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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. 

Pritzker Pavilion at Millenium Park.

PRITZKER PAVILION AT MILLENIUM PARK.

PHOTO © A. ZAHNER COMPANY.

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Photo © A. Zahner Company.
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NonePhoto © A. Zahner Company.
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NonePhoto © A. Zahner Company.
NonePhoto © A. Zahner Company.
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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. 

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https://e5awgs3wuhi.exactdn.com/wp-content/uploads/2020/07/24123011/3_pritzker-paviliion-photo-copyr-zahner-1870-2.jpg?strip=all&lossy=1&quality=92&webp=85&ssl=1 1080 1920 cmorris https://www.azahner.com/wp-content/uploads/2020/05/logo.svg cmorris2016-08-15 23:31:542025-02-20 08:29:21Pritzker Pavilion

The Petersen

August 15, 2016/in Exterior Architecture Automotive, Museum, Parking Structure Los Angeles--California Kohn Pedersen Fox Red, Silver L, XL 2015 Featured, Related Work /by cmorris

The Petersen Automotive Museum in Los Angeles, California:

Situated on Los Angeles’ famous Miracle Mile, the newly renovated Petersen Automotive Museum has achieved an iconic status while creating open spaces which invite community engagement. The design encases the building in a red-painted corrugated aluminum rainscreen system which acts as the backdrop for a series of stainless steel structural ribbons. These scopes were engineered, manufactured, and installed by Zahner.

Designed by Kohn Pedersen Fox (KPF) in New York with the construction management by Matt Construction in Los Angeles, Zahner was brought onto the project early on in the planning and development process. Starting under a Zahner Assist (Design Assist) contract, the construction team developed a fabrication and installation strategy with the engineers at Zahner.

This is the second project completed by Zahner with KPF. The two teams worked together prior on the IBM Headquarters in Armonk, New York.

IBM Headquarters at Armonk, New York. IBM Headquarters at Armonk, New York.
Related Project

IBM Headquarters

Nestled within a landscape of 450 wooded, rocky acres some 50 miles from Manhattan, the IBM World Headquarters exemplifies KPF’s demonstrated ability to respond to the natural context and produce an innovative work of architecture. Completed in 1997, the headquarters is the centerpiece of an existing corporate campus in this wooded setting with deep ravines slicing through the landscape.

Petersen Automotive Museum in Los Angeles, California.

PETERSEN AUTOMOTIVE MUSEUM IN LOS ANGELES, CALIFORNIA.

PHOTO © A. ZAHNER COMPANY.

Making the Petersen Automotive Museum

Design development for the Petersen Automotive Museum began in 2012. Principal Trent Tesch knew that the complex shapes would be best defined under a Design Assist contract with Zahner. Examining the forms gave the team an opportunity to approach their design with as much information as possible. Zahner Assist enabled KPF to bring the client into a conversation with Zahner.

Sharing models and preliminary drawings while the design was still conceptual allowed for conversations regarding costs and aesthetics to remain transparent, assisting the client during the decision making process.

The project made use of several Zahner technologies and methodologies: the ZEPPS Process for designing and manufacturing the building’s curved forms; the Angel Hair non-directional surfacing applied to each of the stainless steel skins attached to the curved forms; and Zahner Assist, Zahner’s method for developing complex projects into factory-produced realities. The project also includes an ImageWall custom perforated metal screen which continues the architect’s design, mimicking the stainless ribbons in a perforated metal graphic across the building’s parking structure. The Petersen Automotive Museum is the direct result of a design team confidently departing from convention.

Perforated metal screenwall by Zahner continues the Petersen Automotive Museum's sculptural motif.

PERFORATED METAL SCREENWALL BY ZAHNER CONTINUES THE PETERSEN AUTOMOTIVE MUSEUM’S SCULPTURAL MOTIF.

PHOTO © A. ZAHNER COMPANY.

Underneath the undulating ribbon facade of the Petersen Automotive Museum.

UNDERNEATH THE UNDULATING RIBBON FACADE OF THE PETERSEN AUTOMOTIVE MUSEUM.

PHOTO © A. ZAHNER COMPANY.

A perforated parking garage facade continues the stainless steel ribbon motif.

