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KCPD Headquarters

August 15, 2016/in Exterior Architecture, Interior Architecture Government, Highrise, LEED Kansas City Helix Blue-grey L 2015 /by cmorris

Kansas City Police Department HQ RENOVATION & EXPANSION

KCPD Headquarters’ renovation and expansion was led by Helix Architecture and features Zahner fabrication and design assist exploration. The existing building, which hadn’t been renovated since opening in 1938, features both a new tower expansion as well as historical restoration and renovation to the original building interior and exterior spaces.

The Kansas City Police Headquarters renovation marks a shift in how police departments can use architecture to shift perception and engagement in the community. The building update provides a modernized facility for KCPD employees, as well as a first floor community atrium for citizens to engage in the Police Department’s Headquarters. 

Zahner’s scope on the project included both interior and exterior cassette panels in pre-weathered zinc. The panel layout positions the zinc skins diagonally skyward, and its unique diamond shape emphasizes the vertical nature of the space, providing the new addition with a sense of fortitude.

THE DE YOUNG MUSEUM IN SAN FRANCISCO. ZAHNER OWNED THE ENTIRE EXTERIOR COPPER SKIN AND GLAZING.
Related System

Embossing

Zahner's unique history of metal embossing for bumped and dimpled metal surfaces has been used over the years to create unique approaches to metal panel systems. Create deep textures in metal surfaces with your designs.

Photograph of the KCPD Community room during the opening ceremony for the renovated police headquarters.

Photograph of the KCPD Community room during the opening ceremony for the renovated police headquarters.

PHOTO © A. ZAHNER COMPANY.

Detail of the punched and custom-embossed zinc exterior facade at KCPD Headquarters.

Detail of the punched and custom-embossed zinc exterior facade at KCPD Headquarters.

PHOTO © A. ZAHNER COMPANY.

Interior space with custom zinc feature wall at KCPD Headquarters.

Interior space with custom zinc feature wall at KCPD Headquarters.

PHOTO © A. ZAHNER COMPANY.

Interior space with custom zinc featurewall at KCPD Headquarters.

Interior space with custom zinc featurewall at KCPD Headquarters.

PHOTO © A. ZAHNER COMPANY.

Rooftop terrace at Kansas City Police Department Headquarters.

Rooftop terrace at Kansas City Police Department Headquarters.

PHOTO © A. ZAHNER COMPANY.

Keeping with the KCPD’s desire to increase community interaction, extensive improvements were also made to the first floor where visitors enter the space. Here a community room serves as a space for meetings and public engagement.

The interior spaces continue the embossed zinc cladding, providing a backdrop for art by Rob Ley of Urbana, and giving cohesion between the addition and the existing historic building. The interior panels also serve the dual purpose of providing noise mitigation at the entrance of the space.

Creating a Custom-Embossed and Perforated Zinc Panel

Rather than adding patina to the sheets, Helix designers were interested exploring various possibilities with machined surfaces. The exterior panels located on the tower expansion feature a racetrack-shaped obround bump which is repeatedly embossed into the metal surface. This texturing of the metal adds rigidity to the panels to prevent wavering in the metal panels. When assembled in unison, the repetition of these shapes emulates the warp and weft of the officers’ cloth uniforms.

The unique panel system was tested in two mockups at Zahner, each of which provided valuable insight into how to provide the complex geometries of the zinc system.

Zinc panel siding mockups are displayed at Zahner for architectural analysis.

Zinc panel siding mockups are displayed at Zahner for architectural analysis.

PHOTO © A. ZAHNER COMPANY.

Interior zinc wall during installation at KCPD Headquarters.

Interior zinc wall during installation at KCPD Headquarters.

PHOTO © A. ZAHNER COMPANY.

Corner mockup for the KCPD facade.

Corner mockup for the KCPD facade.

PHOTO © A. ZAHNER COMPANY.

Rendering of the renovation provided to the KCPD Headquarters.

Rendering of the renovation provided to the KCPD Headquarters.

PHOTO © A. ZAHNER COMPANY.

