XL | Zahner

Google Bay View Campus

Google’s Bay View Campus, located at NASA’s Ames Research Center in Mountain View, California, and comprising three buildings, represents a significant milestone as the company’s first self-designed and built campus.

Opened in 2022 and spanning 1.1 million square feet over 42 acres, the campus was brought to life through the collaborative efforts of renowned architectural firms Bjarke Ingels Group (BIG) and Heatherwick Studio.

Grounded in Google’s core themes of innovation, nature, and community, the design prioritizes flexibility. Team spaces are located on the upper level, with gathering areas below, balancing focus and collaboration. Varied floorplates on the second floor create adaptable “neighborhoods” that evolve with team needs. The layout ensures that no employee is more than a two-and-a-half-minute walk from any other, fostering spontaneous interactions and collaboration.

Google Bay View campus in Mountain View, California.

Photo © Iwan Baan, Courtesy of Heatherwick Studio

Natural light floods the interiors through clerestory windows with “eyebrow” architectural elements crafted from Zahner’s Angel Hair® Stainless Steel, which add aesthetic appeal while diffusing sunlight to minimize glare.

Aerial view of Google Bay View campus in Mountain View, California.

Photo © Iwan Baan, Courtesy of Heatherwick Studio

Zahner also provided Design Assist services to ensure constructability, while preserving design intent and considering budget. Zahner collaborated with BIG and Heatherwick designers, as well as general contractor Whiting-Turner, on material selection, fabrication details, engineering, and installation.

The Zahner team inspects progress on installation of the Angel Hair eyebrows.

PHOTO © A. ZAHNER COMPANY.

Modular construction facilitated efficient installation of the eyebrows.

PHOTO © A. ZAHNER COMPANY.

Another standout feature of the campus is its distinctive “dragonscale” roof, composed of approximately 50,000 custom-designed solar panels, manufactured by SunStyle. This innovative roofing not only generates nearly seven megawatts of energy but also enhances insulation and reduces thermal heat gain.

Zahner Angel Hair eyebrows and Google's custom-designed dragonscale solar skin roofing.

PHOTO © A. ZAHNER COMPANY.

The Zahner team inspecting the Angel Hair eyebrows at Bay View during construction.

PHOTO © A. ZAHNER COMPANY.

Dragonscale building-integrated photovoltaic (BIPV) solar shingles, manufactured by SunStyle, clad the roof at Google's Bay View.

Photo © Iwan Baan, Courtesy of Heatherwick Studio

Zahner Angel Hair eyebrows and Google's custom-designed dragonscale solar skin roofing.

PHOTO © A. ZAHNER COMPANY.

The campus is also home to North America’s largest geothermal pile system, which efficiently manages heating and cooling needs, leading to a projected 50% reduction in carbon emissions and saving an estimated five million gallons of water annually. Furthermore, the campus aims to replenish 120% of its water usage by 2030 through on-site recycled water systems.

Aerial view of Google Bay View campus in Mountain View, California.

Photo © Iwan Baan, Courtesy of Heatherwick Studio

The Google Bay View Campus has earned LEED-NC v4 Platinum certification, making it the largest building in the world to hold this certification. It’s also on track to become the largest facility ever to achieve the International Living Future Institute’s Living Building Challenge (LBC) Water Petal Certification.

Panoramic view of Google Bay View campus in Mountain View, California.

Photo © Iwan Baan, Courtesy of Heatherwick Studio

Google’s Bay View Campus stands as a testament to the company’s vision of integrating cutting-edge design with sustainability and employee-centric spaces, setting a new benchmark for future workplace environments.

Panoramic view of Google Bay View campus in Mountain View, California.

Photo © Iwan Baan, Courtesy of Heatherwick Studio

Panoramic view of Google Bay View campus in Mountain View, California.

Photo © Iwan Baan, Courtesy of Heatherwick Studio

SoFi Stadium

June 11, 2021/in Exterior Architecture Arena & Stadium, Entertainment, Performance Center Inglewood--California HKS Silver, White XL 2020 Homepage Featured /by dsegard

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.

