecture Museum Cleveland--Ohio Fashid Moussavi Architecture, Westlake Reed Leskosky Black, Blue-grey L /by cmorris

The Museum of Contemporary Art in Cleveland

The new Museum of Contemporary Art (MOCA) Cleveland comes from the architects at Farshid Moussavi Architects. The architects designed an elegant prism to house the museum’s collection in a new space that will maximize the 34,000 square foot structure. Zahner was brought on to provide complete facade services for the project, including design assist, engineering, fabrication, and installation of the building envelope & facade of glass and metal.

The design is deceptive in its complexity, appearing at first to be a hexagonal shape. When viewed from above, it becomes clear that the core of the structure is actually 92′ by 92′ cube. This addresses and resolves the common criticism that many of the newer museums with dynamic forms often face — that the space is not actually conducive for the display and viewing of art. This well-thought out museum brings the best of both worlds, with its visually striking design and ample space to display art.

The building’s hexagonal base gives the museum multiple entries, while the building’s square top lends itself to the museum’s rotating collection, allowing the space to be easily divided into flexible temporary spaces. Because the museum has no permanent collection of its own, it was important that the building’s interior lend itself to many different kinds of work.

Museum of Contemporary Art (MOCA) Cleveland.

Museum of Contemporary Art in Cleveland.

Zahner is closely involved with the construction of this shape and surface. Zahner produced a mock-up for the project in June of 2011 pictured below, and will work with the architects to translate the design of this intelligently conceived museum into an efficient and tightly engineered series of components.

TIMELAPSE OF THE MOCKUP FOR MUSEUM OF CONTEMPORARY ART CLEVELAND

FILM © A. ZAHNER COMPANY.

Design Assist for MOCA Cleveland

Zahner provided Design Assist services for the architect. This team of engineers developed the design into a fully defined facade system. The contract entails a design charette, engineering, and a manufactured mockup to test performance details.

This design assist contract enables designers to meet their aesthetic and performance goals, while also working within a prescribed budget. It also puts the owner in control of costs because the entire facade has been defined digitally.

To meet the budget and design constraints required for the project, the team developed a mega-panel; pre-fabricated panels comprised of the finished interior skin, insulation, structure, sheathing, and waterproofing in a single unit.

The Cleveland MOCA’s smart angular design requires a highly engineered and crafted surface. In many ways, the building is as complex to build as some of our more curvilinear projects. The tight corners and edges have acute tolerances, leaving little wiggle room.

During May and June 2011, DAG and Operations teams worked with the architects to produce a mockup. This mockup served as a reference point for the design decisions as the project rolled out into production.

Photograph of the MOCA Cleveland nearing completion.

The mockup was built to simulate a corner-section at the top of the building. The mock-up for MOCA Cleveland was completed in June of 2011, and a few images of the architects’ visit are featured below.

Photograph of the MOCA Cleveland Mockup at Zahner.

Farshid Moussavi speaks with Zahner engineers about the MOCA Cleveland Mockup.

MOCA Cleveland Mockup during the FMA Visit.

Detail of the reflected sky in the MOCA Cleveland Mockup.

The material that was selected for this is a seductive dark mirror-polish stainless. Zahner has used a similar finish on a few projects, including a Libeskind-designed residence in the northeast United States. This metal surface is essentially a dark-tinted mirror, reflecting a darker image of its surroundings with perfect mirror accuracy, and imbuing the imagery of the sky and general surroundings on its dark polished surface. The image immediately above shows a detail of the reflected surface of both the inset glazing and the slightly darker reflective metal surface. The Zahner product that enables the flush glass and metal surfaces is called the Inverted Seam™ Glass System.

The building’s upward design was calculated to minimize distraction from reflected surfaces. The design was also tested using computer-modeled simulations of the sun as it arcs across the sky to prevent unwarranted glare and hot-spots.

This is the first museum by FMA, and its first major structure in the United States. Production is slated to begin late 2011, where the operations team and union artisans will begin the process of in-house fabrication and assembly. The custom-designed parts that result from this process are numbered, categorized, and shipped for rapid installation during the final phase of construction on-site. The $26.3-million project is part of a major redevelopment of Cleveland’s uptown area by Case Western Reserve University and MRN, Ltd. as well as others to revitalize the area. The project is managed by Donley’s in Cleveland, and is scheduled to break ground in late 2011.

