Grey | Zahner

Winds of Aphrodite

Bartle Hall Convention Center Loading Dock Remodel

Working with artist Suikang Zhao, Crawford Architects led a redesign of the Bartle Hall Loading Dock to provide both a face-lift and a functionality-lift. The new design features an expanded aluminum screen wall developed by Zahner, offering a uniquely artistic first-impression of downtown Kansas City. The project aluminum screen skin connects to a galvanized steel superstructure, and as night falls, thousands of computer-color-controlled LEDS light up the mesh screen.

Working collaboratively with Crawford Architects, I designed art that is integrated into architect and the north and west facade of the screen-covered loading dock. The basic design idea is about soften monolithic monstrous design of 70’s into tangible / feminine touch as if a piece of giant fabric flying from sky and happen to catch up the corner of the Convention Center. Layers of steel meshes creates changing moment of mystical appearance depending on weather and time of day, and is lit up by computer-color-controlled LED light in the evening.

Completed in 2008, the project required the transformation of a 70’s brutalist structure into a softened and tangible work, as if it were a giant strip of fabric flying from the sky which happened to catch the corners of the convention center. Because of the way that downtown Kansas City highways are organized, when visitors first exited the highway, they would see the Bartle Hall Convention Center’s loading docks, replete with overflowing dumpsters and big trucks unloading for the upcoming show.

Dusk photograph of the Winds of Aphrodite artwork on Bartle Hall Loading Dock.

Moire patterns on the expanded aluminum facade and artwork at Bartle Hall

Light filters through the Winds of Aphrodite's aluminum surface on Bartle Hall Loading Dock.

The formed expanded aluminum surface allows light to filter into the Bartle Hall Loading Dock.

The corner of the Bartle Hall Loading Dock renovation.

The other part of the problem was that it was hard for the large trucks to enter the space because the original space wasn’t well thought-out. Architects at Crawford re-designed the framework and brought in Chinese artist Suikang Zhao to bring a flowing perforated aluminum screen, produced, fabricated, and installed by Zahner. Zahner was also integral in the Design Assist Process, where the artists, architects and Zahner engineering directors and designers work to maximize and refine the end design.

Drawing of the semi-truck pathways taken at Bartle Hall's loading dock.

The result of all this preparation is a new Bartle Hall Convention Center that works. The triangular screens appear as sails flowing in the wind, allowing light to enter and disguising the view of the docks. The previously underused loading docks are now used by every big truck that unloads at Bartle Hall.

The architects’ redesign of the Bartle Hall Loading Dock included looking at the paths that a truck takes, making it more efficient for semi-trucks to pull in, unload, and depart from the loading bay.

Winds of Aphrodite by Suikang Zhao and Crawford Architects.

Entrance to the Bartle Hall Loading Dock in Kansas City.

Zahner installers during the renovation of the Bartle Hall Loading Dock.

Winner: 2008 Kansas City Capstone Award

W Hollywood

August 15, 2016/in Exterior Architecture, Landscape Architecture Highrise, Hospitality, LEED Los Angeles--California Daly Genik, HKS Grey M 2010 /by cmorris

W Hollywood Flagship Hotel and Residences, Rooftop Canopy

One of the earliest completed architectural works which could be described as “generative design”, the rooftop canopy for the W Hollywood flagship was designed by HKS and Daly Genik. The design team’s concept was ahead of its time: the lightweight shingled surface which allows air and light to flow through its surface is both functionally and aesthetically forward-thinking, an aesthetic which became highly visible years after its completion.

Its form evokes the effect of a ruffled skirt, a concept which has become more prevalent since the structure’s completion. The design also provides a cooling effect both for its shade and breeze.

The 15-story award winning building is certified LEED Silver, winning the prestigious Millennium Award. Completed in 2010, the hotel is located in downtown Hollywood in California, an area which is becoming vertically dense with highrise buildings such as the W Hollywood.