A PERFORATED PARKING GARAGE FACADE CONTINUES THE STAINLESS STEEL RIBBON MOTIF.

PHOTO © A. ZAHNER COMPANY.

Detail of the facade of the Petersen Automotive Museum.

DETAIL OF THE FACADE OF THE PETERSEN AUTOMOTIVE MUSEUM.

PHOTO © A. ZAHNER COMPANY.

Petersen Automotive Museum

PETERSEN AUTOMOTIVE MUSEUM

PHOTO © A. ZAHNER COMPANY.

Design Assist Mockup for the Petersen Automotive Museum.

Design Assist Mockup for the Petersen Automotive Museum.

Photo © A. Zahner Company.

Design Assist Mockup at dusk for the Petersen Automotive Museum.

Design Assist Mockup at dusk for the Petersen Automotive Museum.

Photo © A. Zahner Company.

The Mock Up as a Design Catalyst

As part of the Zahner Assist contract, we included a to-scale visual mockup. Mockups are included as part of this process in order to aid in design decision making and determine the best method for building any given form. The team selected the lower northeast corner of the building’s design to fabricate as a mockup section. This empowered the design team to determine how the ribbons would wrap around the corner, an integral aspect of the building’s design.

The mockup process provided Zahner crucial insight into how to best develop the red-painted structural steel armatures which are used throughout the project. The mockup also helped the design team establish the ideal color for the painted corrugated aluminum surface.

Zahner installers hang a ZEPPS Ribbon Assembly at the Petersen Automotive Museum.

Zahner installers hang a ZEPPS Ribbon Assembly at the Petersen Automotive Museum.

Photo © A. Zahner Company.

Zahner fabricators create the ZEPPS Ribbon assemblies for the Petersen Automotive Museum.

Zahner fabricators create the ZEPPS Ribbon assemblies for the Petersen Automotive Museum.

Photo © A. Zahner Company.

3D Model of a single ZEPPS Assembly for the Petersen Automotive Museum.

3D Model of a single ZEPPS Assembly for the Petersen Automotive Museum.

Photo © A. Zahner Company.

Zahner field installers at the construction site for the Petersen Automotive Museum.

Zahner field installers at the construction site for the Petersen Automotive Museum.

Photo © A. Zahner Company.

Creating the new Petersen Automotive Museum facade

The existing building, purchased by the Petersen Automotive Museum in 1994, was rectilinear and fairly straightforward in form. It was originally a department store. Six years after the store closed, museum founder Robert Petersen chose the site to house his automotive museum. Since the Museum is nearly devoid of windows, the site was ideal for safely housing Mr. Petersen’s collection without harmful exposure to sunlight.

Because the existing building contained very little glass and was box-like in form, it acted as a blank canvas for the design team. ZEPPS, the Zahner system for developing sculptural forms, was used to build curving stainless steel ‘ribbons’ which wrap the building, giving it a feeling of rapid motion. The result looks similar to the aerodynamic flow diagrams drawn in wind tunnel tests by automotive designers.

Using ZEPPS to Create Dual-Curving Forms

To build complex dual curving forms with the lightest structural loads, Zahner uses the ZEPPS process. ZEPPS stands for Zahner Engineered Profiled Panel Systems, and comprises Zahner’s approach to building complex, curvilinear forms. The crux of the system is the paring down of a complex design into manageable parts for manufacturing.

Using an architect’s 3D model, Zahner’s engineers examine geometry with a manufacturing mindset. Each curve is analyzed and developed into a series of patented aluminum structural components. These components are pre-assembled at the shop and compose the structural form for each ZEPPS Asssembly. Using aluminum extrusions rather than steel allows for a lighter load on the structure of the façade, and also allows for more economical fabrication methods.

The final step in creating with ZEPPS is to clad it in surface material. For the Petersen Automotive Museum, Zahner’s Angel Hair Stainless Steel surface was selected. After the structure is built, each ZEPPS is clad in the desired metal, and loaded onto a truck for field install. By breaking dual curves into units, ZEPPS creates precision within the manufacturing process, and allows for much quicker field installation.

Detail of the Petersen Automotive Museum's Angel Hair Stainless steel.

