Exterior Architecture

Columbia University

August 15, 2016/in Exterior Architecture Education, Highrise, LEED New York City Moneo Brock Studio Grey L /by cmorris

Columbia University Northwest Corner Building

Completed in 2010, the Northwest Corner Building was developed by Columbia University for the beginning of their campus expansion on the upper-west side of Manhattan, New York. The design by architect Rafael Moneo features an extruded aluminum facade, a system that was designed-engineered and fabricated by Zahner for the cladding of the structure.

The building’s engineering is a bold feat of structure and construction. Its design called for a 125′ span across the existing gymnasium on ground level. Because Columbia opted to build around an existing gymnasium, the building design was modeled after a high-rise bridge. The construction process took place during the school’s basketball season, and due to this, many aspects of the construction process required surgical precision.

The angularity of the facade is designed to express both the building’s randomized structural bracing, as well as the tailored building systems. The architects and engineers faced many unique layout challenges and the building required long-term flexibility. The extruded aluminum facade is an engineering-intensive surface designed and fabricated to evoke the same unified precision as the building itself.

Detail of the Columbia University Northwest Corner Building.

Columbia University Northwest Corner Building.

Detail of the aluminum facade system used on Columbia University Northwest Corner Building.

Creating the Energy-Efficient Aluminum Facade System

The new university building is certified LEED Gold. Integrating into the the building’s LEED aspirations was a simple process for A. Zahner Company because the operations and manufacturing of the plant is already well-suited for LEED applications.

Zahner delivered the aluminum system for this project under a design assist mode of production. Using this method enabled Zahner’s engineering and design team to reduce the construction waste for the facade down to a fraction of the building’s footprint.

Columbia University's first installed aluminum panels.

Zahner-produced mockup for wind-testing the Columbia facade system.

Detail of the aluminum extrusion system facade used on Columbia University.

Columbia University Northwest Corner Building: in the Press

“The building is a gleaming physical expression of the university’s desire to bridge the divide between the insular world of the campus and the community beyond its walls.”

—Nicolai Ouroussoff, New York Times

The New Columbia University Sciences building has attracted many news outlets and media interest due to its unique facade and intelligent engineering by the architectural team lead by Rafael Moneo. Learn more about the project via both internal and external links below.

Metals in Construction Columbia University (PDF) by Adam Friedberg, p22-31 (Columbia)
New York Times A Building Forms a Bridge by Nicolai Ouroussoff February 2011

Chihuly Bridge of Glass

August 15, 2016/in Exterior Architecture, Landscape Architecture Bridge, Exhibit, Museum, Pedestrian Bridge Tacoma--Washington Andersson-Wise Architects Dale Chihuly Blue, Grey M 2002 /by cmorris

Chihuly Bridge at the Museum of Glass in Tacoma, Washington

The Chihuly Bridge is a destination feature for Tacoma, Washington. Designed by Andersson-Wise Architects as an addition to the Tacoma Museum of Glass, the project provides a pedestrian bridge to downtown Tacoma. Made possible by a donation from Jim and Carolyn Milgard, the bridge crosses over major rail lines and links the Museum of Glass to Union Station and the State History Museum.

Zahner served as both the sole contractor and manufacturer in the production of the Chihuly Bridge of Glass. This construction included all structural steel, glazing and cladding elements as well as fiber optics and vacuum HVAC system within the cases.

Related Project

Museum of Glass

Zahner produced the metalwork for the glass bridge as well as the massive cone which can be identified throughout the downtown area. The cone was manufactured in stainless steel diamond panel system which was attached to a ZEPPS structural framework, each made by Zahner.

The system that Zahner used for the glass encasement of the artworks is the Drop Lock glass installation system, which allows for easy installation and sustainable maintenance. The system builds on Zahner’s patented Inverted Seam system for creating co-planar metal facades and roofs. The assembled panels provide rapid installation, require no silicone, and result in a visually clean edge with a dry look.