Zahner was involved with the Daly Genik-designed curvilinear aluminum and steel canopy on the building’s rooftop garden. The canopy brings thousands of shingled aluminum panels to adorn the curving form which serves as a shade canopy for W Hollywood pool-side guests.

W Hollywood Hotel in CAD

Image © A. Zahner Company.

Architects from Daly Genik examine the mockup at Zahner.

The system borrows components from the ZEPPS process, which informed both the fabrication and installation process for the rooftop cabana. Zahner’s Design Assist team designed the details and engineered the structural canopy. The Design Assist team met with architects from Daly Genik to develop a section of the canopy as a mockup, which was constructed in the Zahner shop in Kansas City.

Architect's Rendering of the W Hollywood Flagship Hotel.

W Hollywood Further Reading

The highlight of the hotel’s rooftop pool area is a curving cabana wrapped in aluminum scales; it was designed by Daly Genik Architects, which also was responsible for the condominium interiors and the striking Douglas fir-lined lobby for the condo tower. Kevin Daly, a founder of the firm, said the W asked him to design the cabana as ‘a Venus’ flytrap for supermodels.

— Christopher Hawthorne, LA Times

Below are links to both external resources, articles, and press, as well as internal links to similar projects and products used in the W Hollywood Flagship Hotel.

W Hollywood Awards The W Hollywood Website.
Architects Newspaper Team Hollywood Alissa Walker, January 2010
LA Times W Hotel: An Urban Complexity Christopher Hawthorne, January 2010
Google Maps W Hotel Hollywood Map in Zahner Earth
Zahner Product: ZEPPS Process for building complex curves

The William T. Kemper Painting Studios

August 15, 2016/in Exterior Architecture Education, Renovation Kansas City Gastinger Walker Harden Black, Gold, Grey M 2006 /by cmorris

William T. Kemper Painting Studios

The 34,000 square foot William T. Kemper Painting Studios is a renovation to the existing building used by the painting department at KCAI for over thirty years.

The new building was designed by Gastinger Walker Harden, features unique patterning and rich customizations throughout the project. Diamond-shaped preweathered grey zinc panels adorn the building’s south elevation. A utility fence, perforated and undulated, wraps the crown of the building. Over the building’s north entrance, a custom embossed indentation provides a historic technique to achieve a modern aesthetic.

The building is clad in a variety of metal surfaces developed by Zahner — copper, zinc, and aluminum adorn the building in near equal parts. The copper was installed as a raw “red” sheet with the intention that it would weather over time and eventually become green. This process will take 10 to 20 years typically.

In addition to using prestige metals these custom surface adjustments are designed to smoothly transition around edges. The copper facade has a creased hatch edge emboss which continues parametrically, even where it breaks for gaps in various slots and windows. To achieve this parametric quality, the entire building’s facade was digitally defined. This enabled Zahner engineers to control corners, wrapping the custom emboss patterns around corners and under the soffits. Each piece of metal has its designated destination before it’s even manufactured. The building is also clad in a preweathered zinc facade. These diamond-shaped panels are fabricated with a custom recessed flat-seam system.

Corner detail of the zinc facade on the Dodge Painting Building at KCAI

South elevation of the dodge building's preweathered zinc facade

East elevation of the Dodge Building's copper facade, shortly after installation

Tacoma Art Museum

August 15, 2016/in Exterior Architecture Museum Tacoma--Washington Antoine Predock Architect PC, Olson-- Sundbert-- Kundig-- Allen Architects Grey L 2003 /by cmorris

The Tacoma Art Museum in downtown Tacoma, Washington

The new Tacoma Art Museum opened in 2003, doubling it’s square footage from the old museum and creating new flexible gallery space for it’s collection. Zahner provided the custom facade for the building, which was designed by Antoine Predock Architect PC.

