Scottsdale Civic Center

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Lake|Flato and Dig Studio collaborated with the City of Scottsdale to transform the Civic Center into a vibrant, family-friendly green space and premier event destination in Scottsdale’s Historic Old Town. Zahner provided engineering, fabrication, and installation expertise for key architectural elements, enhancing the park’s artistic and structural identity.

Surrounded by significant cultural and civic institutions, the Civic Center’s design connects the city, the arts, and the community in a unified space. The Civic Center features multiple pavilions, including a new multifunctional 360-degree event structure. These purposefully designed spaces come together to create a cohesive and welcoming environment.

Aerial view of the Scottsdale Civic Center.

Aerial view of the Scottsdale Civic Center.

Aerial view of the Scottsdale Civic Center.

Aerial view of the Scottsdale Civic Center.

Lighting emphasizes the sculptural qualities of the pavilions at night.

Lighting emphasizes the sculptural qualities of the pavilions at night.

The perforations in the pavilions create dappled shade.

The perforations in the pavilions create dappled shade.

Eaves made of the same panel material as the pavilions creates an cohesive aesthetic.

Eaves made of the same panel material as the pavilions creates an cohesive aesthetic.

Detail view of the pavilion structure during the day.

Detail view of the pavilion structure during the day.

Detail view of one of the pavilions at night.

Detail view of one of the pavilions at night.

Aerial view of the multifunction event space.

Aerial view of the multifunction event space.

Grand Foyer in the Ambassador Building at Embassy Gardens

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Located in London’s Nine Elms cultural district, the Embassy Gardens residential and commercial development features an award-winning lobby in the Ambassador Building across from the US Embassy.

Zahner collaborated with Luis Bustamante on the stunning lobby design which also features an art wall design by Jan Hendrix, illuminated by Gia Equation. Zahner crafted waterjet-cut aluminum panels, using 12mm recycled aluminum, with a white powder coating.

The panels feature a unique v-cut fold, giving a sculptural edge without welds, showcasing Zahner’s advanced machining technology. This seamless design enhances the forest canopy image as studied and designed by Hendrix. The project exemplifies innovative collaboration and sustainability, with all cut-out material recycled and the artwork designed for future recyclability.

Interior art wall featured within the lobby of the Embassy Gardens in London.

Interior art wall featured within the lobby of the Embassy Gardens in London.

PHOTO © A. ZAHNER COMPANY.
Close up of interior art wall featured in the Embassy Gardens. The image depicts a forest canopy.

Close up of interior art wall featured in the Embassy Gardens. The image depicts a forest canopy.

PHOTO © A. ZAHNER COMPANY.
Detailed side view of interior art wall.

Detailed side view of interior art wall.

PHOTO © A. ZAHNER COMPANY.
Detail of the panels' v-cut, miter-like folded corners.

Detail of the panels' v-cut, miter-like folded corners.

PHOTO © A. ZAHNER COMPANY.

Mount Sinai Medical Center Parking Garage

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Zahner’s latest collaboration with facade designer Faulders Studio and KVC Constructors has produced the stunning Mount Sinai Medical Center Parking Garage Facade in Miami Beach, Florida. The 6-story, 929-automobile Employee Parking Garage is enveloped by a nearly 27,000 sq ft facade that covers three elevations of the parking structure, conceptualized by Netta Architects.

Positioned near the bustling Julia Tuttle Expressway, the facade’s sweeping contours echo the continuous flow of passing vehicles and the soothing waters of Biscayne Bay. The facade’s design blends broad horizontal lines with dynamic geometric contours, accentuated by a series of projected fins that create shadows throughout the day and provide a sense of movement. This visually arresting pattern complements and enhances the architectural landscape of the Mount Sinai Medical Center campus.

The facade’s design is not only aesthetically pleasing but also functional, allowing natural ventilation and daylight penetration. The structure maintains a balance between its functional role and its architectural presence, aiming to support and supplement the other medical buildings nearby.

