M | Zahner

Dome on the Plaza

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.

Dayton Residence

August 15, 2016/in Exterior Architecture Residential Vail--Colorado James Dayton Design Brown M 2009 /by cmorris

Dayton Residence in Vail, Colorado

The Dayton Residence is a private mountain home conceived by the architects at James Dayton Design in Minneapolis. Completed in 2009, the project began as a renovation of an existing 70’s ski lodge and expanded into a new construction.

Zahner developed details and provide Solanum Steel, Zahner’s exclusive darkened weathering steel panel system. The variegated material provides improved performance over Cor-ten steel, which has a tendency to stain adjacent surfaces. Zahner provided engineering, fabrication, delivery, and installation for the project.

Related Surface

Dayton Residence

Serenity at the Dayton Residence in Vail, Colorado.

Snow falls at the Dayton Residence in Vail, Colorado.

Drawing diagram of the Dayton Residence in Vail, Colorado.

Daeyang Gallery

August 15, 2016/in Exterior Architecture Museum, Residential Asia, International, Seoul--South Korea E.Rae Architects, Steven Holl Architects Red M 2011 /by cmorris

WRNS Studio is an architecture and planning firm that provides sustainable design for education, healthcare, transportation, civic and urban mixed-use. The award-winning firm is recognized nationally, and is based in San Francisco with offices in New York City and Honolulu.

The firm has developed a growing number of works with Zahner, starting with the the Studio Libeskind-designed Contemporary Jewish Museum in which WRNS served as Architect of Record. Since then, Zahner has worked with WRNS on a number of projects, develop their unique design concepts into custom architectural systems, featured below.

Daeyang Gallery and House

Designed by Steven Holl Architects with architect of record E.Rae Architects of Seoul, this unique structure serves dual purposes, as both a residential guest house as well as an art gallery for visitors. JongSeo Lee of Steven Holl Architects was the associate in charge, and the project was completed in 2011.

The structure’s geometry is inspired by a John Cage sketch for a music score by the composer Istvan Anhalt, ‘Symphony of Modules,’ which Cage illustrated in an abstract form. The unusual shaped composition has now been reimagined as the plan layout of the Daeyang residence, continuing the chain from music, to art, to architecture.

This state of continued change and process informs many aspects of the building. Zahner worked closely with both the owner and the design team to develop a custom patina for the copper panel system that would match the desired coloration with natural warmth and texture.

Related Surface

Daeyang Gallery

Because of the unique range of tones and the material’s rich aging process, copper holds a special significance in the hearts and minds of those at Zahner. The material’s tone and color is perpetually in a state of flux, changing with each location based on the temperature, moisture, and pollutants in its environment.

This constant state of change will add character and soul to the gallery’s surface. The custom deep red tone that was developed will likely darken over time, and eventually may even begin to green and blue. The difference between copper and other materials, is that this constant state of ‘corrosion’ is actually the process of forming a stunningly beautiful protective barrier which will outlast any sealer, paint, or protective coating.

View through the slats of the Daeyang Gallery entrance.

Architect's model of the Daeyang Gallery and House.

Front gates of the Daeyang Gallery and House.

Detail of the copper patina for the Daeyang Gallery and House.

Panoramic of the Daeyang Gallery and House during construction.

Bamboo form construction for Daeyang Gallery and House.

Copper wall panel for the Daeyang Gallery and House.

Daeyang Gallery and House during construction.

Installation of wall panel systems for Daeyang Gallery and House.

The custom panels were installed by local workers in Seoul, South Korea. Zahner supplied the pre-engineered panels which securely locked into the substructure. Photographs of the completed building can be viewed at Steven Holl Architects website.

Crosstown Substation

August 15, 2016/in Exterior Architecture Industrial Kansas City Pendulum James Woodfill Brown M 2013 /by cmorris

Crosstown Substation Renovation for the KCP&L

The architects at Pendulum developed a synthesizing design which combines elements of public art, architecture, and kinetic motion-based visual arts to create a low-profile barrier wall wrapping the KCP&L Substation.

