Yellow | Zahner

Guggenheim Canopy

December 30, 2016/in Art & Sculpture, Exterior Architecture Museum, Public Art New York City Frank Gehry Partners Rose, Yellow M 2001 /by cmorris

Guggenheim Canopy at the Solomon R. Guggenheim Museum

The Guggenheim Canopy, designed by Frank Gehry Partners, is a Zahner-manufactured installation which was on view at the Solomon R. Guggenheim Museum in New York City beginning in 2001. The artwork was erected for a Frank Gehry retrospective at the Museum in May-August, 2001. In addition to providing the canopy, Zahner also manufactured a number of mirror-polish stainless steel tables for the rooftop cafe.

The canopy artwork was manufactured using a titanium skin and aluminum structure. The form was made using ZEPPS, the Zahner-patented technology for building sculptural forms. This system was used to build the aluminum structure. The titanium was then clad over the aluminum substrate using a custom flat seam system.

The titanium’s luminescent coloring was made possible by a thick layer of oxide on the metal surface. There are two distinct overlapping forms, and each is colored using a unique color of titanium-cladding made by varying the oxide thicknesses. This oxide process is called interference-coating, and can be used to create a range of iridescent colors on stainless steels and titanium surfaces.

Guggenheim Canopy during its installation at the Guggenheim in NYC.

Detail of the two color tones used on the Guggenheim Canopy.

Guggenheim Canopy during its installation.

Guggenheim Canopy at the Zahner facility in Kansas City.

Structural bones of the Guggenheim Canopy.

100th Anniversary SMWIA

August 15, 2016/in Interior Architecture Exhibit, Museum Washington D.C. Frank Gehry Partners Silver, Yellow M 1988 /by cmorris

a Centennial celebration of monumental proportions

To celebrate the 1988 centennial of the Sheet Metal Workers International Association, the organization commissioned the then emerging architect, Frank Gehry, to design a temporary architectural structure to be placed inside the National Building Museum in Washington, D.C.

Engineered, fabricated, and installed through a collaborative process, the project was one of the first produced by Gehry with Zahner.

Zahner provided the four types of metal panel used to create the 65-foot-high structure: copper, polished brass, galvanized steel, and terne plate. The varying metal types and tones emphasized Gehry’s vision to represent a city in terms of ‘a collage of disparate pieces.’ Each panel, cut to various size, was placed in thoughtful juxtaposition, conveying a sense of organized chaos.

“

It’s like if you threw a bunch of objects into a can. You would still recognize them all. That’s what a city is, a collage of disparate pieces.

Frank O. Gehry

Zahner engineered, fabricated and installed of this custom sculptural form inside the National Building Museum. The installation was constructed for the Summer of 1988, afterwhich it was dismantled, repurposed and recycled.

Hope Tower at UNMC

August 15, 2016/in Art & Sculpture Education, Monument, Sculpture Omaha--Nebraska James Carpenter Design Associates Gold, Yellow L, M 2010 /by cmorris

Tower at University of Nebraska Medical Center

The Tower at UNMC is a James Carpenter Design Associates project. The project’s design team was led by Richard Kress. The campus art feature stands at 120 feet. A private donation led by Ruth and Bill Scott brought this iconic campus feature to the University of Nebraska Medical Center.

The tower serves provides a beacon for students, serving as both a navigational tool and an artistic centerpiece. Zahner provided the ti-coated stainless steel panels, perforated and prepped for installation onto the architect’s engineered frame. These panels were engineered and produced at Zahner at the Kansas City plant.

Related Surface

Hope Tower at UNMC

Detail of the steel structure and perforated ti-coated stainless steel.

The design features hundreds of triangular perforated 16ga titanium-coated stainless steel panels which attach to an open structure. The perforations effectively create a visually lightweight aesthetic.

The tower was designed to reflect the beautiful effects that occur in the Nebraska sky. It combines stainless steel and natural light to embody UNMC’s scientific character and the transient qualities of Nebraska’s skies. If it’s a bright sunny day, it will appear to shimmer. At dusk, it will reflect the variety of colors that are in the sky.

Installers place the triangular curving panels at UNMC in Nebraska.

Detail of the perforated triangular panels used on Hope Tower at UNMC.

The project was built in the course of a year, and completed in 2010. This is the second project that Zahner has completed for the architects and artists at James Carpenter Design Associates, the first being the Silver Towers Courtyard in New York City. The designers at James Carpenter provide a unique outlook on the play of light on surfaces, an effect which is best perceived in person.