MIT Stata Center

August 15, 2016/in Exterior Architecture Education Cambridge--Massachusetts Frank Gehry Partners Blue, Yellow XL 2004 /by cmorris

The Ray and Maria Stata Center at MIT, Building 32

Designed for the Computer, Information, and Intelligence Sciences programs at MIT, Frank Gehry and his architectural team at Gehry Partners envisioned a sprawling academic complex of visually amorphous structures which provide a combination of study and social space for students. The project is comprised of 47 unique elements, using a variety of materials, from brick to glass and architectural metals.

Zahner developed the geometry and cladding the structure with rain screen panels in stainless steel, aluminum, and titanium. As the facade provider, Zahner designed the structural forms to match the designer’s aesthetic, fabricated the forms, skins, and window units, and installed the facade onsite at the Cambridge, Massachusetts campus.

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.

Designing the Building Envelope for Stata Center

Because of the complex nature of the project, the designers used ZEPPS, Zahner’s structural system for building complex forms. Using ZEPPS allows the engineers to simplify the design into buildable components using 3D fabrication processes. Parts were then assembled either at the Zahner shop or in the field depending on their complexity and ease of shipment.

An onsite team of installers lifted and secured each ZEPPS assembly. In total there were 1,500 individual ZEPPS assemblies manufactured for the project. Each of these assemblies was lifted into place for this project and then surfaced with a metal skin in one of several specified metal surfaces. More than 10,000 individual skins were installed to the surface and roof.

One of the distinct advantages of the ZEPPS is that it allows fully functional window boxes, over six feet in height, to be pre-installed on these panels. For that reason, the system is often described as prefab for custom buildings.

Detail of the flatseam panel system for Stata Center at MIT.

Facade installers in their office at MIT.

Detail CAD comparison of the Giraffe building at MIT Stata Center.

Interior metalwork, mirror-polish stainless steel flatseam panels at MIT.

Mockup for one of the buildings at MIT Stata Center.

Construction comparison of the MIT Stata Center giraffe building.

Aerial photograph of MIT Stata Center during construction.

Sunrise glows over the Pisa building at MIT Stata Center during construction.

Vista building at MIT Stata Center during construction.

Twins building during construction revealing the ZEPPS panel understructure.

The Twins building at MIT, installation detail.

Michigan Avenue Plaza

August 15, 2016/in Exterior Architecture Renovation Chicago--Illinois FGM Architects Red S 2008 /by cmorris

Michigan Avenue Plaza in Chicago, Illinois

The addition of a bold red canopy to the decades-old Boulevard Towers at 225 Michigan Avenue has provided the buildings with a new distinctive basing in the Chicago architectural landscape.

While the buildings’ original design was completed in the early 1980’s by Fujikawa Johnson Associates (FJA Architects), this project was conceived as a renovation in the early 2000’s designed by FGM Architects.

Zahner was brought on to design and engineer the system, as well as providing the manufacture and installation of the prefabricated components of the distinctive red awning. Fabricated in aluminum panels with a red protective enamel coating, the understructure is made possible by a lightweight ZEPPS framework of preassembled panels.

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.

The red aluminum canopy for Michigan Avenue Plaza in Chicago.

The new addition of new crimson canopy was imagined by FGM Architects and made possible by a design team including A. Zahner Company, H+P Engineering, and Reed Construction for the client MB Real Estate in Chicago.

Related System

Canopy

Custom canopies fabricated with Zahner engineering benefit from high-quality craft and attention to detail. Zahner engineers work with designers and contractors to develop integrated systems which meet a range of desired aesthetics, from historic restorations and filigree to contemporary geometric forms.

Construction photo of the Michigan Avenue Plaza awning in Chicago.

Construction photo shows a man standing on the top of the Michigan Avenue Plaza awning in Chicago.

View of the red painted aluminum canopy from Michigan Avenue in Chicago.

Detail of the Michigan Avenue Plaza canpopy ceiling panels.

The canopy continues into the building's interior lobby, where an interior lighting system was integrated.

Detail of the recessed lighting system detailed in the aluminum canopy's interior ceiling panels.