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.

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.

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.

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

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.

Single panel design with fabrication details and instructions.

Closeup of panel design details.

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

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.

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

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

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

Zahner worker on site for the construction of SoFi Stadium.

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

PHOTO © NIC LEHOUX

Brickell Flatiron Parking Garage

November 4, 2020/in Exterior Architecture Parking Structure Miami--Florida Revuelta Architecture International Blue, Grey, Silver L, XL 2019 /by dsegard

Brickell Flatiron is a residential high-rise that towers above the Brickell district of Miami, Florida, at 736 ft. The name “flatiron” references the triangular lot that the 64-floor condominium sits on. Zahner worked closely with the architect, Luis Revuelta, and the developer, CMC Group, through the Zahner Assist process.

Zahner’s scope of work included design assist services, engineering, fabrication, and installation of the podium’s 13-story, 100,000 square foot parking garage façade. In total, the design team went through four façade design iterations before ultimately determining that the final design both creatively complimented the curvilinear forms of the architecture above and met the established budget.

Brickell flatiron is a 64-story residential high rise in Miami, Florida.

Photo by Curtis Smith | ARKO © A. Zahner Company

Zahner engineered and fabricated a custom perforated-metal facade for the 13-story Brickell Flatiron Parking Garage.

Photo by Curtis Smith | ARKO © A. Zahner Company

Closeup of the custom metal facade for the Brickell Flatiron Parking Garage, produced by Zahner.

Photo by Curtis Smith | ARKO © A. Zahner Company

Custom perforated-metal facade for Brickell Flatiron in Miami, produced by Zahner.

Photo by Curtis Smith | ARKO © A. Zahner Company

Perspective view of the Brickell Flatiron parking facade.

Photo by Curtis Smith | ARKO © A. Zahner Company

Penthouse facade on top of Brickell Flatiron fabricated by Zahner.

Photo by Curtis Smith | ARKO © A. Zahner Company

Zahner also engineered and fabricated the penthouse facade.

Zahner provided an extra facade at the crown on a tight schedule.

Photo by Curtis Smith | ARKO © A. Zahner Company

Harim Tower

January 4, 2017/in Exterior Architecture Corporate, Highrise Asia, International, Seoul--South Korea Beck Group Silver XL 2016 /by cmorris

Harim Group Headquarters in Seoul, Korea

Harim Tower in Gangnam, Seoul is the Beck Group-designed headquarters for the Harim Group company. The building features a Zahner engineered cladding system and custom bumped and perforated stainless steel throughout the interior and exterior.

The Harim Group wanted its new corporate headquarters to reflect its focus on sustainability and caring for its employees and the public. Beck provided a unique design solution which introduced 86,000 SF of mid-rise office tower on a small but high-value site. The project includes a boardroom for Harim Group, high-end restaurants, and a café in addition to a range of office spaces.

To reduce Korea’s high energy cost and to enhance the indoor air quality, Beck designed an operable window system for natural ventilation, high performance Low-E coated windows, LED light fixtures, building automation system, green roof, rainwater harvesting system and underfloor air distribution system.

Harim Group Headquarters entrance has a curving stainless steel facade system made by Zahner.

Curved metal facade of Harim Group Headquarters in Seoul.

Curved metal 'S' shape facade of the Harim facade in stainless steel.

Making the Curved Metal Facade for Harim Group Headquarters

Working under Mijie Industrial Company, Zahner developed a custom ZEPPS feature to produce an ‘S’ shaped recess in the building’s facade. ZEPPS is the Zahner system for developing unique forms and curvatures in metal. The ‘S’ shape for Harim Tower provides a unique aesthetic and design signature for the corporate headquarters. This recessed shape also creates a low pressure zone, facilitating natural ventilation on each of the floors.

The metal system Zahner provided was developed with a deep recess cavity for the lighting system. Zahner engineers introduced a modified ZEPPS hardware component which extended the panels 14″ from the building’ surface while retaining the precision curves.