Designing Custom Perforated Panels using Zinc

The existing entrance for the project is largely composed of non-absorptive materials such as glass and tile. This meant that finding a solution to mitigate noise in the community entrance was of utmost importance. The designers at Helix worked with Zahner to develop a series of micro perforations and sound-absorptive backing on the panels.

The perforations allow noise to enter, while acoustic material nestled within the panel absorbs noise. The perforated surface of the zinc further prevents echo and reverberation of sound from coming back out of the panels. Zahner provided the entire custom perforated panel as one unit, with the acoustic backing already within each panel and ready for installation.

Detail of the punched and custom-embossed zinc acoustic panels at KCPD Headquarters.

Detail of the punched and custom-embossed zinc panels at KCPD Headquarters.

PHOTO © A. ZAHNER COMPANY.

The building facade has an appearance of armored cladding.

The building facade has an appearance of armored cladding.

PHOTO © A. ZAHNER COMPANY.

Interior and exterior zinc metalwork at the Kansas City Police Department Headquarters.

Interior and exterior zinc metalwork at the Kansas City Police Department Headquarters.

PHOTO © A. ZAHNER COMPANY.

Managing the Building’s Historic and Green Construction

In order to accommodate the police department’s need for continued use of the space, the general contractor, JE Dunn, divided the project into several phases. Special consideration was also taken towards historic pieces, such as marble in the restroom. Historically significant materials were refurbished and reused in other areas of the building.

This eco-friendly design decision is also echoed in Helix’s desire to use zinc panels. The zinc was sourced from Jarden Zinc, who also provides coin blanks to mints from around the world (including the blanks used to make the US penny). The leftover material from the coinage is melted down to produce sheets. All zinc used for the KCPD Headquarters is 100% recyclable and environmentally friendly. The project is anticipated to receive a LEED Gold certification.

Interior walls with zinc cladding, photographed with the Rob Ley interior sculpture at KCPD Headquarters.

Interior walls with zinc cladding, photographed with the Rob Ley interior sculpture at KCPD Headquarters.

PHOTO © A. ZAHNER COMPANY.

Detail of the punched and custom-embossed zinc acoustic panels at KCPD Headquarters.

Detail of the punched and custom-embossed zinc panels at KCPD Headquarters.

PHOTO © A. ZAHNER COMPANY.

https://e5awgs3wuhi.exactdn.com/wp-content/uploads/2020/07/24110607/4_custom-embossed-metal-panels-custom-bumped-surface.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 23:31:152024-04-09 12:54:56KCPD Headquarters

Kauffman Stadium

August 15, 2016/in Exterior Architecture Kansas City Populous L 2009 /by cmorris

Kauffman Stadium Improvements at Royals Ballpark

The recent Kauffman Stadium renovation for the Royals Ballpark in Kansas City was lead by the architects at Populous. Zahner provided an exterior stainless steel facade as well as improvements to the interior experience. The Zahner scope also included the Royals Crown artwork which can be seen atop the ballpark’s digital scoreboard.

The new structure at the Royals stadium features two sections which use selective perforations in stainless steel to create the image of the Royals logo on the surface of the metal.  This perforated surface  wraps the entire building, yielding a mesh facade which provides light, air control, and a visually intriguing artistic aesthetic.

A pattern of perforations and dimples allows glimpses of the original structure and the emblazoned the Royals’ graphic adds visual delight. Daylight and air transverse the facade, and the result is a breezy atmosphere which anticipates the excitement of the ballpark within.

Related Project

Royals Crown

Zahner was responsible for engineering, fabricating, and installing the Kauffman Stadium Crown using gold interference-coated stainless steel. The metal skin of the interference coating is nearly iridescent, and gives the surface an additional bright sparkle.

Kauffman stadium facade with perforated Royals logo emblazoned on its wall.

Kauffman stadium facade with perforated “Royals” logo emblazoned on its wall.

IMAGE © MIKE SINCLAIR

Light flows into through the perforated facade.

Light flows into through the perforated facade.

Photo © Mike Sinclair

Detail of the facade and shadows cast through the perforated metal.

Detail of the facade and shadows cast through the perforated metal.

Photo © Mike Sinclair

Detail of the perforated and embossed facade.

Detail of the perforated and embossed facade.