Miami Intermodal Center

August 15, 2016/in Exterior Architecture Transportation Miami--Florida Perez & Perez XL 2012 /by cmorris

Metro Rail & Bus Canopy at the Miami Intermodal Center (MIC)

The Miami Intermodal Center is a multi-transit hub serving the Miami Dade International Airport. The transportation project features Zahner manufactured and installed structural forms (ZEPPS) made in aluminum, glass, and stainless steel.

Designed by architects Perez & Perez, the construction team brought Zahner into the project to engineer, fabricate, and install the transit station’s exterior canopy. Zahner worked under Odebrecht of Brazil to produce this extensive project, completed in July 2012. The scope for Zahner includes the metal and glass for the metro rail canopy as well as the adjacent bus canopy.

The most visible aspect of the project is the unique curving train canopy whose window slits glazed-in throughout the whole. The multi-million dollar contract required much of the Zahner fabrication facility for nearly a full year of manufacturing the hundreds of massive ZEPPS assemblies for nearly a year.

Miami Intermodal Center wins Engineering Award

Italian firm Rizzani de Echer fabricated and installed all segmental bridges. The design of the three-level Metrorail station—which features glass fabricated in Colombia—caught the attention of ENR’s judges, with one calling it “visually stunning.” Zahner provided the engineered structure and surface, fabricating and installing the components for the Miami Intermodal Center at the Airport.

Photograph of a train leaving the Miami Intermodal Center.

Miami Intermodal Center metal clad ZEPPS® panels with Angel Hair® Stainless Steel.

Interior metalwork underneath the MIC Canopy.

Zahner used ZEPPS to manufacture prefabricated assemblies which were shipped to Miami. ZEPPS, is a Zahner building system for manufacturing unique forms. The prefab technology streamlines and maximizes efficiency for the construction of any unique design. It also provides flexibility and can be used to manufacture parts with all of the electrical, insulation, water-proofing, and fenestrations contained.

Related System

Miami Intermodal Center

The Main Canopy is composed of 156 ZEPPS assemblies. Each of these parts were preassembled in the Zahner shop. The semi-typical assemblies measure over forty feet long. The total length of the building is just under five-hundred feet in length.

The ZEPPS assemblies were tested and re-tested in a wind-tunnel at 150PSF to withstand 250MPH winds, or nearly twice that of a category five hurricane. The Miami Intermodal Center is situated just a mile from the airport, which is less than ten miles from the Atlantic ocean, so the potential for a hurricane is real possibility. After the panels were tested, each of the subsequent panels produced were designed and built using these specifications.

Each assembly provides a substrate for the stainless steel skins which provide the final cladding. These are finished with Angel Hair diffuse surfacing, which creates a gentle glow on the metal surface of these canopies.

Zahner shop welder tack-weld components on an assembly for Miami Intermodal Center.

Zahner Shop floor during the production of Miami Intermodal Center

Zahner field operators install the ZEPPS® Assemblies on the adjacent bus canopy.

McMurtry Building

August 15, 2016/in Exterior Architecture Education Stanford--California Bora Architects, Diller Scofidio + Renfro Brown, Orange L 2015 /by cmorris

McMurtry Building for the Department of Art and Art History

A work of architecture which both matches the surrounding aesthetics and yet stands out as an icon of its own, the McMurtry Building is a unique architectural project in Stanford, California. The structure features Zahner craftsmanship in both its custom patinated zinc facade and the courtyard’s grand stairway.

The McMurtry Building was designed by Diller Scofidio + Renfro whose design team worked with executive designers Boora Architects to bring this 100,000-square-foot project to fruition. The building was named for donors Burt & Deedee McMurtry who contributed over a third of the building’s costs. The campus building brings studio art, design, art history, film, and media studies together under a zinc roof.

Zahner’s scope required a unique warm-toned brown patinated zinc, which would encompass the roof, facades, soffit, and other areas of the building. Zahner developed this preweathered patina on zinc in multiple variations as part of the Design Assist process.

During the development of details, three final ‘color’ options were presented in mockup form. The architect then narrowed the selection down to the finalized stable patina option. The chosen patina has a rich brown hue, interspersed with variegated grey and umber. The tone defines the McMurtry Building.