The building features several of Zahner’s proprietary systems and processes, including the Inverted Seam Wall and Roof panel system. Use of the Inverted Seam system provides insulation, rain screen, and water-channeling, all on a minimal surface. The surface of the museum includes 36,000 square feet of 14ga. Stainless Steel with a Shadow finished surface.

Related Project

El Paso Courthouse

The courthouse has been recognized around the United States for both its architectural qualities and its environmentally innovative design.

The Tacoma Art Museum in downtown Tacoma, Washington.

Parking for the Tacoma Art Museum in downtown Tacoma, Washington.

Entry for the Tacoma Art Museum in downtown Tacoma, Washington.

View of the Tacoma Art Museum from across the Internstate in Tahoma.

Detail of the stainless steel facade of the Tacoma Art Museum.

Standard Parking

August 15, 2016/in Exterior Architecture Parking Structure Kansas City George Butler Architects Grey, Silver L 2001 /by cmorris

Standard Parking Garage at 11th & Oak

Designed by George Butler Architects for the Power & Light District of Downtown Kansas City, this is a parking structure’s facade was constructed using stainless steel as well as perforated aluminum surface to allow airflow for an otherwise congested space.

The aluminum screen wall was engineered, custom perforated, and installed as an facade panel system. The system also has uses for unusual panel sizes and unique details, as was the case with Standard Parking. Each of the panels was installed using an the Inverted Seam dry-joint system for integrated walls. The cornice and bold stainless steel fins were engineered, fabricated and installed to digitally defined coordinates.

Four massive stainless steel-clad fins rise at the building's center.

Standard Parking Garage at 11th and Oak.

Standard Parking Garage During Construction.

Interior staircase details at Standard Parking Garage in Kansas City.

West elevation of Standard Parking Garage in Kansas City.

Detail of the Angel Hair® surface used on the stainless steel fins.

Detail of the stainless steel fins with Angel Hair® Stainless Steel.

Interior mullion attachment for the perforated metal aluminum panels.

Building the Standard Parking Garage

Zahner developed the design for Standard Parking Garage using drop and lock details to enable quick and simple installation. Each of the panels locks into anchored connections on the concrete structure. This enabled a rapid schedule for the project’s facade.

The above photographs were more than a decade after the project’s completion. Stainless steel is often chosen over aluminum due to its high-performance sheen which never dulls and requires no maintenance. Aluminum is more porous, and over time it begins to dull, but this is not yet the case with Standard Parking Garage screen-wall.

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

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

Oscura™ Blackened Steel – Archive

Oscura is a Zahner blackened patina on steel that has been developed for interior use. Activated steel surfaces create a mottled and artistic ambiance that varies from sheet to sheet. The primary surface is sealed with a clear coat to mitigate rusting due to the effects of the ambient interior environment.

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.

Juilliard Stairs

August 15, 2016/in Interior Architecture Education New York City Diller Scofidio + Renfro, FXFOWLE Architects Grey, Red M 2009 /by cmorris

Slow Stairs at The Juilliard School in New York City

Zahner worked with the architects at Diller Scofidio + Renfro to develop a gliding red stairway for the recent renovations at The Juilliard School in New York City. Zahner was responsible to Turner Construction in New York City for producing the design engineered metal-work. The two staircases are located one after the other, on the eastern-most side of the school from the third to fifth floors. There the students can collect their thoughts around the adjacent study areas.

The stairway was designed to appear as though it were made from a single sheet of metal. In actuality, the stair is made possible by several plates of 3/4″ low-carbon steel, seamlessly welded and painstakingly ground to achieve the look of a unified single piece of metal. Each step is a separate plate, bent at a 90 degree angle on either side, and then welded to either side of the staircase. The stairs are placed at a non-standard height and depth, so that the effect is a “slow staircase” where each step is only slightly elevated from the last.

Juilliard Staircase designed by Diller Scofidio + Renfro.