Working with Well-Light, a Korean lighting design consultant, the team installed more than 10,000 LED lights of 4,000k color temperature which show through the building’s millions of perforations. “We tested several different color temperatures,” says Jay Chung, Director of Korea Operations at Beck Group. ”When we tried 3,000k color temperature lights it looked like the building was on fire. The 4,000k lights ended up giving us the perfect light. Plus they’re energy efficient.”

Detail of the curved stainless steel facade with custom perforated emboss panels.

Detail of the custom perforated emboss used to bump and perf the stainless steel facade.

Fresno City Hall

December 30, 2016/in Exterior Architecture Government Fresno--California Arthur Erickson, Lew & Patnaude Architects Silver XL 1992 /by cmorris

Fresno City Hall in Historic Fresno, California

The Fresno City Hall, designed by Arthur Erickson, features a number of Zahner-manufactured systems throughout the interior and exterior of the building. Developed with associate architects Lew & Patnaude and Edwin S. Darden & Associates, the building includes a massive stainless steel roof and facade with a muted finish provided by Zahner. The 300,000 SF structure is five stories high, and measures 66′ at its highest point.

Aluminum and stainless steel custom details can be seen throughout the interior and exterior. Zahner provided not only the exterior stainless steel metalwork, but also its interior stainless steel metalwork and staircase.

Related Project

Museum of Glass

Zahner produced the metalwork for the glass bridge as well as the massive cone which can be identified throughout the downtown area. The cone was manufactured in stainless steel diamond panel system which was attached to a ZEPPS structural framework, each made by Zahner.

The building includes a range of metal details provided by Zahner. The metal aspects of its building envelope, the custom columns at its rear entrance, various soffit and metal cladding, awnings, mullions, and transoms.

All of these metal components are designed and fabricated to endure the test of time. This building was completed in 1991, but the photographs below were taken in 2016, nearly thirty years after the project’s completion. The images are a testament to the durability and longevity of stainless steel.

Aerial photo of Fresno City Hall in Fresno, California.

An shaded walkway covers both the South and North (pictured) wings of the Fresno City Hall exterior.

Details of the metalwork for Fresno City Hall.

Bullnose stainless steel details, Fresno City Hall.

Custom mullion and soffit on Fresno City Hall.

Custom stainless steel column and light fixtures on the Northeast elevation of Fresno City Hall.

Stainless steel column systems for Fresno City Hall.

Custom stainless steel column-clad system for Fresno City Hall.

Custom bullnose mullion and soffit details.

Custom mullion details for the Fresno City Hall curtainwall.

Tsing Yi Station

December 14, 2016/in Exterior Architecture Airport, Transportation Asia, Hong Kong, International Wong Tung Green XL 1998 /by cmorris

Tsing Yi Terminal Roof in Hong Kong

Tsing Yi Terminal is an intermodal center and train station on the Tung Chung Line of MTR and Airport Express, located on Tsing Yi Island in Hong Kong.

Designed by Wong Tung, the building features the largest copper roof in Hong Kong. Zahner manufactured the copper standing seam roof system with built-in gutters and associated flashing and fascia. The roof panels were installed as a pre-patinated copper. This means that the copper material went through a patination process in the United States, where it developed an advanced patina, a protective layer resulting from a built-up oxide on the copper surface.

Related Project

Kowloon Station

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

Tsing Yi Station connects the island of Tsing Yi with the mainland of Hong Kong.

Installers complete the Tsing Yi Terminal Roof in Hong Kong.

Subtle curvatures along the profile of the Tsing Yi Station Terminal Roof.

Photo © A. Zahner Company.

Tsing Yi Station Terminal Roof includes custom fascia and flashing.

Tsing Yi Station Terminal Roof, running bond pattern on double-lock standing seam roof.

Zahner provided metalwork for the project. The roof edge folds over to create a clean, trimless appearance. A running bond pattern was designed for the double-lock standing seam. The project is one of a number works that Zahner has produced in Asia.

The project is located between Airport Station and Kowloon Station, another Hong Kong work of architecture featuring Zahner metalwork.