Detail of the Petersen Automotive Museum’s Angel Hair Stainless steel.

Photo © A. Zahner Co.

Petersen Automotive Museum in Los Angeles, California.

PETERSEN AUTOMOTIVE MUSEUM IN LOS ANGELES, CALIFORNIA.

PHOTO © A. ZAHNER COMPANY.

Roof of the Petersen Automotive Museum.

ROOF OF THE PETERSEN AUTOMOTIVE MUSEUM.

PHOTO © A. ZAHNER COMPANY.

View of Wilshire Blvd during the construction of the Petersen.

View of Wilshire Blvd during the construction of the Petersen.

Photo © A. Zahner Company.

Screenwall at the Petersen Automotive Museum in Los Angeles, California.

SCREENWALL AT THE PETERSEN AUTOMOTIVE MUSEUM IN LOS ANGELES, CALIFORNIA.

PHOTO © A. ZAHNER COMPANY.

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Underneath the Roof of the Petersen Automotive Museum.

UNDERNEATH THE ROOF OF THE PETERSEN AUTOMOTIVE MUSEUM.

PHOTO © A. ZAHNER COMPANY.

Structural Steel

A new structural steel exoskeleton was needed to carry the loads from the red corrugated rainscreen as well as the cantilevered stainless steel ribbons which arch over the rooftop to provide shading for a private event space.

Working with the designers’ 3D models, Zahner’s team of engineers developed a series of tree-like forms in structural steel to support the ZEPPS Ribbon assemblies. The structural steel skeleton was inspired by hot rod manifolds to serve the dual purpose of providing aesthetic cohesiveness as well as functional support for cantilevered elements of the design. The structural ‘trees’ support the ribbons that flow over the roof area, as well as the Fairfax Ave ground level ribbons.

The ZEPPS ribbons required custom curved structural steel within each unit. Zahner mapped out each curved radius using the 3D model, allowing for fabrication in the shop to be handled quickly and precisely.

Custom Corrugated Aluminum

Painted aluminum acts as the backdrop for the stainless steel ZEPPS forms, echoing the concept of a sports car in bright red intensity. The aluminum was completely custom, and unlike any standard corrugated pattern. The corrugated profile formed an exact 90 degree angle, versus the typical sine wave that is commonly seen in corrugated metals.

To accommodate for the custom nature of this design element, Zahner formed each of the corrugated panels in house, utilizing a custom die within the press brake.

ImageWall Screenwall for the Petersen Parking Enclosure

As a continuation of the stainless steel ribbons, the design team also selected a painted red aluminum ImageWall for the Museum’s Parking Garage. Using Zahner’s patented technology, ImageWall uses perforated holes to map an image across multiple panels. In this case, the image provides cohesiveness, and ties the parking garage in with the larger facade.

ImageWall Screenwall enclosing the Parking Structure of the Petersen Automotive Museum.

IMAGEWALL SCREENWALL ENCLOSING THE PARKING STRUCTURE OF THE PETERSEN AUTOMOTIVE MUSEUM.

PHOTO © A. ZAHNER COMPANY.

Detail of the screenwall facade of the Petersen Automotive Museum.

DETAIL OF THE SCREENWALL FACADE OF THE PETERSEN AUTOMOTIVE MUSEUM.

PHOTO © A. ZAHNER COMPANY.

Parking Structure Screenwall at the Petersen Automotive Museum in Los Angeles, California.

PARKING STRUCTURE SCREENWALL AT THE PETERSEN AUTOMOTIVE MUSEUM IN LOS ANGELES, CALIFORNIA.

PHOTO © A. ZAHNER COMPANY.

https://e5awgs3wuhi.exactdn.com/wp-content/uploads/2020/07/24112219/1_petersen-museum-c-zahner-tex-jernigan-8531.jpg?strip=all&lossy=1&quality=92&webp=85&ssl=1 1080 1920 cmorris https://www.azahner.com/wp-content/uploads/2020/05/logo.svg cmorris2016-08-15 23:31:532025-05-05 08:14:56The Petersen

Nissan Styling Studio

August 15, 2016/in Exterior Architecture Automotive Farmington Hills--Michigan Luce et Studio Silver M 2005 /by cmorris

Nissan Styling Studio and Technology Center

Nissan Design America commissioned Luce et Studio to design an elegant courtyard for the Nissan Design Group, where the company’s design team could privately showcase its new technologies and concept cars. Zahner worked with partners Wallace Engineering and Turner Construction to produce the courtyard for the campus.