Visitors who walk across the bridge get a closer look at the work of artist Dale Chihuly. The bridge is divided into three sections:

— Seaform Pavilion: a glass ceiling and canopy system showcasing 2,364 works of Chihuly glass from his Seaform and Persian series.
— Crystal Towers: a permanent art installation by Chihuly, rising 40 feet above the bridge deck and serve as beacons of light.
— Venetian Wall: an eighty-foot long installation displaying 109 sculptures from three of Chihuly’s series: Venetians, Ikebana, and Putti.

Venetian Wall for the Chihuly Bridge of Glass, with Museum of Glass in the background

Pedestrians cross the Chihuly Bridge of Glass

Venetian Wall at the Chihuly Bridge of Glass

Seaform Pavilion at the Chihuly Bridge of Glass

Chihuly Bridge Seaform Pavilion, designed by Andersson Wise

Zahner field construction crew delivers the Seaform Pavilion for the Chihuly Bridge of Glass

Zahner field construction crew installs the Seaform Pavilion for the Chihuly Bridge of Glass

Plaque for the Venetian Wall at the Chihuly Bridge of Glass

Chihuly Bridge designed by Andersson Wise.

Press

US Glass Magazine – Chihuly Connections: New Bridge Creates A Link to Museum of Glass.
ArchNewsNow – Chihuly Bridge of Glass By Arthur W. Andersson, AIA/Andersson-Wise Architects

Cerner Headquarters

August 15, 2016/in Art & Sculpture, Exterior Architecture Flagship, Workplace Kansas City Gould Evans Associates Silver M, S 2005 /by cmorris

Signage for Cerner Headquarters Vision Center Forum Portals

The Cerner Corporation World Headquarters is designed by Gould Evans and features Zahner-manfufactured signage systems. Zahner produced this uniquely perforated stainless steel sculpture and sign for the Cerner Corporation in North Kansas City.

Two sculptural navigational displays were built: a small corner entrance sign adjacent to the building’s main entrance, and a large signage system visible from the nearby highway. This larger sign features an illuminated Cerner logo mounted on the perforated stainless steel screen wall.

Each of the displays were fabricated by Zahner using ZIRA, a patented technology developed by Zahner creating perforated imagery. The architects and client designed a non-repeating pattern of 1’s and 0’s, binary code in a non-repeating pattern. Zahner developed a process to rapidly punch the numbers using multiple dies.

Detail of the perforated metal signage system at Cerner Headquarters.

Cerner signage wall at the Cerner World Headquarters.

Detail of the perforated metal system used for Cerner Headquarters.

Detail of the Cerner World Headquarters signage wall.

The larger of the two displays, visible from the end of 210 Highway in North Kansas City, was produced with lighting systems embedded in the aluminum and stainless steel framework. Pictured above and below are photos of the signage at night, and during the day. As cars drive by, it appears to flash and animate due to the lights parallactic relationship with the perforations.

The complete system for the 61′ long sign structure comprises 72 panels supported vertically by stainless steel structural fins of varying depth and shape. Each panel is constructed from 18-gauge stainless steel, with a perforation pattern generated from a random sequence of binary code.

The display closest to the building features a DNA strand within the sign, visible as an orange tube. The structure was built with 1/4″ aluminum fins, attached to square tubes which create the sign’s profile. The face of the fins were installed with 14 gauge Angel Hair Stainless steel panels.

Additional metal signage at Cerner Headquarters.

Fabricating the Cerner Signs

The sculptural sign was custom perforated from stainless steel plates using binary code to create the pattern. The surface is an array of 1’s and 0’s randomly placed across the plates of stainless steel.

Below are photos from the Zahner shop in Kansas City, where the material for each display was formed. Each panel was perforated using dies custom-made for the project. Together with the automated punches allowed the fabricators on the shop floor to quickly assemble components after being produced on the computer-controlled punch.

Backlit perforated metal system at Cerner Headquarters.

Cerner signage during fabrication at Zahner .