Facade lighting at night on Mount Sinai Medical Center Parking Garage in Miami Beach, Florida

Facade lighting at night on Mount Sinai Medical Center Parking Garage in Miami Beach, Florida

Photography courtesy of Miami In Focus, Inc. – Peter Leifer, Cheryl Stieffel
Mount Sinai Medical Center Parking Garage Facade in Miami Beach, Florida

Mount Sinai Medical Center Parking Garage Facade in Miami Beach, Florida

Photography courtesy of Miami In Focus, Inc. – Peter Leifer, Cheryl Stieffel

Mount Sinai's Parking Garage allows for natural ventilation and daylight penetration

Mount Sinai's Parking Garage allows for natural ventilation and daylight penetration

Photography courtesy of Miami In Focus, Inc. – Peter Leifer, Cheryl Stieffel
Detail view of facade mounting hardware on Mount Sinai's Parking Garage

Detail view of facade mounting hardware on Mount Sinai's Parking Garage

Photography courtesy of Miami In Focus, Inc. – Peter Leifer, Cheryl Stieffel

Preservation Plaza

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The Preservation Plaza Stage offers a one-of-a-kind concert setting with the backdrop of West Lake Okoboji’s blue waters glistening in the background. The desire by the Historic Arnolds Park Incorporation (HAPI) and RDG Planning & Design to transform the area into a permanent event space has been realized from what was previously a green space frequented by lake goers for events.

Through a Zahner Assist engagement, Zahner worked with RDG to develop and refine the 6,400 square foot amphitheater that resembles the lake waves above and wooden boat hulls below. Nestled within the structural steel bays are Zahner’s patented aluminum ZEPPS. The structure finishes out with custom finished stainless steel flat seamroof panels, painted aluminum perimeter fascia, and columns covers.

Incorporated within Zahner’s work is the phenolic soffit system underneath which required intricate coordination with the provider. Apart from the structural steel and phenolic system, Zahner self-performed the installation over the course of six months and the project was completed in September of 2022. The Preservation Plaza Stage offers yet another unique experience to the charm and delight of the area and serves as a cornerstone anchoring the park for enjoyment by future generations.

The Preservation Plaza Stage in Arnolds Park, Iowa.

The Preservation Plaza Stage in Arnolds Park, Iowa.

PHOTO © A. ZAHNER COMPANY.

The preservation plaza creates a permanent event space within Arnolds park.

The preservation plaza creates a permanent event space within Arnolds park.

PHOTO © A. ZAHNER COMPANY.
THE PRESERVATION PLAZA STAGE IN ARNOLDS PARK, IOWA.

THE PRESERVATION PLAZA STAGE IN ARNOLDS PARK, IOWA.

PHOTO © A. ZAHNER COMPANY.
THE PRESERVATION PLAZA STAGE IN ARNOLDS PARK, IOWA.

THE PRESERVATION PLAZA STAGE IN ARNOLDS PARK, IOWA.

PHOTO © A. ZAHNER COMPANY.

Mockup stainless steel skins were created to determine the best finish

Stainless steel skin mockup for THE PRESERVATION PLAZA.

Stainless steel skin mockup for THE PRESERVATION PLAZA.

PHOTO © A. ZAHNER COMPANY.
Custom finished stainless steel skins.

Custom finished stainless steel skins.

PHOTO © A. ZAHNER COMPANY.
PHOTO © A. ZAHNER COMPANY.
PHOTO © A. ZAHNER COMPANY.

The Preservation Plaza Stage lights up the night

The Preservation Plaza Stage offers a one-of-a-kind concert setting.

The Preservation Plaza Stage offers a one-of-a-kind concert setting.

PHOTO © A. ZAHNER COMPANY.

Paradise Plaza

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Paradise Plaza at the Miami Design District

Paradise Plaza is a one-of-a-kind venue in the Miami Design District, which can be easily transformed for any occasion or event. The space features modern, colorful architecture with floor-to-ceiling windows that look out at incredible views of the District and the Museum Garage.

Zahner provided design assist (through our Zahner Assist service), which included collaboration with the ownership team at Dacra and the architects of record at SB Architects, as well as design engineering for the individual design architects, FreelandBuck and Johnston Marklee.

