Vancouver BC | Zahner

Fabricating the Weathered Steel Facade

The only way to reach this island is by taking a ferry directly from Vancouver, traveling through the narrow passage separating Mayne Island and Galiano Island. Because traveling to the house is an adventure of itself, the structural modules that make up the house had to be prefabricated, shipped over by ferry, and driven up the site on 23 trucks. Zahner provided the Solanum Steel pre-weathered sheets to local fabricators.

The design has many interior elements that bring the modern edge inside such as skylights framed with red steel beams, giant glass walls, and high windows hidden by the perforated Solanum Steel surface. The high windows are hidden so the rock-shaped perforations can cast light onto the adjacent wall adding a playful pattern to the room throughout the day. This same perforated pattern can be seen with the powder-coated aluminum on the edge of the infinity pool that is equipped with a waterslide.

This residence at Gulf Islands evokes the ebb and flow of its surrounding landscape. To learn more about Zahner’s custom patinas, see the surfaces page of the website, or contact Zahner about developing a custom patina to fit the needs of your project.

Fairmont Pacific Rim in Downtown Vancouver BC, Canada

Located in downtown Vancouver, BC, Canada, a 44-story hotel was designed by James KM Cheng, just blocks from the Pacific Ocean. Zahner became involved when the architects opted for a perforated screen system which would disguise the first few floors of office and parking structures, while allowing light and air to enter through the thousands of tiny perforations.

What sets this perforated screen apart from standard fare is its unique surface design, a patterned perforated and bumped texture which subtly glistens across the surface. Architects wanted to solve two problems with one solution: creating a parking garage with an open air-flow, and an artistic facade surface that reflected the building’s natural surroundings.

Using Zahner’s patented ZIRA system, architects supplied Zahner with a photograph of the surrounding forest. The image was transferred onto the metal using perforations and dimples in the stainless steel. All across the building’s structure, trees create vertical lines running up and down the facade, and the forest emerges.

Fairmont Pacific Rim designed by James KM Cheng.

Translating the Image to Metal

The architect supplied a photograph of redwood trees taken in the surrounding nature of Vancouver, pictured below. The image was translated using software originally developed by Zahner for the de Young Museum in San Francisco.

The translated image data was applied across the metal surface algorithmically to account for panelization. Each of the perforated metal panels is designed with metal flange details that the ZIRA™ Process had to account for in the process of translating data. The image flows seamlessly across these panels and around the building’s corner edges.

Original Photograph supplied to Zahner for the ZIRA™ Visualizer Process.

The architects wanted to create a rippled effect with the metal, to create a surface both luxurious and functional. Using the ZIRA Process enables the architect to create this surface at a cost not much higher than a uniformly perforated surface.

No panel is the same, and the pattern never repeats itself across the stainless steel surface. Both the perforated surface as well as the bumped and dimpled texture were produced using a system of CNC-controlled punches and dies.