Photo © Mike Sinclair

The details above show the exquisite stainless steel surface, a process Zahner developed for a soft semi-reflective surface known as Angel Hair stainless steel. The detail photos also reveal how the logo is composed of a dimpled and perforated facade. When standing a hundred feet from the facade, these dimples and perforations disappear to the naked eye, becoming the Royals graphic seen above and below.

The Technology Behind the Surface

The pattern which determines the location of perforations and dimples is made using the Zahner-patented ZIRA Process. It allowed the client to choose a picture or graphic. The designers selected the Royals logo, which was then translated into machine language, fabricated, and installed by a team of Zahner engineers and artisans working together to ensure the highest quality result.

Today designers have access to ImageWall, which provides a fast way to upload images and automatically design perforated image metal systems. Many improvements in technology have occurred since this piece was manufactured. One example is the improved parametric relationship and perforation across a panel’s seam. This innovation is called Cross-Seam Perf, and it provides a more seamless aesthetic for perforated metal.

Related System

Kauffman Stadium

Detail of the perforated metal facade.

Detail of the perforated metal facade.

Photo © Mike Sinclair

Detail of the interior light filtration by the perforated metal facade.

Detail of the interior light filtration by the perforated metal facade.

Photo © Mike Sinclair

Photo © Mike Sinclair
Photo © Mike Sinclair
https://e5awgs3wuhi.exactdn.com/wp-content/uploads/2020/07/24115107/1_royals-stadium-c-sinclair-534402.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 23:31:152025-05-05 08:01:01Kauffman Stadium

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

Kansas City Star

August 15, 2016/in Exterior Architecture Industrial, LEED Kansas City Austin Group Green L 2006 /by cmorris

Kansas City Star Production Facility

The production facility for the Kansas City Star includes a locally manufactured, custom-patinated copper, created by Zahner for the building’s facade. The new production facility for the Kansas City Star was designed and developed by The Austin Company, an engineering design firm specializing in large-scale industrial facilities.

Zahner developed a preweathered copper patination system for this building. An estimated 4155 pre-patina copper panels were installed on the building’s surface to create the 80,000 SF surface area. The building’s green surface is mottled and variegated, a patina designed to age the building’s copper surface by 200 years. The natural patina will continue to grow and change in appearance as it ages. The patina provides a layer of natural protection for the copper alloy.

Related Surface

Custom Patinated Copper

Zahner has developed proprietary techniques to preweather copper and copper-alloyed sheets with deep, rich patinas not unlike those that formerly took several decades to develop naturally. Some of these techniques can develop the rich green and blue tones of cupric nitrate on the copper surface. Other techniques will develop browns, yellows, and oranges in various hues.

The Kansas City Star Production Facility.

The Kansas City Star Production Facility.

PHOTO © A. ZAHNER COMPANY.

The Kansas City Star Production Facility.

The Kansas City Star Production Facility.

PHOTO © A. ZAHNER COMPANY.

The Kansas City Star Production Facility.

The Kansas City Star Production Facility.

PHOTO © A. ZAHNER COMPANY.

The Kansas City Star Production Facility.

The Kansas City Star Production Facility.

PHOTO © A. ZAHNER COMPANY.

The Kansas City Star Production Facility.

The Kansas City Star Production Facility.

PHOTO © A. ZAHNER COMPANY.

https://e5awgs3wuhi.exactdn.com/wp-content/uploads/2020/07/24121557/1_natural-prewewathered-copper-kc-star-c-zahner-tex-jernigan-801.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 23:31:132020-10-30 18:32:00Kansas City Star

IwamotoScott

August 15, 2016/in Exterior Architecture Parking Structure Miami--Florida Iwamoto Scott, TimHaahs Blue, Blue-grey, Light blue L 2015 /by cmorris

City View Garage, Miami Design District

A geometric display of varying blue-toned aluminum skins adorns the Southeastern facade of the City View Garage in the Miami Design District. Designed by IwamotoScott Architecture, the Zahner-manufactured facade was developed in Kansas City and shipped as nesting parts to the job site in Miami, Florida. Zahner field installers hung the panels.