Completed in 2005, the Nissan Styling Studio features a double layered perforated metal skin which has an offset spiral, 30 feet into the sky.  The perforated screen allows light to enter while preventing viewers from peering in from the outside. This was a key aspect of the design, because the courtyard was used to display concept cars that weren’t yet available to the public. The oval shaped space at the Farmington Hills Facility is known as ‘The Egg,’ an exterior courtyard where final prototypes could be viewed in natural daylight.

Nissan Styling Studio and Technology Center.

NISSAN STYLING STUDIO AND TECHNOLOGY CENTER.

PHOTO COURTESY LUCE ET STUDIO

Nissan Studio, generating a unique architectural moire at Dusk.

NISSAN STUDIO, GENERATING A UNIQUE ARCHITECTURAL MOIRE AT DUSK.

PHOTO COURTESY LUCE ET STUDIO

Photograph of the Nissan Egg during a heavy snow.

PHOTOGRAPH OF THE NISSAN EGG DURING A HEAVY SNOW.

PHOTO COURTESY LUCE ET STUDIO

Interior metalwork for the Nissan Design Studio in Michigan.

INTERIOR METALWORK FOR THE NISSAN DESIGN STUDIO IN MICHIGAN.

PHOTO COURTESY LUCE ET STUDIO

Nissan Styling Studio and Technology Center.

NISSAN STYLING STUDIO AND TECHNOLOGY CENTER.

PHOTO COURTESY LUCE ET STUDIO

Nissan Styling Studio and Technology Center.

Developing the Moiré Design as an Architectural Feature

As part of the project’s design development, Zahner produced a mockup for the architects at Luce et Studio. The mockup was manufactured and displayed at the Zahner HQ in Kansas City.

Nissan Styling Studio mockup at Zahner Headquarters in Kansas City.

Nissan Styling Studio mockup at Zahner Headquarters in Kansas City.

Nissan Styling Studio mockup at Zahner Headquarters in Kansas City

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Architect drawing of the Nissan Styling Studio and Technology Center

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Neiman Marcus

August 15, 2016/in Exterior Architecture, Interior Architecture Retail & Commerce Natick--Massachusetts Elkus Manfredi Charcoal, Gold, Orange, Silver L 2007 /by cmorris

Neiman Marcus Flagship Store by Elkus Manfredi

The Neiman Marcus in Natick, Massachusetts is the store’s Flagship property featuring a billowing facade designed by Elkus Manfredi Architects in Boston. The entire surface of the building is wrapped in a stainless steel curtain, a feature which flows throughout and into the building in the same style.

Elkus Manfredi Architects designed the facade’s undulations with perspective in mind. When travelers drive by, the structure appears animated and kinetic, an effect caused by the way the facade curves in and out. Zahner worked with the architects to design a curving facade panel system that is both aesthetically powerful as well as economically effective.

Related System

Neiman Marcus

NonePHOTO © A. ZAHNER COMPANY.
Related Surface

Neiman Marcus

The skin is actually three different tones of colored stainless steel. Two of these tones were formed by a electro-chemical process which permanently changes the tone of stainless steel. Zahner has used this process for several other projects, including the Contemporary Jewish Museum which has a dark blue interference coating and a cross-fire brushed pattern. Interference stainless steel was also used on the The EMP Museum, The Meyer Fletcher Residence, and the Royals Crown at Kauffman Stadium.

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In addition to providing the exterior scope, Zahner also manufactured interior metalwork for the department store interior entrance. This interior wall uses a similar subtle curvature made in a lightweight ZEPPS framework. This scope included the ceiling area, made in a stainless steel with standard polish.

The exterior scope included various metal details, including the soffit at the Neiman Marcus entrance and the throughout areas underneath the facade’s curtain. Providing these standard details for the facade and other areas is typical of Zahner scope. The company routinely handles interior and exterior standard metalwork on a variety of projects.