McMurtry Building in Stanford, California, designed by Diller Scofidio + Renfro.

McMurtry Building interior gathering area for students.

About the McMurtry Building’s Design

The building’s design includes stacking cantilevered forms, broken by a sloping diagonal on both the east and west sides. This balanced criss-crossing of elements divides the various disciplines within its space.

In a speech delivered at the McMurtry Building groundbreaking, principal-in-charge Charles Renfro expounded on the building’s unique design approach. He describes how the two interwoven ‘strands’ influence the building’s form. The strands divide as well as unite the building’s two wings. At one end, classrooms serve as a clean learning space, and at the other, artist studios provide a work area. The strands come together the building’s rooftop communal space, and again the spaces are united at the ground floor library for art and architecture.

The strand of the southern wing is clad in preweathered zinc. Zahner performed the design-engineering and manufacture of the zinc aspects of the McMurtry Building. Zahner also performed the installation of zinc panels and metalwork, working to ensure a high-quality product for the architect and client.

McMurtry Building for the Department of Art and Art History.

Detail of the Zinc panels on-site at the McMurtry Building in California.

Detail of the custom zinc ceiling corner and facade for the McMurtry Building in Stanford, California.

The soffit area is detailed with a preweatehred custom zinc with custom panel-patterns.

Detail of the cantilevered facade with custom-patinated zinc metalwork, on the McMurtry Building in Stanford, California.

Creating a custom roof and facade with Design Assist

Before making the actual facade and roof panels, Zahner was selected to design-engineer the exterior cladding systems. Hiring Zahner through a separate Design Assist contract, the architects were able to solidify the design details before building the actual project.

As part of the Design Assist contract, Zahner also provided multiple mockups for the zinc rain screen. The final mockup was installed just North of the actual McMurtry Building on the University campus. This mockup focused on many of the most difficult and complex aspects of the facade, soffit, and roof. By creating a mockup, the entire project team was able to predict and better develop the final product.

The McMurtry mockup was installed on-site in Stanford, California.

Patina technicians in the Zahner Dallas facility create the custom patina on zinc.

The building's cantilevered form highlights the rooftop area's custom patina on zinc.

Detailed of the corner where the zinc facade meets the zinc soffit.

Custom zinc ceiling soffits and staircase at the McMurtry Building in Stanford, California.

The McMurtry Building's cantilevered forms (zinc panels across the top).

Detail of the custom zinc interior atrium staircase at the McMurtry Building in Stanford, California.

Custom zinc ceiling soffit for the McMurtry Building in Stanford, California.

Detail of the zinc ceiling soffit and recessed lighting.

Detailed metalwork uses Zahner's preweathered custom zinc patina.

West side of the McMurtry Building, detail of the copper-toned patina on zinc.

Detail of the east utility area. The zinc provides an alternative to cor-ten weathering steel.

Cafe on the east side of the McMurtry Building in Stanford, California.

Utility area of the McMurtry Building in Stanford, California.

Detail of the corner edge of the zinc facade and soffit.

Zinc roof with a custom patina, McMurtry Building in California.

The McMurtry project is among several projects featuring Zahner manufacturing at the University campus. Zahner also worked on the WRNS-designed Hoover Garage which is located just a few minutes from the the McMurtry Building.

McCoy Federal Building

August 15, 2016/in Exterior Architecture Government, LEED, Passive Security Jackson--Mississippi CDFL Architects, Hargreaves Associates, Schwartz/Silver Blue, Blue-grey, Grey, White M 2013 /by cmorris

Dr. A.H. McCoy Federal Building Modernization

This upgrade to the McCoy Federal Building includes infrastructure additions to the main building and an ancillary building which serves as a security entrance to the main structure. Designed by Schwartz/Silver architects, Zahner provided the glass facade design along with its structural support system.

In 2010, the General Services Administration (GSA) commissioned Schwartz/Silver to upgrade the McCoy Federal Building Courthouse and GSA Facilities in Jackson, Mississippi. Zahner was brought on to construct the building envelope for the structure, under design assist contract. Zahner provided engineering, fabrication, and installation of the curving glass facade in addition to the various architectural metal surfaces.

McCoy Federal Building in Jackson, Mississippi.