Zahner fabricated and installed the painted aluminum soffits, wall panels, fascia, and column wraps, as well as the stainless steel custom column wraps and pedestrian bridge cladding, which feature Zahner’s Angel Hair® finish and both blue and silver mirror-polished stainless trim.

Painted aluminum soffits, wall panels, and fascia were designed by architects at FreelandBuck Design.

Painted aluminum soffits, wall panels, and fascia were designed by architects at FreelandBuck Design.

Photo by Chris Wells, ARKO | © A. Zahner Company

FreelandBuck Design

To create the surface geometry of the custom soffit, designed by FreelandBuck architects, Zahner engineers utilized a modified, more detailed version of our ZEPPS™ technology. This panel system also continues onto the space’s adjacent fascia, walls, and supporting columns.

View of the soffit and wall panel systems.

View of the soffit and wall panel systems.

Photo by Chris Wells, ARKO | © A. Zahner Company

The undulating geometric surface of the soffit system was created with Zahner's ZEPPS (Zahner Engineered Profile Panel System) technology.

The undulating geometric surface of the soffit system was created with Zahner's ZEPPS (Zahner Engineered Profile Panel System) technology.

Photo by Chris Wells, ARKO | © A. Zahner Company
View of the soffit system and wall panel systems (painted aluminum), trim (silver mirror-polished stainless trim), and column covers (Zahner Angel Hair stainless steel and blue stainless steel).

View of the soffit system and wall panel systems (painted aluminum), trim (silver mirror-polished stainless trim), and column covers (Zahner Angel Hair stainless steel and blue stainless steel).

Photo by Chris Wells, ARKO | © A. Zahner Company
Silver mirror-polished stainless trim connects the FreelandBuck and Johnston Marklee designs.

Silver mirror-polished stainless trim connects the FreelandBuck and Johnston Marklee designs.

Photo by Chris Wells, ARKO | © A. Zahner Company
The triangular design motif that is rendered through painted aluminum on the soffit system continues into the wall system, which is rendered via perforated metal wall panels.

The triangular design motif that is rendered through painted aluminum on the soffit system continues into the wall system, which is rendered via perforated metal wall panels.

Photo by Chris Wells, ARKO | © A. Zahner Company
View of the soffit and wall systems near the escalators on the second floor.

View of the soffit and wall systems near the escalators on the second floor.

Photo by Chris Wells, ARKO | © A. Zahner Company
View of the soffit and wall systems near the elevators on the second floor.

View of the soffit and wall systems near the elevators on the second floor.

Photo by Chris Wells, ARKO | © A. Zahner Company
Close-up view of the Zahner-fabricated and installed wall cladding.

Close-up view of the Zahner-fabricated and installed wall cladding.

Photo by Chris Wells, ARKO | © A. Zahner Company

Johston Marklee Design

The stainless steel custom column covers and pedestrian bridge cladding were both designed by Johnston Marklee architects. The column covers achieve the appearance of selective polish across the surface through the combination of separate parts assembled together, each featuring a different finish: Zahner Angel Hair, mirror stainless on the face, and blue mirror-polished on the inside edges.

The Johnston Marklee design features silver mirror-polish stainless steel trim, Zahner Angel Hair cladding, and blue stainless steel window trim.

The Johnston Marklee design features silver mirror-polish stainless steel trim, Zahner Angel Hair cladding, and blue stainless steel window trim.

Photo by Chris Wells, ARKO | © A. Zahner Company

The mirror-polish stainless steel trim reflects the sky, echoing the blue stainless steel of the window trim.

The mirror-polish stainless steel trim reflects the sky, echoing the blue stainless steel of the window trim.

Photo by Chris Wells, ARKO | © A. Zahner Company
Detail view of the mirror-polish stainless steel trim, Angel Hair cladding, and blue stainless window trim.

Detail view of the mirror-polish stainless steel trim, Angel Hair cladding, and blue stainless window trim.

Photo by Chris Wells, ARKO | © A. Zahner Company
Detail view of the Johnston Marklee design.

Detail view of the Johnston Marklee design.