Pearl Marriott

August 15, 2016/in Exterior Architecture Hospitality, LEED Pacific Northwest, Portland--Oregon SERA Architects Gold, Yellow M 2014 /by cmorris

Pearl District Marriott Residence Inn

The Pearl District Marriott Residence Inn, designed by SERA Architects, is a project featuring a bumped and perforated screenwall supplied by Zahner. Named for its neighborhood, the Pearl District is a historic area of Portland. Local businesses liken the urban district’s buildings to oysters, whose hidden ‘pearls’ were the gallery and artists’ spaces contained within — hence the name.

The Pearl District Residence Inn boasts 223 guestrooms in its six story building. A series of custom perforated aluminum panels by Zahner provide privacy screens for the rooms and decorative shading along the front of the façade. These painted yellow screens also add an element of modernity to the surrounding historic warehouse structures, elevating the extended stay hotel from the typical guest experience.

Parametrically Designed Perforation and Embossing

When SERA Architects approached Zahner with their idea for the perforation pattern, it existed as a simple jpeg image of an evanescent starburst shape. Zahner’s team of design engineers used that image to create an algorithmic concept that mathematically defined each perforation. The process uses a customized ImageWall system to perforate imagery on the metal surface, and create subtle variation the building’s screen wall.

Pearl District Residence Inn Marriott in Portland, Oregon.

During the design phase, there was active communication between Zahner and SERA Architects regarding parameters and variables. This exchange of ideas was essential to reach the final design. In order to make the gradation blend in a more nuanced, subtle manner, dithering was applied during the engineering process. Zahner also worked with the designers to create a series of embossed and debossed bumps, which added texture as well as rigidity to the panels. This additional rigidity means that the metal could be specified at a thinner gauge, reducing the material cost for the client.

During this design engineering process, files were exchanged between Zahner and the architects, along with several different iterations of samples. Once the final design was determined, the files went from design engineering into production engineering.

Efficient Installation of Custom Perf Panels

The architects wanted to create seamless connection details with no visible fasteners and clean edges. The system used to achieve this is the Inverted Seam, a patented system developed for this purpose. In addition to the wall panels, Zahner provided vertical aluminum extrusions which provide the support structure. These vertical extrusions have slots so that the aluminum panels lower in and lock into place without any need for additional fasteners. This is a Drop & Lock connection.

Zahner’s locking panels require no additional hardware or attachment methods, making for a straightforward install and no visible fasteners. Each panel was also labeled with a unique code, corresponding to its location on the building. This streamlined process enabled the local installers to position and fasten the panels with ease, reducing the schedule for the client.

MIT Stata Center

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

The Ray and Maria Stata Center at MIT, Building 32

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

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

Related Project

Fisher Center

The performance center was completed in 2003, designed by Frank Gehry Partners. Zahner has been involved with Gehry's firm since the beginning, and has been involved in a number of featured Gehry projects over the years. The Bard College was finished a year after Weatherhead at Case Western, and a year prior to the Pritzker Pavilion in Millennium Park, Chicago. All three were built using Zahner engineering-design, fabrication, and installation.

Designing the Building Envelope for Stata Center

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

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

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

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

Facade installers in their office at MIT.

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

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

Mockup for one of the buildings at MIT Stata Center.

Construction comparison of the MIT Stata Center giraffe building.

Aerial photograph of MIT Stata Center during construction.

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

Vista building at MIT Stata Center during construction.

Twins building during construction revealing the ZEPPS panel understructure.

The Twins building at MIT, installation detail.

Dome on the Plaza

August 15, 2016/in Exterior Architecture Historic Kansas City Gastinger Walker Harden Brown, Orange, Red, Yellow M 2008 /by cmorris

The Dome on the Country Club Plaza

Working with Gastinger Walker Harden Architects and Highwood Properties, Zahner produced the subtly spiraling domed roof for Baja 600 Restaurant on the Country Club Plaza in Kansas City. Zahner designed, engineered, fabricated, and installed the Dome using zinc with custom patina.

The Dome on The Plaza uses Roano Zinc, a preweathered zinc with custom patina. The Roano Zinc surface is an aged patina whose variegated tones vary from panel to panel, creating an aged aesthetic suitable for both contemporary and historic architecture.

Domed roofs are complex feats of engineering, and this one is no different. Constructing the dome’s cladding required sophisticated planning and layout. Each row of panels is characterized by a unique panel shape, requiring over twenty panel types. Zahner engineers mapped the thirty foot diameter dome so that the complex surface would be easily installed.

Roano Zinc patina featured as part of the Dome on the Plaza.

Photograph of the Dome on the Plaza after decade of aging.

Roano Zinc-clad Dome on the Country Club Plaza during installation.

Denny’s Flagship

August 15, 2016/in Exterior Architecture, Interior Architecture Flagship, Furniture, Restaurant Las Vegas--Nevada James Wines Yellow M 2012 /by cmorris

Denny’s Flagship Diner in Las Vegas

Wrapped in a yolk-yellow nest of painted aluminum cantilevered ribbons, the Denny’s Flagship acts as a bright yellow beacon even at the center of 3 miles of neon lights. Denny’s executives are calling it the ‘Diner of the Future’.