Jakarta Australian Embassy

December 7, 2016/in Exterior Architecture Government, Passive Security International, Jakarta--Indonesia Denton Corker Marshall Blue, Gold, Green, Grey, Red XL 2016 /by cmorris

Australian Embassy in Jakarta, Indonesia

The Australian Embassy in Jakarta features a number of buildings manufactured in a variety of metal surfaces. The Embassy features an expansive palette of custom Zahner finishes and patinas on high-performance metal alloys.

The design by Denton Corker Marshall was the winning entry in limited design competition. The materials reflect not only characteristic colors of the Australian landscape but also convey something of the natural resources and mineral wealth. Each building at the Embassy is clad in a distinct metal, representing Australia’s wealth in these materials: copper, zinc, brass, steel and aluminum.

The Australian Embassy complex houses the Department of Foreign Affairs and Trade and 13 other government departments and agencies. Denton Corker Marshall’s design includes a massive complex, covering over 530,000 square feet of space.

Creating an Embassy with Enduring Metals

The building complex includes both housing as well as a chancery for the building’s staff. The Embassy chancery was clad in a full range of trademark metal materials made by Zahner. Each of these high-end surfaces are detailed to provide high-performance and endure city pollutants over time.

The building complex was split into a number of modules, each designed with a unique metal surface. Zahner custom-fabricated and delivered the facade systems for each of the towers, which are clad top-to-bottom in their respective metal surfaces.

The metal panels, manufactured by Zahner, include stainless steel, patinated copper and zinc, color anodized aluminum, and preweathered steel. In total, Zahner manufactured 70,000 panels and trims. These were engineered, fabricated, and shipped 13,000 miles — on time and within the budget of the project.

Signature Surfaces for the Chancery

The patinated materials and custom finishes developed for the buildings include a range of Zahner-developed products. Surface materials used include Star Blue Copper, a prepatinated copper material; Solanum Steel, a preweathered deep earthen-colored metal; and Hunter Zinc, a limestone-toned metal patina on zinc. The building also included anodized aluminum, made in both clear and gold.

In the Embassy’s official press release for the unveiling, the metals chosen provide insight into Australia’s mineral economy:

“The distinctive colours chosen for the Chancery are designed to represent Australia’s wealth in minerals such as copper, zinc, brass, steel and aluminium.”

The panels also feature a series of circular ‘bumps’, which offer added texture and dimensionality. The delineation of the embossed and debossed metal was done under close collaboration between the architects at Denton Corker Marshall and Zahner. Total Bangun Persada and Leighton served as the General Contractors for the project, with Aurecon Australia serving as the primary engineer. Zahner worked closely with Leighton Asia, whose team ensured good communication and success for the building complex construction.

Zahner has two production plants (one in Grand Prairie, Texas and another in Kansas City, Missouri), so the company was able to work in tandem between sheet production, engineering and shop-forming. This provided the massive output needed to cover the 330,000 square-feet of metal panels under the project’s aggressive 12-month schedule.

In an interview by ABC, Australian Ambassador to Indonesia Paul Grigson lauded the building’s architectural design, and celebrated its ecological imperative:

“The Embassy showcases the best in Australian innovative design and cutting edge technology to make the most out of the Indonesia’s environment while minimising the impact on local water and energy sources,”

Construction of the new embassy, which commenced in 2012, cost $415 million. This is the biggest project that the Australian government has spent on a building complex outside the shores of Australia.

Features of the Building Complex

The new complex is at Patra Kuningan in the southern area of Jakarta. The Embassy includes a five-storey Chancery, accommodation for some Embassy staff, and recreation and medical centers. The grounds cover over 530,000 SF of space.

According to the official press release, the compound can withstand a one in 2,500-year earthquake and can move 600 millimetres in any direction. The Embassy complex uses low resource technologies such as collecting and using rainwater as well as solar hot water heating systems.

One of the most exciting aspects of the new complex, is how the ground’s massive banyan trees have put the Australian embassy into the Indonesian Guinness Book of Records. Four mature trees were relocated near the building’s entrance, the biggest tree relocation of its kind ever taken.