Photo by Chris Wells, ARKO | © A. Zahner Company

Suzanne and Walter Scott Aquarium

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Suzanne and Walter Scott Aquarium at Omaha’s Henry Doorly Zoo

Originally built in 1995, renovations for the Suzanne and Walter Scott Aquarium at the Omaha Zoo were completed in May 2020, featuring a redesigned facade, an updated outdoor cafeteria area, and new entrance features to the aquarium and aquarium conference center. As our third project in the Omaha metro area, Zahner provided various new design elements for this renovation, including the stainless steel wave facade on top of the building, the custom-cut metal coral features and column covers, the dimpled blue stainless steel cladding around the café, and the milled sea creatures that adorn the walls surrounding the space.

Completed Sea Turtle Cafe at the Suzanne and Walter Scott Aquarium.

Completed Sea Turtle Cafe at the Suzanne and Walter Scott Aquarium.

Photo by Alexandra Hoffman, ARKO | © A. Zahner Company
Completed entrance sign for the aquarium, fabricated utilizing Zahner's ZEPPS system.

Completed entrance sign for the aquarium, fabricated utilizing Zahner's ZEPPS system.

Photo by Alexandra Hoffman, ARKO | © A. Zahner Company
Suzanne and Walter Scott Aquarium exterior and Sea Turtle Cafe at Omaha's Henry Doorly Zoo at sunset.

Suzanne and Walter Scott Aquarium exterior and Sea Turtle Cafe at Omaha's Henry Doorly Zoo at sunset.

Photo by Alexandra Hoffman, ARKO | © A. Zahner Company

Zahner was brought on early in the concept development stage to provide Design Assist, which allowed us to work closely with the project team to refine the design intent, provide guidance on materials and finishes, and construct a comprehensive mockup for review before the project went into full fabrication. Due to this collaboration, there were zero change orders on the scope, and installation ran smoothly in cooperation with the contractor and the other trades’ schedules.

Original sketch for the Suzanne and Walter Scott Aquarium facade, by Mark Bourne.

Original sketch for the Suzanne and Walter Scott Aquarium facade, by Mark Bourne.

Photo courtesy of Henry Doorly Zoo
Visual mockup for the Suzanne and Walter Scott Aquarium facade, assembled in Zahner's Kansas City facility.

Visual mockup for the Suzanne and Walter Scott Aquarium facade, assembled in Zahner's Kansas City facility.

© A. Zahner Company
Night viewing of the mockup for the Suzanne and Walter Scott Aquarium facade.

Night viewing of the mockup for the Suzanne and Walter Scott Aquarium facade.

© A. Zahner Company

The freeform wave facade that sits atop the Sea Turtle Café was fabricated using Zahner’s ZEPPS™ technology, which combined the framing structure and the exterior skin into a complete curvilinear system. The individual wave units were pre-fabricated in our shop and shipped to the job site, where Zahner field technicians installed the full facade.

Zahner field workers install the wave facade on top of the Suzanne and Walter Scott Aquarium.

Zahner field workers install the wave facade on top of the Suzanne and Walter Scott Aquarium.

PHOTO © A. ZAHNER COMPANY
Profile of the completed wave facade on top of the Sea Turtle Cafe at Omaha's Henry Doorly Zoo.

Profile of the completed wave facade on top of the Sea Turtle Cafe at Omaha's Henry Doorly Zoo.

Photo by Alexandra Hoffman, ARKO | © A. Zahner Company
The face of the waves features a custom etched pattern that provides a reflective, rippling water effect.

The face of the waves features a custom etched pattern that provides a reflective, rippling water effect.

Photo by Alexandra Hoffman, ARKO | © A. Zahner Company
View of the Sea Turtle Cafe outdoor space at sunset with lighting.

View of the Sea Turtle Cafe outdoor space at sunset with lighting.

Photo by Alexandra Hoffman, ARKO | © A. Zahner Company
Various multi-color lighting systems were incorporated into the design to emphasize the aquatic theme at night.

Various multi-color lighting systems were incorporated into the design to emphasize the aquatic theme at night.

Photo by Alexandra Hoffman, ARKO | © A. Zahner Company

Decorative painted aluminum coral features adorn the edges of the café’s canopy and wrap the supporting columns. These were cut on our water jet before they were hand-rolled to the correct radius.