Sited along the Southern edge of the Miami Design District adjacent to I-195, the parking structure is part of a larger plan to bring arts, luxury, and culture into the new district. The main body of the building is a parking structure above a level of retail storefront and includes a small six story office block.

The building’s design averted the need for industrial ventilation of the parking area. IwamotoScott met this challenge with a modular decorative metal screen, whose mechanically-folded aluminum system features variously sized apertures to provide the required porosity for natural ventilation.

IwamotoScott was commissioned alongside New York-based architects Leong Leong and Southern California-based artist John Baldessari, by Dacra and L Real Estate to create three unique facades for the City View Garage in Miami’s Design District. The IwamotoScott portion of the facade wraps around the parking structure’s Southeast corner and includes an elevator lobby, exterior stair, and the office block.

Miami Design District City View Garage

featuring Baldessari's artwork between the Leong Leong Facade and the IwamotoScott facade.

featuring Baldessari's artwork between the Leong Leong Facade and the IwamotoScott facade.
Photo of IwamotoScott Facade for the Miami Design District City View Garage

Detail of the IwamotoScott Facade for the Miami Design District City View Garage.

Photo © A. Zahner Co.
Interior detail view of the IwamotoScott Facade for the Miami Design District City View Garage

Interior and roof view of the IwamotoScott Facade for the Miami Design District City View Garage.

Photo © A. Zahner Company.
Photograph of the IwamotoScott Facade during construction, Miami Design District City View Garage.

Photograph of the IwamotoScott Facade during construction, Miami Design District City View Garage.

PHOTO © A. ZAHNER COMPANY.

Developing the IwamotoScott facade for City View Garage

There are five different repeating modules, which are custom-fabricated by Zahner using 40 panel types. Zahner developed the modular design using powercopies to programmatically control the design’s various parts in both the operational engineering, plant, and hanging in the field.

The aluminum parts were painted using a gradient coloring scheme, which provides a subtle gradation of its five unique aperture sizes, suspended from fins which cantilever from the edges of the garage’s concrete slabs.

Digital model of the IwamotoScott facade, color-coded to indicate its five repeating panel types.

Digital model of the IwamotoScott facade, color-coded to indicate its five repeating panel types.

IMAGE © A. ZAHNER COMPANY.
DIAGRAMS FOR THE IWAMOTOSCOTT FACADE FOR THE MIAMI DESIGN DISTRICT CITY VIEW GARAGE.

Diagrams for the IwamotoScott Facade for the Miami Design District City View Garage.

IMAGE © A. ZAHNER COMPANY.
Diagram of the 40 panel types used to create the IwamotoScott Facade at Miami Design District.

Diagram of the 40 panel types used to create the IwamotoScott Facade at Miami Design District.

Images © A. Zahner Company.
Nested parts for the IwamotoScott facade in the Zahner Kansas City facility.

Nested parts for the IwamotoScott facade in the Zahner Kansas City facility.

Photo © A. Zahner Company.
Example photo of the crated IwamotoScott facade parts used on the City View Garage

Zahner fabricator crates the aluminum parts for the IwamotoScott Facade.

Photo © A. Zahner Company.
Photo of the IwamotoScott Facade for the Miami Design District City View Garage

Eastern view of the IwamotoScott Facade for the Miami Design District City View Garage.

Photo © A. Zahner Company.
Upward view of the IwamotoScott Facade for the Miami Design District City View Garage

Upward view of the IwamotoScott Facade for the Miami Design District City View Garage.

© A. Zahner Company
https://e5awgs3wuhi.exactdn.com/wp-content/uploads/2020/07/24111122/1_miami-cvg-copyright-lorraine-boogich-zahner-457.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 23:31:122023-01-30 15:08:30IwamotoScott

Instructional Centre

August 15, 2016/in Exterior Architecture, Interior Architecture Education, LEED Toronto--Canada Perkins + Will Blue, Charcoal, Green L 2011 /by cmorris

University of Toronto Mississauga Instructional Centre

The University of Toronto at Mississauga (UTM) has developed a number of unique buildings to serve the students on its campus.  The Instructional Centre at UTM is no different. Clad in a Zahner pre-patinated copper surface, this custom blue patina on copper was developed specifically for the project. 