Related System

Soffit

Soffit systems engineered and manufactured by Zahner are the result of innovative architects, designers, and artists who challenged the norms of what to expect in the built environment. Working with Zahner to develop a custom metal soffit system begins with your design.

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Designing the complex curtain system for the Neiman Marcus facade was made possible through Design Assist. Zahner worked with the architects at Elkus Manfredi to develop a design, mockup, and manufacturing process to efficiently fabricate, deliver, and install the exterior metal facade.

Related Post

Building a dual-curved facade with pre-fabricated panels.

The building’s 570-foot-long undulating stainless steel façade, in tones of bronze, champagne and silver, “waves in and out and top to bottom almost as if someone was wearing a dress and walking,” said Elkus.

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https://e5awgs3wuhi.exactdn.com/wp-content/uploads/2020/07/24123237/1_neiman-marcus-copyright-zahner-9174-2.jpg?strip=all&lossy=1&quality=92&webp=85&ssl=1 1080 1920 cmorris https://www.azahner.com/wp-content/uploads/2020/05/logo.svg cmorris2016-08-15 23:31:322020-10-30 18:36:09Neiman Marcus

NASCAR Hall of Fame

August 15, 2016/in Exterior Architecture Museum Charlotte--North Carolina Pei Cobb Freed Silver L, XL 2010 /by cmorris

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.

NonePHOTO © A. ZAHNER COMPANY.
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NASCAR Hall of Fame during the day.

NASCAR Hall of Fame during the day.

Photo © A. Zahner Company

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NonePhoto © A. Zahner Company
NonePHOTO © A. ZAHNER COMPANY.

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.

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

Hanging a single NASCAR Hall of Fame ZEPPS Panel.

Hanging a single NASCAR Hall of Fame ZEPPS Panel.

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

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.

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

PHOTO © A. ZAHNER COMPANY.
https://e5awgs3wuhi.exactdn.com/wp-content/uploads/2020/07/24111203/1_nascar-hall-of-fame-copyr-zahner-8391.jpg?strip=all&lossy=1&quality=92&webp=85&ssl=1 1080 1920 cmorris https://www.azahner.com/wp-content/uploads/2020/05/logo.svg cmorris2016-08-15 23:31:322025-03-05 18:19:51NASCAR 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.

Aerial imagery of Tampa Museum of Science and Industry.

Image courtesy Google.

Tampa MOSI during construction.

Tampa MOSI during construction.

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

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.

Roof of the MOSI Dome in Tampa — Dual Curvatures.

Detail of the MOSI dual curvature roof panel system.

DETAIL OF THE MOSI DUAL CURVATURE ROOF PANEL SYSTEM.

Museum of Science & Industry, Florida.

Museum of Science & Industry, Florida.

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

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

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

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.

Giftshop at MOSI Science Museum.

Giftshop at MOSI Science Museum.

https://e5awgs3wuhi.exactdn.com/wp-content/uploads/2020/07/24111013/1_aerial-tampa-museum.jpg?strip=all&lossy=1&quality=92&webp=85&ssl=1 1080 1920 cmorris https://www.azahner.com/wp-content/uploads/2020/05/logo.svg cmorris2016-08-15 23:31:312025-04-21 06:34:01Museum of Science and Industry

Murphysboro Sculpture

August 15, 2016/in Art & Sculpture Public Art, Sculpture Murphysboro--Illinois John Medwedeff Silver M 2010 /by cmorris

Carl Lee Park Pavilion and Bandshell in Murphysboro

The Carl Lee Park Pavilion and Bandshell is a sculptural form which features Zahner manufacturing and engineering technologies. Designed by artist John Medwedeff, this public art project is located at the town center of Murphysboro, Illinois. The project was completed in 2010, and measures 35′ long. The artwork provides a small amphitheater for the town’s public park where musicians perform outdoor concerts.

The project uses the same ZEPPS technology that Zahner developed on such buildings designed by Frank Gehry Partners and Randall Stout. These building designs required metal to curve and twist, all the while remaining highly accurate from edge to edge. Using ZEPPS, the patented technology for building unique forms, Zahner was able to design and manufacture the curvilinear framework for the Murphsyboro Bandshell.