Custom-embossed blue stainless steel clads the walls of the Sea Turtle Café and mimics the look of rippling water. Zahner fabricated a custom die to create this seemingly random emboss pattern. This feature is further highlighted by the lighting throughout the space, creating a fully immersive experience for visitors.


Zahner also provided the various metal sea creatures that decorate the walls of the café and the entrance sign. Each sea creature was individually milled out of aluminum on our CNC equipment.

The dual-layered coral feaures were waterjet cut out of aluminum to clad the edge of the canopy.

The dual-layered coral feaures were waterjet cut out of aluminum to clad the edge of the canopy.

Photo by Alexandra Hoffman, ARKO | © A. Zahner Company

Custom rippled blue stainless steel clads the ceiling of the outdoor cafe to create an underwater feel to the space.

Custom rippled blue stainless steel clads the ceiling of the outdoor cafe to create an underwater feel to the space.

Photo by Alexandra Hoffman, ARKO | © A. Zahner Company

Custom milled sea turtles and starfish against the rippled blue stainless steel cladding.

Custom milled sea turtles and starfish against the rippled blue stainless steel cladding.

Photo by Alexandra Hoffman, ARKO | © A. Zahner Company
Zahner millled out several different sea creatures to decorate the walls of the cafe, including sharks, jellyfish, turtles, stingrays, and starfish.

Zahner millled out several different sea creatures to decorate the walls of the cafe, including sharks, jellyfish, turtles, stingrays, and starfish.

Photo by Alexandra Hoffman, ARKO | © A. Zahner Company
All elements of Zahner's scope are further emphasized at night time.

All elements of Zahner's scope are further emphasized at night time.

Photo by Alexandra Hoffman, ARKO | © A. Zahner Company

SoFi Stadium

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SoFi Stadium is a sports and entertainment destination built in Inglewood, CA. Referred to as “unprecedented and unparalleled,” SoFi Stadium is the indoor/outdoor home of the Los Angeles Chargers and the Los Angeles Rams. SoFi will host a variety of events year-round, including Super Bowl LVI, the 2023 College Football Championship Game, and the 2028 Opening and Closing Ceremonies of the Olympic Games.

Designed by HKS, the 70,000-seat stadium also has a 6,000-seat venue and a 2.5-acre plaza, all of which are covered by a canopy of translucent ETFE membrane and 34,789 unique panels both in perforation and shape. Zahner’s expertise in perforated imagery (ImageWall®) was put to the test by HKS LINE and their image discretization algorithms/software. The panels were then manufactured by Zahner using a mass customization process developed in coordination with the architect.

THE INDEPENDENTLY-SUPPORTED CANOPY ALLOWS FOR WIND CIRCULATION, PROVIDES DIFFUSED LIGHTING, AND PROTECTS EVENT-GOERS FROM WEATHER.

HKS designed a unique canopy and skin for SoFi Stadium featuring custom-perforated anodized aluminum panels from Zahner.

PHOTO © NIC LEHOUX
ZAHNER PRODUCED 512 PANELS PER WEEK, OVER 67 WEEKS TO BE DELIVERED ON-SITE AND INSTALLED.

ZAHNER PRODUCED 512 PANELS PER WEEK, OVER 67 WEEKS TO BE DELIVERED ON-SITE AND INSTALLED.

PHOTO © NIC LEHOUX

Zahner was brought on board to provide Zahner Assist, which allowed the architect to prove out their design and materials. As a result of the design team’s satisfaction, Zahner was ultimately chosen to furnish the outer shell scope of the stadium.

Drone view of the Frost White anodized aluminum front soffit of SoFi Stadium.

Drone view of the Frost White anodized aluminum front soffit of SoFi Stadium.

Photo by Jesse Pacheco, ARKO | © A Zahner Company

Drone Video

Custom Frost White Anodized Aluminum

During the Zahner Assist phase, Zahner was asked to develop an anodized finish with a white tint for the project, which did not exist in the market at that time. Using Zahner’s expertise in metallurgy, the Frost White anodized finish was developed specifically for SoFi Stadium. Due to its weight and strength, aluminum has a great benefit in many architectural applications. This finish was also applied to the 16 feet-long leading edge fascia of the canopy, which Zahner fabricated and supplied.