The patina was an inspired decision by the architects at Perkins + Will whose design required a number of unique aspects for both the interior and exterior of the building.

The architects wanted a facade with an artistic patina, revealing the bare copper in some areas, and hitting dark points in others. This mottled appearance appears natural, but it is manufactured by Zahner. 

The award-winning University of Toronto Instruction Centre’s new building is certified LEED Silver, and was completed in 2011.

Related Surface

Instructional Centre

Under normal circumstances, raw copper sheet will develop a copper patina after ten to twenty years. In the case of the UTM Instructional Centre, this patina was developed in a matter of weeks by chemically oxidizing the metal in a controlled environment.

Zahner patina technicians developed a custom Star Blue patina on the copper, modifying its application technique for artistic effect. Zahner cultivates and trains patination experts for both their scientific prowess as well as their artistic vision, because many clients require a high-performance artistic patinated panel rather than a uniform machine-produced surface.

These copper sheets were then formed by Zahner into a panels. The prefabricated panels were crated and shipped to the job site in Toronto, where the pre-patinated panels were installed.

Students walking at dawn amidst the blue copper facade.

Students walking at dawn amidst the blue copper facade.

Photo © Lisa Logan, courtesy of Perkins + Will Architects.

Students walk up and down the main staircase.

Students walk up and down the main staircase.

Photo © Lisa Logan, courtesy of Perkins + Will Architects.

NonePhoto © Lisa Logan, courtesy of Perkins + Will Architects.
Detail of the exterior copper facade.

Detail of the exterior copper facade.

Photo © Lisa Logan, courtesy of Perkins + Will Architects.

Overhead view of the new building at UTM.

Overhead view of the new building at UTM.

Photo © Lisa Logan, courtesy of Perkins + Will Architects.

Interior view showing the variance of brown and green copper.

Interior view showing the variance of brown and green copper.

Photo © Lisa Logan, courtesy of Perkins + Will Architects.

Interior view showing the variance of brown and green copper.

Interior view showing the variance of brown and green copper.

Photo © Lisa Logan, courtesy of Perkins + Will Architects.

The mood of the patinated copper interior walls changes during the evening.

The mood of the patinated copper interior walls changes during the evening.

Photo courtesy of Perkins + Will Architects.

The Instructional Centre is built just northwest of the recently completed Hazel McCallion Academic Learning Centre. The new building features a cafe in the main entrance and lobby underneath the main staircase.

The Instructional Centre’s design includes two lecture halls stacked vertically and organized into three towers, each clad in the pre-patinated copper. Each of these solid volumes enclose smaller perimeter lounges, enticing students to gather before and after lectures.

The UTM Instructional Centre is located at the north end of campus in place of a parking lot.Read more about the pre-patinated Star Blue patina used on the surface of the building, or Contact Zahner to request custom samples for your project.

https://e5awgs3wuhi.exactdn.com/wp-content/uploads/2020/07/24112509/1_university-of-toronto-missassago-canada-flynn.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 23:31:102025-02-20 08:36:28Instructional Centre

Independence Temple

August 15, 2016/in Exterior Architecture Worship Center Independence--Missouri HOK L /by cmorris

Independence Temple & Community of Christ International HQ

Independence Temple is one of the first architectural icons produced in the Kansas City region with Zahner engineering and fabrication. Located in Independence, Missouri, the building was built in 1994. At the time of construction, it was the RLDS Temple, and later was renamed Independence Temple.

The shape of the design evokes the form of a spiral nautilus shell. Gyo Obata of HOK asked Zahner to develop a conical roof based on a conch shell that he had selected from a large collection of seashells during a design meeting. This form was developed with Zahner engineers into a roof system for the new church headquarters.

Related Project

White Chapel

Zahner was responsible to the Rose-Hulman Institute of Technology for the production and installation of the total building envelope. Zahner designed, fabricated, and installed the custom tapered roof and glazing system.

Independence Temple designed by Gyo Obata of HOK.

Independence Temple designed by Gyo Obata of HOK.

Aerial photograph of the Independence Temple designed by Gyo Obata of HOK.

Aerial photograph of the Independence Temple designed by Gyo Obata of HOK.

Photo © Bing.