One of the issues with welding metal is its tendency to warp itself towards the weld. When it came time to weld the long pipe which serves as the hand rail, Zahner identified this as a potential problem. If this wasn’t done correctly, the entire staircase would bow to the left or right as one looked up at it. After debating different ways to prevent warpage, the solution Zahner employed was an old ship building technique — we welded the handrail from both sides at the same time. The result is a highly accurate straight piece of steel with only three connections to the building.

Custom staircase loaded on a truck to be shipped to Juilliard School in New York City.

Detail of the staircase design's joints, ground to a seamless finish.

Hunter Museum

August 15, 2016/in Exterior Architecture, Interior Architecture Museum Chattanooga--Tennessee Derthick-- Henley & Wilkerson, Hefferlin + Kronenberg Architects, Musalli-- Shakir-- and Mandilli, Randall Stout Architects Blue-grey, Grey, Silver L 2005 /by cmorris

THE Hunter Museum of American Art

Designed by architect Randall Stout Architects, the Hunter Museum of American Art is Zahner’s first project with the renowned firm. Mr. Stout grew up in Tennessee, so to be chosen to design Chattanooga’s new wing of the Hunter Museum was particularly meaningful for both the community as well as the architect.

The Museum sits on an 80′ tall bluff above the Tennessee River where the building’s dynamic lines and twisting curves provide a contrast to the original museum’s classic style, adjacent to Randall Stout’s contemporary design. In 2002 the Hunter Museum of American Art partnered with the City of Chattanooga, the Tennessee Aquarium and the Creative Discovery Museum to finish the 21st Century Waterfront Plan.

Zahner produced the geometric zinc metal surface as well as the curvilinear Angel Hair stainless steel roof forms, interior stainless steel stairway, and various metal details throughout the building.

Related Project

Taubman Museum

Designed by Randall Stout Architects, the building includes a range of metal components manufactured and installed by Zahner engineers and artisans. Zahner was responsible for engineering, fabrication, and installation of the exterior secondary structure and facade. Zahner also provided interior metal surfaces for the project.

View of the Hunter Museum of American Art at sunrise.

Detail of the New Hunter Museum entrance.

Visitors on the outdoor deck of the Hunter Museum.

Selecting the Surface

The architect’s specifications originally called for a limestone exterior in additional to the stainless steel curving roof. Limestone would have cladded the vertical walls as well as many of the slanting angles throughout the building. As the project progressed, it became apparent that installing limestone was implausible in many areas due to the structural weight of the material.

At this point, Zahner was already contracted to produce the stainless steel roof. The architect asked Zahner to come up with some textured surfaces to match the limestone aesthetic.

Zahner had already been developing a wide range of custom patinas on many alloys of metal. The design team worked through several options, and decided to replace the limestone with a light gauge Hunter Zinc panels system. The preweathered zinc surface has a tonality which closely resembles the limestone surroundings. This material was used throughout the museum, on both the interior walls and the exterior building envelope.

Building the Hunter’s Curves

The bright curving stainless steel surfaces on the Hunter Museum use two signature Zahner systems, ZEPPS and the Inverted Seam system. These systems combine to make a roof which curves exactly as the architect’s original drawings. This curving surface is visibly seamless and completely protects the building against the elements.

The stainless steel is treated and processed with the Angel Hair mechanical finish, which reduces the glaring hotspots common on more reflective stainless steel, and enhances the sheen and glowing bounce of light that it generates.

Contractors standing below several recently installed ZEPPS® Panels during construction.

The most efficient and effective way to build these curves is with large ZEPPS assemblies which are produced in the fabrication shop and shipped to the site as preassembled massive panels, as pictured above the construction workers in the reference image, above.

Each of these ZEPPS lines up with adjacent panels, and includes flexible connections which allow for tolerance if the structural steel that it bolts onto is misaligned. Ensuring the subtle curvatures is crucial, so building in these types of safeguards is an effective way to save time and money during the installation process.