Closeup of Frost White anodized aluminum triskin panels.

Closeup of Frost White anodized aluminum triskin panels.

© A Zahner Company
The unique Frost White anodized finish on 1/8 inch thick aluminum panels has never been used before in any other project.

The unique Frost White anodized finish on 1/8 inch thick aluminum panels has never been used before in any other project.

Photo by Jesse Pacheco, ARKO | © A Zahner Company
Drone view of the Frost White anodized aluminum front soffit of SoFi Stadium.

Drone view of the Frost White anodized aluminum front soffit of SoFi Stadium.

Photo by Jesse Pacheco, ARKO | © A Zahner Company

Mass Customization Through Digital Fabrication

Together with HKS, Zahner created a parametric design-to-fabrication workflow that streamlined production activities from the design model to the fabrication machine. On SoFi Stadium the promise of mass customization (part variation without additional cost) was realized through novel software automation and atypical project delivery methods.

A key to the production process was the transfer of design intent from the architect to Zahner. Instead of creating individual panel drawings (labor intensive to make and review), the architect provided ‘encoded’ text files with design intent for each unique panel. Zahner developed an automation script that automatically read each text file, nested each panel, and applied part specific fabrication parameters.

By virtue of this analysis, we were able to generate machine instructions directly from the design model, removing laborious tasks that traditionally add cost but not value. Ultimately this streamlined, collaborative process led to a drastic cut in the programming time for each panel from an unacceptable 15 min to an impressive 7 seconds per panel, managing the volume of unique panels efficiently and affordably.

Graphic showing the typical CNC fabrication method of one program producing 1000x parts.

Graphic showing the typical CNC fabrication method of one program producing 1000x parts.

© A Zahner Company
Graphic showing Zahner's challenge of 10,000x programs producing one unique part per program.

Graphic showing Zahner's challenge of 10,000x programs producing one unique part per program.

© A Zahner Company

This process fluidity is not typical in traditional production workflows where design and engineering tools are siloed from manufacturing tools. Here we wielded a computational dexterity common in the design/engineering software further downstream within the manufacturing process. The workflow allowed us to embed fabrication and sequence information directly into the CAD model during the design and engineering phase.

Included in the embedded information was an inscribed “dot code” on each panel, trackable via a custom app through the fabrication, shipping, and installation processes. This was a critical part of fabricating and shipping all 34,789 unique triskins under an expedited project schedule. Using this improved process, communication between architect, engineer, fabricator, and installer was seamless and the team was able to respond to project changes without incurring extra costs.

Project Timeline showing the reduction of computation and the growth of costs as a project progresses.

Project Timeline showing the reduction of computation and the growth of costs as a project progresses.

© A Zahner Company
Single panel design with fabrication details and instructions.

Single panel design with fabrication details and instructions.

© A Zahner Company
Closeup of panel design details.

Closeup of panel design details.

© A Zahner Company
Closeup of the inscribed "dot code" used to track the panel through the fabrication, shipping, and installation processes.

Closeup of the inscribed "dot code" used to track the panel through the fabrication, shipping, and installation processes.

© A Zahner Company

Fabrication Process

The panels attach to a steel space frame, which attaches to the steel superstructure surrounding the stadium; along with the roof, this makes up the canopy. The independently supported canopy (separate from the stadium bowl structure) covers the stadium, allowing for wind circulation, diffused lighting, and protection from the elements.

Custom tooling was designed by Zahner for creating the softened edges around the perforations.

Custom tooling was designed by Zahner for creating the softened edges around the perforations.

© A Zahner Company
Underside of the support structure that forms the SoFi Stadium canopy.

Underside of the support structure that forms the SoFi Stadium canopy.

© A Zahner Company
The triangular panels attach to a support system, which attaches to the steel structure surrounding the stadium.

The triangular panels attach to a support system, which attaches to the steel structure surrounding the stadium.

© A Zahner Company
Pre-fabricated mega panel being installed into place on-site.