For this, the building received a Museum Rekor Indonesia (MURI) award. This award is in recognition of how the new Embassy celebrates the Indonesian national pride. Part of the Indonesian coat of arms, the Banyan tree is a symbol which represents for the Indonesian-Australian partnership, denoting how a single nation can have far-flung roots.

Among its green features are a living rooftop, rainwater harvesting, energy efficient air-conditioning and a number of solar hot water systems.

“The Embassy showcases the best in Australian innovative design and cutting edge technology to make the most out of the Indonesia’s environment while minimising the impact on local water and energy sources,” said Australian Ambassador to Indonesia Paul Grigson.

Team Disney

November 8, 2016/in Exterior Architecture Workplace Anaheim--California, Los Angeles--California Frank Gehry Partners Blue, Green, Violet XL 1995, 1996 /by cmorris

disneyland theme park offices, Anaheim

A pillowed facade of iridescent green, blue and violet adorns the surface of the Team Disney building in Anaheim, California. Designed by Frank Gehry Partners, the building serves as the administrative offices of the Disneyland theme park.

Zahner provided the custom green interference-coated stainless steel. The iridescent surface changes from blue to green to violet when viewed at varying angles. The addition of an embossed diamond pattern creates a quilted, pillow-like effect.

At the time it was constructed, it was the largest green stainless steel surface ever produced. Completion of the structure marks the first time all administrative staff have been located in one facility since the park opened in 1955.

“We’ll get more work done in the hallways than we did in the conference rooms. This finally brings it all together.”
— Disneyland President Paul Pressler.

Related Surface

Team Disney

North-side of the Team Disney Anaheim building.

Detail of the interference stainless steel at Team Disney Anaheim.

View from across the highway at Team Disney Anaheim.

Church of the Resurrection

October 11, 2016/in Exterior Architecture, Interior Architecture Worship Center Leawood--Kansas Gould Evans Associates, HGA Architects Silver L, XL 2016 /by cmorris

United Methodist Church of the Resurrection in Leawood, KS

The Church of the Resurrection is a new construction for the Leawood congregation designed by HGA with Gould Evans. Zahner provided the exterior secondary structure (ZEPPS), and the stainless steel cladding in Angel Hair finish on 304 alloy.

Seven stainless-steel clad sails, inspired by the seven days of creation, alternate with diffuse slot windows to create a light-filled volume that draws attention upward for reflection, prayer and adoration.

Landscaped parking extends to an arrival plaza, welcoming the community to the sanctuary from all directions. Inside, a thrust chancel platform and a single balcony bring congregants close to the worship leaders, with a variety of seating types allowing flexibility in service size.

United Methodist Church of the Resurrection in Leawood, Kansas.

Founded in 1990, the Church of the Resurrection has grown into the largest United Methodist Church in the U.S. with 18,000 members. Seeking to expand and remodel its existing facility on a 76-acre site, the church is adding an acoustically versatile sanctuary seating 3,500 and converting the existing auditorium into a multi-purpose room.

Related Project

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.

None

Cowboys Stadium

August 15, 2016/in Exterior Architecture Arena & Stadium Dallas--Texas HKS Silver XL 2009 /by cmorris

Dallas Cowboys Stadium

Designed by HKS, the Dallas Cowboys Stadium is among the largest in the world, seating 100,000 people. Zahner produced the stainless steel perimeter metalwork on the exterior and the interior of the stadium.

Due to the geometric complexities of these areas, HKS selected Zahner to produce the custom finished steel work. Zahner design-engineered the HKS entrance archway using ZEPPS, a system created for creating and manufacturing complex forms. Using the ZEPPS system allowed for fabricating structural sections that were easily installed.

“

HKS’s spirit of cooperation in providing leadership, design innovation, delivery and execution to our project superseded even my high expectations and helped bring our dreams to life. AT&T Stadium has proven itself not only as a football stadium, but as a venue for other sports and large entertainment events. It has been an instant hit – recognizable worldwide.

Jerry JonesOwner, President and General Manager, Dallas Cowboys.at