Aerial photograph of the Independence Temple in Missouri.

Aerial photograph of the Independence Temple in Missouri.

Detail of the Independence Temple spire, designed by Gyo Obata of HOK.

Detail of the Independence Temple spire, designed by Gyo Obata of HOK.

PHOTO © A. ZAHNER COMPANY.

A prefabricated element of the roof spire is secured for shipment.

A prefabricated element of the roof spire is secured for shipment.

PHOTO © A. ZAHNER COMPANY.

The above picture provides a view into the engineering and construction used on the top of the spire.  Union workers at Zahner prepare the part for shipment.  After its installation, custom engineered panels are attached to the face of the this sub-structure, resulting in a quick and smart installation.

The solution for producing the roof consisting of more than 300 uniquely assembled megapanels, each tapered and unique in shape. This sheet metal skins of the roof cladding are produced in a custom-finish stainless steel. The complexity of this roof attests to the engineering and design prowess, as well as the skilled Zahner fabricators and installation team involved with this project.

How Buildings were Made in the Digital Dark Age

When this building was made in 1994, the architects at HOK used a proprietary software system to complete their design work.  At the same time, Zahner engineers were producing their work using AutoCAD to augment what was still mostly drafting at the time.

Today, everything is defined digitally, but in the 1990’s this task was very manual. To develop the project with accuracy, Zahner took field measurements of certain defining points of the roof, and radioed them back to the shop, where a custom written AutoCAD script was waiting to divide the roof surface into panels.

Today, a similar design would be developed from a digital model. However, at the time, using process was sufficient to give Zahner engineers the tools to produce this very intricate design. If Zahner were to produce the project today, the current technologies would cut the project’s schedule in half.

https://e5awgs3wuhi.exactdn.com/wp-content/uploads/2020/07/24121520/1_rlds-spire.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 23:31:102020-10-26 15:53:05Independence Temple

IBM Headquarters

August 15, 2016/in Exterior Architecture Corporate Armonk--New York Kohn Pedersen Fox L 1997 /by cmorris

IBM Headquarters at Armonk, New York.

Designed by KPF Architects for the international company IBM, the facade features a unique finish developed by Zahner engineers and fabricators.

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.

Designed to interact with its natural surroundings as much as possible, the building has a generous provision of controlled natural light and excellent views out to the landscape and open terraces for relaxation and informal meetings.

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. 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.
Related Project

The Petersen

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.

IBM Headquarters at Armonk, New York.

IBM Headquarters at Armonk, New York.

PHOTO © A. ZAHNER COMPANY.

How the IBM Headquarters Quietly Made Architectural History

The projects worked on by Zahner engineers and fabricators often provide great design challenges, not only for Zahner, but often for the entire architectural team. Some of the best architectural R&D happens in architecture by way of this collaboration — the mind and the hands, or the designers and the builders. 

For the IBM Headquarters, the desire to push the boundaries by KPF Architects was met and matched in an equal willingness for risk by the engineers and fabricators at A. Zahner Company. The architects wanted an softened reflectivity in its metal surface. This is something which wasn’t being offered in architecture at the time. The architects also wanted pristine edges at a time when most sheet metal fabrication was done by metal braking systems, which gave the metal corners a rounded radius. 

Zahner set about developing these two technologies that would go on to shape and influence facade design and architecture aesthetics. The first was its surface, a uniform non-directional finish on stainless steel developed with Rimex in the United Kingdom. The surface which went on to influence Zahner’s own GB-60 stainless steel.

The second innovation is a metal fabrication technique used to create sharp uniform corners, Zahner’s Radius Reduction technologies. Instead of traditional brake-forming of the panels, the metal’s edges were formed by deeply scoring the backside of the panels so that the folds were sharply creased, so much so that the front panels appear as solid metal surfaces.

Detail of the thick machined plate stainless steel on the IBM Headquarters.

Detail of the thick machined plate stainless steel on the IBM Headquarters.

PHOTO © A. ZAHNER COMPANY.

Detail of the plate panel systems on the IBM Headquarters.

Detail of the plate panel systems on the IBM Headquarters.

PHOTO © A. ZAHNER COMPANY.