Related System

Murphysboro Sculpture

Murphysboro Town Park Pavilion and Bandshell by John Medwedeff

MURPHYSBORO TOWN PARK PAVILION AND BANDSHELL BY JOHN MEDWEDEFF

PHOTO © A. ZAHNER COMPANY.

Murphysboro Town Park Pavilion and Bandshell by John Medwedeff

MURPHYSBORO TOWN PARK PAVILION AND BANDSHELL BY JOHN MEDWEDEFF

PHOTO © A. ZAHNER COMPANY.

Murphysboro Town Park Pavilion and Bandshell by John Medwedeff

MURPHYSBORO TOWN PARK PAVILION AND BANDSHELL BY JOHN MEDWEDEFF

PHOTO © A. ZAHNER COMPANY.

Murphysboro Town Park Pavilion and Bandshell by John Medwedeff

Murphysboro Town Park Pavilion and Bandshell by John Medwedeff

Photograph © A. Zahner Company.

Murphysboro Town Park Pavilion and Bandshell by John Medwedeff

Murphysboro Town Park Pavilion and Bandshell by John Medwedeff

Photograph © A. Zahner Company.

Fabricating Public Art using a Digital Model

The Design Assist Team modeled the project using the artist’s maquette as reference. Zahner scanned the artist’s model and developed an art fabrication plan for the sculpture. The model’s design details were further developed by Zahner engineers, dividing the model into several buildable subsections.

These subsections were then fabricated at the Zahner shop, and shipped to the job site. There the installers connected the frameworks, and secured the stainless steel skins to the aluminum substrate.

By using digital processes, Zahner was able to closely match the artist’s original model, and produce a large-scale version in aluminum substructure with stainless steel sheeting.

Zahner used an Angel Hair stainless steel surface for its cladding, which was secured to the ZEPPS framework during installation by Zahner field crew.

Digital model for the Town Park Pavilion and Bandshell by John Medwedeff

Digital model for the Town Park Pavilion and Bandshell by John Medwedeff

Digital model screenshot © A. Zahner Company.

Digital model for the Town Park Pavilion and Bandshell by John Medwedeff

Digital model for the Town Park Pavilion and Bandshell by John Medwedeff

Digital model screenshot © A. Zahner Company.

Murphysboro Town Park Pavilion and Bandshell by John Medwedeff

Murphysboro Town Park Pavilion and Bandshell by John Medwedeff

Photograph © A. Zahner Company.

Zahner installation crew installs the fabricated ZEPPS components for the Medwedeff sculpture

Zahner installation crew installs the fabricated ZEPPS components for the Medwedeff sculpture

Photograph © A. Zahner Company.

The final artwork is an exacting fabrication of its digital model.

The final artwork is an exacting fabrication of its digital model.

Photograph © A. Zahner Company.

https://e5awgs3wuhi.exactdn.com/wp-content/uploads/2020/07/24110756/1_murphysboro-sculpture-c-zahner-tex-jernigan-4489.jpg?strip=all&lossy=1&quality=92&webp=85&ssl=1 1080 1920 cmorris https://www.azahner.com/wp-content/uploads/2020/05/logo.svg cmorris2016-08-15 23:31:302021-08-31 16:01:25Murphysboro Sculpture

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.

Related Post

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.

Dusk photograph of Lumenhaus, Virginia Tech.

Photo courtesy Alden Haley..

Exterior detail of the Lumenhaus facade.

Exterior detail of the Lumenhaus facade.

Photo courtesy Lumenhaus.

Exterior detail of the Lumenhaus facade.

Exterior detail of the Lumenhaus facade.

Photo courtesy Lumenhaus.

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 for Virginia Tech.

Photo courtesy Lumenhaus.

Photograph of the Lumenhaus facade at Dusk.

Photograph of the Lumenhaus facade at Dusk.

Photo courtesy Lumenhaus.

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

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

Photo courtesy Lumenhaus.

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.

Detail of the facade pattern for the Lumenhaus project.

Detail of the facade pattern for the Lumenhaus project.

Photo courtesy Lumenhaus.

Detail of the imaginative facade pattern for the Lumenhaus project.