Pre-fabricated mega panel being installed into place on-site.

© A Zahner Company
Zahner worker on site for the construction of SoFi Stadium.

Zahner worker on site for the construction of SoFi Stadium.

© A Zahner Company
Underside of the support structure that forms the SoFi Stadium canopy.

Underside of the support structure that forms the SoFi Stadium canopy.

PHOTO © NIC LEHOUX

Wynwood Garage

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The Wynwood Garage is a transformational mixed-use project that offers approximately 20,500 square feet of retail space, 428 parking spaces and 30,000 square feet of creative office space. The garage is also the first structured parking facility in Wynwood, at the center of the district.


The painted aluminum facade, designed by Faulders Studio, merges artistic unpredictability with the edgy neighborhood context and seamlessly blends the public benefit of parking with the commercial demands of Wynwood. According to Thom Faulders, “The facade and its shape-shifting patterns are “mega-subtle.” The perforated planes create multiple sight-lines that cascade around and envelop the structure in a way that is both highly specific and subdued. The wall is also designed to allow for additional artwork to be hung on the facade.

Custom perforated painted aluminum screen engineered and fabricated by Zahner.

Custom perforated painted aluminum screen engineered and fabricated by Zahner.

Photo by Tex Jernigan, ARKO | © A Zahner Company

Custom perforated painted aluminum screen engineered and fabricated by Zahner.

Custom perforated painted aluminum screen engineered and fabricated by Zahner.

Photo by Tex Jernigan, ARKO | © A Zahner Company
ZAHNER ENGINEERED AND FABRICATED OVER 54,000 SQUARE FEET OF FACADE PANELS.

ZAHNER ENGINEERED AND FABRICATED OVER 54,000 SQUARE FEET OF FACADE PANELS.

Photo by Tex Jernigan, ARKO | © A Zahner Company

The facade itself is constructed of a series of 1/8″ thick aluminum Drop & Lock panels, mounted to black painted aluminum mullions. A series of projected fin-like elements are mounted to the panels to provide depth to the design. The rounded corners appear to be free floating and utilize hot-dipped galvanized steel shapes to mount the mullions. These support points were design, fabricated and installed by Zahner.


Zahner was brought on to the project team early in the schematic design phase by Goldman Properties and Thom Faulders to develop his unique vison for the site in the Wynwood section of Miami. Zahner worked closely with the team, including the contractor, KVC Constructors, to design with the established budget in mind. This Zahner Assist approach yielded a series of tabletop mock-ups, and ultimately a large prototype, complete with the integrated lighting, was fabricated and installed at the Kansas City facility.

THE WALL IS DESIGNED TO ALLOW FOR ADDITIONAL ARTWORK TO BE HUNG ON THE FAÇADE.

THE WALL IS DESIGNED TO ALLOW FOR ADDITIONAL ARTWORK TO BE HUNG ON THE FACADE.

Photo by Tex Jernigan, ARKO | © A Zahner Company
Mockup created by Zahner with integrated lighting, fabricated and installed at the Kansas City facility.

Mockup created by Zahner with integrated lighting, fabricated and installed at the Kansas City facility.

© A. Zahner Company
Mockup created by Zahner through Zahner Assist process

Mockup created by Zahner through Zahner Assist process

© A. Zahner Company

Through Zahner Assist, we deliver enhanced value to the Design Assist phase by making it easier for owners, contractors, architects, and fabricators to communicate and work together towards project success. We have the experience and engineering capabilities all under one roof to develop system details, project budgets, and engineering specifications that create a general framework that the construction team can easily follow throughout the fabrication and installation phases.

Final installation of Zahner panels

Final installation of Zahner panels

Photo by Tex Jernigan, ARKO | © A Zahner Company
Final installation of Zahner panels

Final installation of Zahner panels

Photo by Tex Jernigan, ARKO | © A Zahner Company

Kravis Bench

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Kravis Bench; West Palm Beach, Florida

Located in West Palm Beach, Florida, the Kravis Center for the Performing Arts commissioned artist Robin Oglesbee-Venghaus to design, build and deliver a sculptural entrance setting. He collaborated with Zahner to develop an elegant solution for his composition entitled “The Embrace.”