Cedar & Kettner

August 15, 2016/in Exterior Architecture Parking Structure San Diego--California IPD: International Parking Design Silver L 2015 /by cmorris

Cedar & Kettner Development, Little Italy Parking Structure

Cedar & Kettner Development Parking Structure is located in downtown San Diego and features a Zahner-manufactured CloudWall facade system. The striking new parking garage anchors the corner of Cedar Street and Kettner Boulevard in the Little Italy area of downtown San Diego.

The series of vertical facade fins were made using the Zahner-patented CloudWall™ system. These fins were installed using custom extruded channel embeds which were set in concrete. Zahner worked with McCarthy to coordinate the location for each embed. Bassett Construction was the installer, and came to the project with experience on several other Zahner jobs.

The 240,000 SF design-build garage provides 650 spaces with three levels below grade and six levels above, serving as both a work garage for employees of the County of San Diego, as well as night parking for events in the downtown area.

Cedar Kettner Parking Structure in San Diego, California.

PHOTO © CHANY PHOTOGRAPHY.

The design team visited Zahner’s Headquarters prior to working on the job, and experienced the CloudWall system installed on the building’s facade. The project was led by IPD, who served as the architect of record. The team worked with construction manager McCarthy Builders in San Diego, and Bassett in San Diego led the install team.

The CloudWall fins were designed and shaped using 3-D computer-generated studies which resulted in an undulating façade that visually changes based on the point of view and sun angle. This new structure promises more than just additional spaces to park.

The Cedar & Kettner Parking Structure improves the commuter experience, offering a canopy over the adjacent trolley platform. The hope is that by offering more space for visitors, the already vibrant tourism within Little Italy will have room to increase. The new parking building is a key structure towards bringing more construction for additional projects in San Diego.

Cedar Kettner Parking Structure in San Diego, California.

PHOTO © CHANY PHOTOGRAPHY.

Cedar Kettner Parking Structure in San Diego, California.

PHOTO © CHANY PHOTOGRAPHY.

Completed in 2015, this new building provides much needed parking for visitors in a bustling area of tourism. 645 new spaces to park give the county the ability to accommodate greater amounts of tourism, bolster the local economy, and look great while doing so.

Reminiscent of ripples in the San Diego Bay, the CloudWall surface follows the recently completed waterfront park. The facade encompasses the building’s seven above-ground levels. Three additional levels exist underground.

Cedar Kettner Parking Structure in San Diego, California.

PHOTO © CHANY PHOTOGRAPHY.

Switching from Phenolic Plastic to Aluminum Plate

The wave-like fins were originally designed as a phenolic plank system. Design authorities determined some environmental and combustion concerns with the phenolic material. In the interest of public safety and longevity of the surface, all parties agreed that the design needed to be revisited in another material.

Following initial discussions with the group, Zahner visited onsite with the city and county officials, architects, and general contractors. The team reviewed the design and determined the specifics for providing the desired aesthetic.

Clear anodized aluminum was selected for both the fins and the cross bracing. The aluminum’s light material weight allowed for the phenolic system to easily be replaced with metal, without any structural redesign. The economical cost of aluminum also helped to lighten any budgetary concerns.

Scaling the CloudWall System

Prior to the Cedar & Kettner project, the CloudWall system was limited to one or two-story buildings. This was due to limitations of material lengths for the aluminum hardware. The CloudWall system was modified and custom-engineered for the project to span the six-story Cedar & Kettner building. This was accomplished by dividing the metal components into two lengths.

Zahner built a mockup to test how the new components would fit together, and also to test lighting and color options for the client.

Mockup showing the connection between two vertical fins for Cedar Kettner.

Photo © A. Zahner Company.

Mockup for Cedar Kettner Parking Structure.

Photo © A. Zahner Company.

Mockup for Cedar Kettner Parking Structure.

Photo © A. Zahner Company.

Mockup with varying color palettes for Cedar Kettner.