James Wines of SITE in New York was chosen to lead the design of the rebranded Denny’s Flagship Diner. The team wanted to create a striking surface with visual intrigue to mark a transformation of the Denny’s brand. Zahner’s Design Assist Group worked with James Wines’ team of architects, designers, and executives to arrive at a custom formed aluminum surface. This material was shaped and then painted to create an undulating wave of yellow.

The undulating wall appears to emerge from the flat plane. Curving lace-work falls back to the surface in an unbroken, seamless manner. This is the Denny’s of the future.

Photograph of the completed Denny's Flagship Diner / Early rendering of the desgin.

Building a New Brand for Dennys

Over the years, Zahner has played a role in the architectural rebranding for various flagship properties such as Nike, Diesel, and Burberry. More than simply producing the facades specified by the designers specify, the Zahner team offers an exploration of materials and processes, employing artistic and technical innovation to their fabrication expertise. For the Denny’s Flagship Diner, Zahner provided the architects with a tailored R&D experience.

This process usually occurs as the project begins during Design Assist. The Design Assist contract provides the design team with ways to reduce the project’s cost, improve efficiency, and explore processes that can meet the Designer’s expectations with ingenuity.

Preliminary project sketches by James Wines.

Zahner mockup tower shows Denny's prototype adjacent to the Basra Stadium mockup.

Close-up of the Denny's Flagship metalwork in Las Vegas.

Details shows the custom milled interlocking metalwork on the facade-testing tower.

Denny's Flagship Diner in Las Vegas on Fremont Street.

Fabricating the Denny’s Facade

The intricate metal surface was water jet cut using a pattern provided by the architects. The pieces were all pre-assembled in the Zahner shop. Zahner produced the facade to meet code requirements and added concealed joinery for visual aesthetic. Where exposed bolts were used, a custom milled interlocking system was implemented to provide visually seamless connections. The surfaces were painted locally using a bright yellow painted finish to match the Denny’s corporate branding.

The building began fabrication in July 2012 and was completed in November 2012. Working to promote James Wine’s vision, the Zahner team helping bring the design to life.

Column covers at the Zahner shop during fabrication.

Denny’s Flagship Diner in Las Vegas on Fremont Street.

Images courtesy SITE | Matthew Gindlesperger.

Clyde Frazier NYC

August 15, 2016/in Interior Architecture Restaurant New York City Morphosis Black, Blue, Blue-grey, Brown, Charcoal, Gold, Green, Grey, Indigo, Light blue, Magenta, Orange, Red, Silver, Violet, White, Yellow M 2012 /by cmorris

Clyde Frazier’s Wine & Dine in New York City

Clyde Frazier’s Wine & Dine is a new construction high-end sports bar and eatery designed by Morphosis. The space features a Zahner-manufactured ceiling, made using generative design and automated fabrication.

Designed by Morphosis for NBA Champion and former New York Knicks Player Walt Clyde Frazier, this New York City restaurant expands a full city block in the Hell’s Kitchen neighborhood. A swarm of suit jackets dominates the central corridor of Clyde Frazier’s Wine and Dine, a 10,000 square foot experience which mixes American and Asian cuisines.

Zahner provided the ceiling architectural feature. This ceiling is made up of custom cut and folded aluminum plates, 544 in total. The aluminum plates are printed from photographs of Mr. Frazier’s suit jackets. These parts are segmented into six unique shapes, where are placed at intervals of increasing distance. This interval placement creates the illusion that every part is unique.

Clyde Frazier's Wine & Dine in New York City.

The colors in the model categorize the panels according to breaks and sizes. Between the differing anchor placements, prints, panel sizes, and panel shapes, all 544 aluminum panels ended up being unique.

Even more complex were the ribs which held them in place. Because the panels were anchored at different angles, every drill hole had to be custom placed. Thus, each of the 69 ribs had 6 segments for a total of 463 segments, each with 3 unique faces.

3D model for Clyde Frazier's Wine and Dine.

“The transformative feature in the room, however, is suspended from the ceiling, where a 170-foot-long assemblage of colorful, patterned, flat and folded aluminum fins floats over the dining area, bar, and lounge. Morphosis found the stripes, plaids, and prints for this polychromatic sculptural reef in Frazier’s closets.

The architects photographed their contents and, working with Zahner’s metal fabricators, digitally printed images for a film adhesive applied to 544 aluminum panels of six shapes. The palette varies from blue to brown-gold to charcoal, with red painted undersides enhancing the gestalt. ‘It’s mesmerizing,’ says Frazier.” — Suzanne Stephens, Architectural Record.