Detail of the satin reflectivity of the plate panels used on IBM Headquarters.

Detail of the satin reflectivity of the plate panels used on IBM Headquarters

PHOTO © A. ZAHNER COMPANY.

Stainless steel plate panel system developed by Zahner for IBM Headquarters.

Stainless steel plate panel system developed by Zahner for IBM Headquarters.

PHOTO © A. ZAHNER COMPANY.

IBM Headquarters Entrance at Armonk, New York.

IBM Headquarters Entrance at Armonk, New York.

PHOTO © A. ZAHNER COMPANY.

Upward view of the IBM Headquarters Entrance at Armonk, New York.

Upward view of the IBM Headquarters Entrance at Armonk, New York.

PHOTO © A. ZAHNER COMPANY.

Aerial photograph of the IBM Headquarters in Armonk, New York.

Aerial photograph of the IBM Headquarters in Armonk, New York.

PHOTO © BING.

The building assumes an extended, tapering Z-shape, which adapts well to both the existing site contours and to the open space program required by IBM as a significant change to their corporate culture. The central wing includes areas of enclosed space for executive offices and meeting rooms. The connecting wings maintain a highly functional core-to-wall depth to accommodate the open office workstations. The internal, irregular spaces within the plan are utilized for conference rooms, services and core functions.

The client for the project was IBM Corporation, and the design team included Swank Hayden Connell as interior designer. The entire project’s footprint is 280,000SF.

The award-winning design was recongnized by The Chicago Athenaeum: Museum of Architecture & Design American Architecture Award as well as AIA Westchester Chapter Architecture Award.

https://e5awgs3wuhi.exactdn.com/wp-content/uploads/2020/07/24114616/1_ibm-world-headquarters-c-zahner-6100.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 23:31:092025-05-05 08:42:38IBM Headquarters

Hunter Museum

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

THE Hunter Museum of American Art

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

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

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

Related Project

Taubman Museum

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

View of the Hunter Museum of American Art at sunrise.

View of the Hunter Museum of American Art at sunrise.

Detail of the New Hunter Museum entrance.

Detail of the New Hunter Museum entrance.

Photo © Scott Moore.

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Visitors on the outdoor deck of the Hunter Museum.

Visitors on the outdoor deck of the Hunter Museum.

Interior of the Hunter Museum.

Selecting the Surface

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

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

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

Building the Hunter’s Curves

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

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

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

Contractors standing below several recently installed ZEPPS Panels during construction.

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

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

View of the exposed beams which will soon form the upward-curving awning.

View of the exposed beams which will soon form the upward-curving awning.

View of the awning, partially clad in its finished stainless steel surface.

partially clad in its finished stainless steel surface.

partially clad in its finished stainless steel surface.

View of the Preweathered Zinc Museum.

View of the Preweathered Zinc Museum.

CAD-view of the Hunter Interior Staircase, with rendered ZEPPS® Components.

with rendered ZEPPS Components.

with rendered ZEPPS Components.

View of the Hunter Interior Staircase in CAD, with rendered skin surface.

with rendered skin surface.

with rendered skin surface.

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View of the Hunter Museum interior staircase after completion.

View of the Hunter Museum interior staircase after completion.

Unique lines made by the interior stainless steel wall-panels.

Unique lines made by the interior stainless steel wall-panels.

Geometric zinc panels on the Hunter Museum.

Geometric zinc panels on the Hunter Museum.

Winding path to the entrance of the Hunter Museum.

Winding path to the entrance of the Hunter Museum.

Stainless steel and Zinc surfaces visible from the Tennessee River bluff.

Stainless steel and Zinc surfaces visible from the Tennessee River bluff.

Aerial view of the Hunter Museum.

Aerial view of the Hunter Museum.

Image courtesy

 

https://e5awgs3wuhi.exactdn.com/wp-content/uploads/2020/07/24113019/1_hunter-museum-american-art-sunrise.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 23:31:082025-02-20 08:01:05Hunter Museum

Hoover Garage

August 15, 2016/in Exterior Architecture Parking Structure Stanford--California WRNS Studio Gold L 2014 /by cmorris

HOOVER GARAGE AT STANFORD UNIVERSITY

In 2013, Zahner began working on a third project with WRNS Studio, the San Francisco architecture firm whose designs have played a transformative role on the parking garage typology.