Photo © A. Zahner Company.

Cedar Kettner Parking Structure in San Diego, California.

PHOTO © CHANY PHOTOGRAPHY.

Cedar Kettner Parking Structure in San Diego, California.

PHOTO © CHANY PHOTOGRAPHY.

SUNY New Paltz

August 15, 2016/in Exterior Architecture Education New Paltz--New York ikon.5 architects Blue, Green M 2010 /by cmorris

SUNY Campus Commons at New Paltz

The State University of New York (SUNY) Campus Commons addition in New Paltz is a centerpiece for the school’s audacious program. Designed by ikon.5 architects, the glass and metal ‘crystalline palisade’ was ‘grown’ on the plinth of an existing concrete building. The new construction is designed for LEED Silver certification, incorporating radiant heating and cooling, photo-optic lighting controls, and substantial natural day lighting and views.

The muted turquoise surface is made using a pure copper alloy, preweathered and patinated (the process of developing a patina on metal) using a proprietary process developed by Zahner. The process results in an insoluble protective patina on the copper panel’s surface, variegated and eccentric.

The patinated copper surface was chosen by the architects because of the color’s association to nature and how it complements the glass shard. Zahner provided the sheets to local fabricators to create the flat-lock seam. The architects were already working with a manufacturer to fabricate the metal panel system, so the Zahner team supplied pre-patinated flat copper sheet and had a local team produce the panel system.

The ikon.5 architects-designed SUNY New Paltz Student Union Building

Interior view of the Star Blue™ copper panels at SUNY New Paltz Student Union Building

Star Blue™ copper panels at SUNY New Paltz Student Union Building

Detail of the Star Blue™ copper panels at SUNY New Paltz Student Union Building

Creating an Architectural Identity

The new design references the surrounding landscape of the Hudson River Valley and the Catskills. The building’s form was inspired by the nearby Shawangunk palisade, and its jade hue influenced by the Wallkill River’s muted blues.

The building also takes notes from the surrounding campus architecture. While the expanded student center stands in stark contrast to the neutral-toned concrete and brick buildings nearby, its angled roof continues the upward trajectory of an adjacent building’s ascending staircase. This attention to the building’s immediate context gives the new construction an integrated appeal, all-the-while maintaining its contemporary aesthetics.

The new building’s design has become a symbol for SUNY New Paltz, whose logo now incorporates the glass and metal pyramid. The exposed and triangulated framing underneath the glass zigzags across its fractal silhouette. Reflecting this exposed framing is the outdoor seating with its contemporary wireframe where students can enjoy the fresh air and sun while studying.

Photograph of the Shawangunk palisade alongside painting by ikon.5 architects

The building’s profile matches the upward accent of the original building’s staircase

PHOTO © A. ZAHNER COMPANY.

Detail of the exterior glass facade of SUNY New Paltz

Copper and glass facade of SUNY New Paltz

Detail of the copper and glass facade of SUNY New Paltz

Burberry Chicago

August 15, 2016/in Exterior Architecture Retail & Commerce Chicago--Illinois Burberry + Callison Barteluce, Solomon Cordwell Buenz Christopher Bailey Black L 2012 /by cmorris

The Burberry Chicago Flagship Store

The Burberry Chicago Flagship Store features a stainless steel facade system design-engineered and manufactured by Zahner. In the early 2000’s Burberry began a global transition to re-establish the Burberry name as an international brand. As part of this transition, a series of Burberry flagship projects were made, designed by Callison+Barteluce and Burberry Chief Creative Officer Christopher Bailey.

One of the core strategies of Burberry’s transformation has been the re-introduction of its core products through prominent flagship properties. Zahner has been involved as a facade supplier for many concept stores and flagship properties. Designers come to Zahner for the high-quality craft and innovative design-engineered details, which give these stores a sense of quality that moves a brand into museum-quality territory.

Burberry Chicago is no different. Completed in December 2012, the new building features a number of high quality connection details which give the building a unique aesthetic among Chicago architecture.