Zahner designed and engineered the benches which were comprised of individual elements fastened together to form a dynamic bench—forms which use painted aluminum segments to form two 27 foot long curving benches. The bench heights are exaggerated for dramatic effect and taper in counterpoint to each other. The back side of the benches are clad in a translucent LG solid surface and are illuminated by continuous programmable LED fixtures.

Facade for 178 North Eleventh with antique copper patina in Brooklyn, New York.

Photo by Curtis Smith | ARKO​

Photo by Curtis Smith | ARKO​

Facade for 178 North Eleventh with antique copper patina in Brooklyn, New York.

Photo by Curtis Smith | ARKO​

Photo by Curtis Smith | ARKO​

Facade for 178 North Eleventh with antique copper patina in Brooklyn, New York.

Photo by Curtis Smith | ARKO​

Photo by Curtis Smith | ARKO​

Facade for 178 North Eleventh with antique copper patina in Brooklyn, New York.

Photo by Curtis Smith | ARKO​

Photo by Curtis Smith | ARKO​

Facade for 178 North Eleventh with antique copper patina in Brooklyn, New York.

Photo by Curtis Smith | ARKO​

Photo by Curtis Smith | ARKO​

Turbulence House

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An Artistic Guesthouse

Designed by Steven Holl Architects and manufactured using Zahner form-building technologies, Turbulence House functions as a guest home for artists Richard Tuttle and Mei-Mei Berssenbrugge.

Steven Holl likens the design to “the tip of an iceberg indicating a much larger mass below. The form allows turbulent wind to blow through its center.” The stressed skin and aluminum rib construction was digitally prefabricated in Kansas City and assembled on site in Abiquiu, New Mexico.

Related System

Turbulence House
A single ZEPPS Assembly for the Turbulence House is raised for installation.

A SINGLE ZEPPS ASSEMBLY FOR THE TURBULENCE HOUSE IS RAISED FOR INSTALLATION.

PHOTO © A. ZAHNER COMPANY.

Building the Curved Form

The architect initially provided Zahner with a small-scale physical model. Using 3D scanning capabilities, the team developed a digital model in CAD system Pro Engineer. (Today, the company uses a more sophisticated 3DEXPERIENCE platform.)

Zahner engineers used this model to refine the form into ZEPPS assemblies, the Zahner system for building sculptural forms. Typically, the ZEPPS system exists as a secondary structure to a structural steel primary support. For Turbulence House, the ZEPPS assemblies serve as the primary structure, which required additional engineering for full integration.

A total of 31 pre-fabricated metal assemblies, each with a unique shape, form the “shell” of the house. Galvalume, an alloy of zinc and aluminum, was used to create the building skin.

A second version of Turbulence House was installed indoors during an exhibition at the Basilica Palladiana in Vicenza, Italy. It is now permanently displayed on the grounds of a private company in northeastern Italy.

Steven Holl watercolor painting of the Turbulence House.

Steven Holl watercolor painting of the Turbulence House.

Photo © Steven Holl.

Physical model by Steven Holl Architects for the Turbulence House.

Physical model by Steven Holl Architects for the Turbulence House.

Drawings of the Turbulence House.

Drawings of the Turbulence House.

Photos © Steven Holl Architects.

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3D Model of the scanned physical model for Turbulence House.

3D Model of the scanned physical model for Turbulence House.

Image © A. Zahner Company.

ZEPPS conversion of the model, color-coded into individual ZEPPS assemblies.

ZEPPS conversion of the model, color-coded into individual ZEPPS assemblies.

Image © A. Zahner Company.

Turbulence House with partial cladding installed.

Turbulence House with partial cladding installed.

Internal rib system prior to drywall.

Internal rib system prior to drywall.

Interior of the Turbulence Residence.

Interior of the Turbulence Residence.

Photograph courtesy Steven Holl Architects.

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A section of the ZEPPS is lifted into the Basilica Palladiana in Vicenza, Italy.

A SECTION OF THE ZEPPS IS LIFTED INTO THE BASILICA PALLADIANA IN VICENZA, ITALY.