Detail of the imaginative facade pattern for the Lumenhaus project.

Photo courtesy Lumenhaus.

Detail of the facade pattern for the Lumenhaus project.

Detail of the facade pattern for the Lumenhaus project.

PHOTO © A. ZAHNER COMPANY.

https://e5awgs3wuhi.exactdn.com/wp-content/uploads/2020/07/24111953/1_lumenhaus-photograph-by-alden-haley.jpg?strip=all&lossy=1&quality=92&webp=85&ssl=1 1080 1920 cmorris https://www.azahner.com/wp-content/uploads/2020/05/logo.svg cmorris2016-08-15 23:31:192020-10-26 14:27:35Lumenhaus

Kowloon Station

August 15, 2016/in Exterior Architecture, Interior Architecture Airport, Transportation Asia, Hong Kong TFP Farrells Silver, White L, XL 1998 /by cmorris

Kowloon Station in Hong Kong

Kowloon Station is a rail transit station on the Tung Chung Line and the Airport Express of Hong Kong’s MTR. The station provides in-town check-in service for passengers departing from the Hong Kong International Airport, with access to shuttle, bus, train, and other forms of transit.

This station in the Kowloon development in Hong Kong was designed by Farrells (TPP Farrells). The project included a masterplan for the surrounding Union Square, one of the largest air-rights developments in the world. This development included the tallest tower in Hong Kong, the International Commerce Center.

Zahner was brought into the project to provide above-ground exterior metalwork, as well as below-grade metalwork for the station’s interior. This scope includes a Zahner-manufactured aluminum facade, with aluminum and stainless steel interior metalwork. The station was completed in 1998.

None Photograph by Diego Delso licensed CC-BY-SA.
Interior metalwork at Kowloon Station, Hong Kong.

Interior metalwork at Kowloon Station, Hong Kong.

NonePhoto © HK Arun
Interior painted metal systems, Kowloon Station, Hong Kong.

Interior painted metal systems, Kowloon Station, Hong Kong.

Interior painted metal systems, Kowloon Station, Hong Kong.

Interior painted metal systems, Kowloon Station, Hong Kong.

Interior painted metal systems, Kowloon Station, Hong Kong.

Interior painted metal systems, Kowloon Station, Hong Kong.

Related Project

Tsing Yi Station

https://e5awgs3wuhi.exactdn.com/wp-content/uploads/2020/07/24122923/1_kowloon-waterfront-zahner.jpg?strip=all&lossy=1&quality=92&webp=85&ssl=1 1080 1920 cmorris https://www.azahner.com/wp-content/uploads/2020/05/logo.svg cmorris2016-08-15 23:31:162020-10-30 10:57:16Kowloon Station

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.

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.

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

PHOTO © DRONE & FILM STUDIOS.
KAUFFMAN CENTER FOR THE PERFORMING ARTS.

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.

KAUFFMAN CENTER FOR THE PERFORMING ARTS.

PHOTO © DRONE & FILM STUDIOS.
Zahner installers set panels at Kauffman Center.

Zahner installers set panels at Kauffman Center.

Photo © A. Zahner Company.
Installation of Kauffman Center interior metalwork by Zahner field operators

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

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.

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

Photo © A. Zahner Company.
Kauffman Center architectural paneling

Kauffman Center architectural paneling.

Photo © A. Zahner Company.
KAUFFMAN CENTER FOR THE PERFORMING ARTS.

KAUFFMAN CENTER FOR THE PERFORMING ARTS.

PHOTO © DRONE & FILM STUDIOS
KAUFFMAN CENTER FOR THE PERFORMING ARTS.

KAUFFMAN CENTER FOR THE PERFORMING ARTS.

PHOTO © DRONE & FILM STUDIOS.
https://e5awgs3wuhi.exactdn.com/wp-content/uploads/2016/08/20101911/Entire-Structure-Kauffman-Center-Inspection-5-grad.jpg?strip=all&lossy=1&quality=92&webp=85&ssl=1 1665 2500 cmorris https://www.azahner.com/wp-content/uploads/2020/05/logo.svg cmorris2016-08-15 23:31:142023-01-20 10:20:44Kauffman Center
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UT Arlington Cooper Street Bridge

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