“

“What I love are the contradictions of the city. It’s a very artistic city, yet it’s also a real business city. It’s an imposing city, yet one with a lot of green space and an attention to outdoor sculpture. Chicago feels like a place where there’s an admiration for something that has a long heritage, and that of course appeals to us.”

Christopher BaileyBurberry Chief Creative Officer.

Zahner was brought onto the Burberry Chicago project to develop a black stainless steel facade and lighting system which would meet the highest standards of museum-quality metalwork desired by Burberry. Burberry’s in-house designers developed the vision, led by Chief Creative Officer Christopher Bailey. In an interview with Michigan Ave, Bailey described how Burberry’s vision meets Chicago aesthetics: “Chicago feels like a place where there’s an admiration for something that has a long heritage, and that of course appeals to us.”

Burberry designers brought in local and national architects to develop details for the project, including Callison Bartluce Architects in New York, and Solomon Cordwell Buenz as the architect of record in Chicago. Heintges Associates served as the building envelope and curtain wall consultant.

The structure features Burberry’s signature check, rotated and fabricated as three-dimensional forms. The check motif has been a part of Burberry’s core identity since the early twentieth century. By simplifying the classic check as a solid graphic and expanding it as into three-dimensional form, the design team was able to successfully unify the brand’s core identity as an architectural icon.

Burberry Chicago flagship store on Michigan Avenue.

Detail of the mirror-black stainless corner connection.

Elevation view of the Burberry Chicago flagship store.

Building the New Chicago Flagship

The facade is a unitized system featuring a black Ti-Stainless Steel (PVD) surface to create the Burberry’s three-dimensional check. PVD stainless steel can be colorized to meet a variety of tones, and is often used for luxury items such as timepieces and luxury architectural fixtures.

The facade for Burberry Chicago is the second in a series of flagship stores to use the dark reflective material. The first was in Shanghai, produced by a local manufacturer in China. Burberry provided to Zahner a small detail from the original facade. The sample was intelligently crafted but it didn’t mesh with the Zahner manufacturing process.

Zahner’s design and engineering team approached the details from a different perspective, employing heavier gauge stainless steel, v-notched corners, and a interlocking system for efficient installation of the metal panel design. The system is also deeply set, providing a strong sculptural feel to the building’s architectural accents.

The design team visits Zahner in Kansas City to look at the Burberry mockup.

The Burberry mockup at Zahner in Kansas City.

Detail of the Burberry facade in Chicago.

Photo © Robert Heishman.

Brown University APM

August 15, 2016/in Exterior Architecture Education Providence--Rhode Island ARO: Architecture Research Office Brown M 2015 /by cmorris

Brown University Applied Math Building

The new building for Brown University’s Division of Applied Mathematics was completed in 2015. The surface of the building is clad with a custom layout of shingles in Zahner’s Solanum Steel, a preweathered patina on weathering steel alloy. This 13,000 square foot structure offers additional space for faculty, students and staff.

Zahner was specified on the job by the designers at Architectural Research Office (ARO), who had previously worked with the Solanum Steel material on a residence in Telluride, CO. Adapting a similar shingled system for the new design at Brown University, the designers came up with a small tabletop mockup for the layout. This mockup allowed for rationalization of the overlap pattern, and the ability to figure out the layout early on.

Related Surface

Brown University APM

Brown University Applied Math Building, clad in Zahner Solanum Weathering Steel.

Designing the Facade System for Brown University

The project was already streamlined with cut lists ready and Zahner in the specs by the time it arrived in estimating. Because Zahner was clearly listed as the source for the finish, the construction management team at Shawmut knew who to contact, and were offered pricing in a quick and timely manner.

The cut list contained six different profiles for the shingles. These varying profiles were arranged in a stagger, with 2” overlaps to conceal face fasteners. The Architect also had determined their desired stagger for the layout, which would alternate overlaps at every course for the two layout options. Zahner worked with Shawmut Construction to coordinate the locations for the ¼” fastener holes, and provided shop drawings confirming exact dimensions for each of the profiles.