The Hoover Garage parking structure is part of the Stanford Hospital and Clinics and was produced in association with Stanford University in California. The Hoover Parking Garage at Stanford University is a 1,100 stall garage which serves the Hoover Pavilion, a new medical office building for the University.

Hoover Garage is an open-air structure which uses a 3/16′ perforated and anodized aluminum surface. The back-side of the panels are cut and grooved at each corner of the panel to provide a more defined edge. The panels use a proprietary Drop & Lock panel technology, a feature of the Inverted Seam patent. This allows for flexible design and simple installation. Each panel is hung by inserts into the vertical extrusion.

Related Project

Mission Bay Parking

Located in the Mission Bay Block 27 of San Francisco, this design by WRNS Studio for Alexandria Real Estate, houses 1,420 parking spaces on seven elevated levels. The structure features a metal screen with perforated imagery of California's redwood forests. This facade was design-engineered by the Design Assist Group and produced by Zahner.

The perforated metal panel screen system at Stanford University Parking Garage.

The perforated metal panel screen system at Stanford University Parking Garage.

Photo by Bernard Andre.

The perforated metal panel's shadow creates a moire effect against the building's surface.

The perforated metal panel’s shadow creates a moire effect against the building’s surface.

PHOTO © A. ZAHNER COMPANY.

Related Post

Perfectly Perforated

Over the early 1990's, patterned usage of perforated metal began to appear. At the time, the pattern were limited by programming. It wasn't until the early two-thousands, when Herzog & de Meuron designed the de Young Museum, that perforated metal would truly enter into its own.

Hoover Parking structure at dusk on the Stanford University Campus.

Hoover Parking structure at dusk on the Stanford University Campus.

Photo by Bernard Andre.

Developing the Design for the Hoover Garage

Zahner provided design assist as well as fabrication services to the general contractor Vance Brown Builders. While this was the first time Vance Brown and Zahner worked together, Zahner had a relationship with the architect as well as a well-known reputation for its successful track record on similar projects with WRNS Architects.

In addition to the perforated metal facade, Zahner also provided the vertical structure which allowed the design team to reduce the overall budget without changing the visual aesthetic.

In the original document, there was a vertical steel member between panels. The panels had a complex support system hanging off of the steel, so Zahner engineers introduced a custom extrusion that would reduce the redundancy. The architect selected the look of anodized aluminum extrusion Zahner provided over the painted steel.

Detail of the two-plane panel system used on the Stanford University Hoover Parking Structure.

Detail of the two-plane panel system used on the Stanford University Hoover Parking Structure.

Photo by Bernard Andre.

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Zahner designed, milled, and machined all of the connection points on the custom aluminum extrusions, which were provided to the steel contractor to install prior to installation of the Zahner perforated panels. This improved the aesthetic and durability without adding additional cost.

Owning the aluminum vertical structure also simplified the dual planes of the panel system. Zahner was able to reduce the parts for how the second plane of panels connects to the structure.

The perforated panel creates a moire effect against its shadow on the building's surface.

The perforated panel creates a moire effect against its shadow on the building’s surface.

PHOTO © A. ZAHNER COMPANY.

Stanford University Parking Garage during construction.

Stanford University Parking Garage during construction.

Construction photo of the perforated metal panel screen system at Stanford University Parking Garage.

Construction photo of the perforated metal panel screen system at Stanford University Parking Garage.

PHOTO © A. ZAHNER COMPANY.

The engineers at Zahner and the architects at the WRNS office enjoy an integrated relationship that continues to evolve and push the boundaries of what is possible to design and build with parking structures. Learn more about the WRNS designs for which Zahner has built systems, including the Alexandria Parking Structure, the Contemporary Jewish Museum, and the UCSF Parking Garage. See more projects completed by WRNS Studio with Zahner.

https://e5awgs3wuhi.exactdn.com/wp-content/uploads/2020/07/24114528/1_wrns-hoover-parking-garage.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 23:31:082020-10-26 16:07:13Hoover Garage
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