Glass and steel extrusions, each 10 to 25 feet long, thread into ZEPPS Sections to hold 1,078 lites of glass for the design by Schwartz/Silver for the Jackson, Mississippi Federal Courthouse and GSA Building. Locked into place by over 2,000 quills of varying heights, almost every single lite of glass is unique; the lites vary in width and height as specified by Zahner engineering and programming specialists.

New building codes designed to protect sensitive buildings and airports require security check-ins to be performed in a separate building. The addition to the McCoy Federal Building will also improve various functionalities and accessibility, as well as marketability for the value of the property and those around it, a benefit of its use as an example of passive security. It also is suggested that the building will help continue to improve the community interest in the downtown neighborhoods by freshening the street-level image of the Federal courthouse and the downtown area.

The project was completed in 2013, and is LEED Registered and slated to receive LEED Silver certification from the United States Green Building Council.

Panoramic view of the GSA Building in Jackson, Mississippi.

Night view of the glass lites on edge at the McCoy Federal Building.

McCoy GSA Federal Building at dusk in Jackson, Mississippi.

South view of the McCoy Federal Courthouse GSA in Jackson, Mississippi.

ZEPPS understructure visible as Zahner field operators prepare to install the lites of glass.

Zahner Field Operators install clips on the ZEPPS structure.

Detail of the McCoy Federal Building at the Zahner Headquarters.

Mockup for Schwartz/Silver architects at the Zahner Headquarters.

Zahner CAD rendering of the McCoy Federal Building.

Lumenhaus

August 15, 2016/in Exterior Architecture Education Blacksburg--Virginia Virginia Tech Architecture Program Silver S 2011 /by cmorris

Herzog & de Meuron have developed a number of projects with Zahner including three major works. Based in Switzerland, Herzog & de Meuron is a partnership led by Jacques Herzog and Pierre de Meuron with Senior Partners Christine Binswanger, Ascan Mergenthaler and Stefan Marbach.

Architects come to Zahner for the company’s commitment to developing the designer’s aesthetic to completion. Zahner worked with Herzog & de Meuron to develop their design into custom architectural systems, featured below.

Lumenhaus Solar Pre-fab Housing Unit from Virginia Tech

Lumenhaus is an portable housing concept designed and built at Virginia Tech School of Architecture + Design as part of its ongoing architectural research program. Inspired by the Farnsworth House by Mies Van Der Rohe, the north and south walls are all glass, maximizing the owner’s exposure to bright, natural daylight. The fully automated Eclipsis System, comprising independent sliding layers, permits a revolutionary design in a solar-powered house, while filtering light in beautiful, flowing patterns throughout the day.

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.

Dusk photograph of Lumenhaus, Virginia Tech.

Exterior detail of the Lumenhaus facade.

Creating the Lumenhaus Facade

Zahner worked with Virignia Tech to develop the facade system, providing the engineering and fabrication for the project as part of the patented ZIRA™ System for perforating facades with custom patterns and imagery. Instead of adjusting the size of the perforation to create the metal image pattern, Lumenhaus was designed to create unique imagery through changing the angle of the protruding tab. By louvering the perforation, the visual contrast is increased between the negative dark areas and the light-capturing tabbed areas.

This is the third solar house designed and built at Virginia Tech, but it is the first to win international recognition and press. In 2010, the project won the International Solar Decathlon Competition in Madrid, Spain. In January, 2012, it was announced that the Lumenhaus has won a 2012 AIA Honor Award for Architecture. This is the first time this award has been given to a university team.

Photograph of the Lumenhaus facade for Virginia Tech.

Photograph of the Lumenhaus facade at Dusk.

Interior photograph of the Lumenhaus showing the facade and eclipsis system video.

Rooted in the design principles of the Bauhaus, the project imbues 21st century technologies to create a dynamic living situation. The entire mechanics of the house are controllable via mobile phone, so the hand-held phone becomes a remote control for the many features of the house. This Eclipsis System includes a automatic sliding screen-wall engineered and manufactured by Zahner.

Where most energy-conscious houses are closed with strategic openings to resist heat transfer, Lumenhaus has open, flowing spaces linking occupants to each other within the house and to nature outside.

The design served as both aesthetic and function, a compelling surface that filters the harsh rays of the setting sun while letting in ambient light throughout the day.