West elevation of the custom shingle layout for Brown Univeristy Applied Math Building.

ARO designed a custom shingle layout and created a physical model.

Two patterns for the custom shingle system.

Construction drawings showing the six shingle profiles for Brown University.

Broad Art Museum

August 15, 2016/in Exterior Architecture Museum Lansing--Michigan Zaha Hadid Architects L 2012 /by cmorris

Eli & Edythe Broad art Museum in East Lansing

Designed by Zaha Hadid Architects, The Eli & Edythe Broad Art Museum resides on the campus of Michigan State University. Committed to exploring contemporary issues through international art, the Museum functions as an exhibition and community space.

Zaha Hadid Architects worked with Zahner to develop the pleated stainless steel facade, a complex use of metal requiring a high level of precision. The metal is finished in a non-directional, light diffusing surface technique called Angel Hair.

”We were able to achieve a highly refined stainless steel surface for the Broad Art Museum by scaling up technology that once was stuck in the confines of fine machinery or jewelry.“
— L. William Zahner

Related Project

Rosenthal Museum

These plates of blackened aluminum use a siding system which repels moisture. These were engineered to interlock in such a manner to control thermal movement without compromising the moisture deterrence requirements. This was important due to the installation on concrete, which breathes. The aluminum plate panel system features custom extruded hardware fastened using matching aluminum studs for a visually seamless system. This hardware is attached to the horizontal aluminum hat channel.

Design Assist & The Broad Art Museum

Zaha Hadid engaged Zahner in a Design Assist contract during early stages of design development. Due to the complexities of the intended design, both teams deemed it necessary to sufficiently pre-plan constructability, budget and scheduling.

The dynamic design of The Broad Art Museum necessitated re-thinking typical fabrication methodologies. Because every component of the façade is askew, traditional practices for creating square structures were not applicable. New machining processes were created to achieve the architect’s precise, accordion-like edges, which in many ways are more complex than curvilinear designs.

Part of the Design Assist process includes production of a to-scale mock-up. The prototype aids in identifying design and fabrication challenges, ensuring smoother and more directed shop and installation procedures.

”Because it’s all intersecting lines, it had to be even more precise than a curving facade. It might seem counterintuitive, but a facade like The Broad is actually more complex than most curvilinear facades.“
— Craig Long, Engineer

Section of the Broad Museum selected for Zahner's Mockup.

Aligned CAD and photo of the Broad during construction.

Aligned CAD view of the of the Broad Museum / Broad Museum during Installation.

CAD Detail of the fabricated pipe understructure / Photograph of the cladding integrated with fabricated pipes.

Detail photos of the Eli & Edythe Broad Museum.

Reflective metal, viewed from southwest of the Broad Museum.

Interior and exterior views of the fins and fenestration.

South side view of the Broad Museum in East Lansing, Michigan.

Bowdoin Museum of Art

August 15, 2016/in Exterior Architecture Museum Brunswick--Maine Machado & Silvetti Brown, Gold M 2007 /by cmorris

Bowdoin College Museum of Art

The Bowdoin College Museum of Art renovation by Machado & Silvetti features a custom Zahner patinated surface and structural elements at its entry.

The new building entrance resembles a glass box on three sides, with the remaining portion clad in a Zahner fabricated naval brass with a custom bronze patina. The patinated metal panels continue from the exterior to the interior angled soffit, completing a dramatic entry for the museum’s 19th Century collection.

Related Project

Cincinnati Tower

The tower has a number of symbolic aspects in its design. Its square base forms the letters U and C on alternating sides. Above these letters, the main wooden shafts rise in the form of hammers. These motifs reflect the fraternity's motto, "The torch burns; the hammers ring." At the top, a beam of light shines through a stylized stainless steel torch and changes colors through the use of a computer program.

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.