Prior to the new design, the corner of 18th and Locust was deteriorating. KCP&L replaced the wall with a new design, including commissioned artwork, that would reflect the Crossroads’ artistic community spirit.
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The winning design by Pendulum included a space for the light artist James Woodfill to create a kinetic display. As the sun sets, an animated display of lights takes over: 10,500 color-changing LED lights alternate to create an illusion of motion, powered by 117 solar panels.

Photograph of the Crosstown Substation west facade at dusk.

Crosstown Substation designed by Pendulum, featuring Solanum weathering steel metalwork.

Custom cylinder sidewalk lights cast unique shadows through perforations.

The Crosstown Substation, featuring a prepatinated weathering steel custom wall system.

Detail of the Crosstown Substation during daylight.

Manufacturing the Weathering Steel Facade for Pendulum Architects

Zahner was brought on to provide a weathering steel surface that would endure all four seasons in Kansas City, as well as provide a worn steel aeshtetic with minimal corrosion and staining of adjacent surfaces. Using the Solanum Steel process, Zahner was able to provide a warm steel patina. Zahner also worked closely with the project team to provide all structural steel and fabrication required for the project.

Rendering of Crosstown Substation, designed by Pendulum Architects in Kansas City.

Mockup of Crosstown Substation, installed on-site at the previous park.

History of the Crosstown Substation

Originally the KCP&L station was the site of the Holmes Square Park. Designed by George Kessler, the park was originally opened in 1897, the same year A. Zahner Company was founded by Andrew Zahner. The park was directed by Elenore Canny, who was sworn in by the Kansas City Police Department in 1910, becoming the first woman to serve and protect as a police officer in Kansas City, Missouri, and also one of the first female police officers in America.

KCP&L has decided to place a plaque on the gate of the substation commemorating the Holmes Square Park and the accomplishments of Elenor Canny. The material and construction of the plaque was generously donated by A. Zahner Company.

Project Team

Architect/Designer: Pendulum
General Contractor: Turner Construction, Inc.
Lighting Consultant: Derek Porter Studio
Structural Engineer: Du Bois Consultants
Commissioned Artist: James Woodfill
Steel Contractor/Fabricator/Supplier: Zahner

Awards and Recognition

2014 EDC Cornerstone Award Winner for Energy
2014 Kansas City Chapter AGC Building Excellence Award

Columbus Museum of Art

August 15, 2016/in Exterior Architecture, Interior Architecture LEED, Museum Columbus--Ohio DesignGroup Green M 2013 /by cmorris

Margaret M. Walter Wing at the Columbus Museum of Art

The new Margaret M. Walter Wing of the Columbus Museum of Art is a contemporary work of architecture featuring both interior and exterior custom-patinated copper sheets manufactured by Zahner.

In 2013, the Columbus Museum of Art’s Board of Trustees unanimously voted in favor of beginning construction on a new expansion project which would enable the Museum to bring global exhibitions to the residents of Columbus, Ohio. The museum reached out to DesignGroup principal Michael Bongiorno whose design team, including Keoni Fleming, Annie Neumer, and Joseph Mayer, developed a strategy for the museum’s expansion. The expansion’s centerpiece, the Margaret M. Walter Wing, adds 50,000 square feet to the total square footage of the Museum’s available gallery space, and is expected to reach a LEED Silver certification.

Columbus Museum of Art in Columbus, Ohio.

Columbus Museum of Art, East facade, glass, and limestone.

Columbus Museum of Art, detail of the custom copper soffit.

Columbus Museum of Art, detail of the custom copper flashing and metalwork.

The architects worked with their client to develop a design which would pair the Museum’s rich history with its promising future. The designers achieved this balance in many ways, including aesthetics. The design of the building’s form is contemporary, featuring many modern architectural touches, while its surface is an antiqued copper, a rich material which would normally require decades of weathering to achieve.

Developing the Architectural Copper Panels with Custom Patina

Zahner has worked with patinated copper and copper-alloys since the company’s establishment in 1897, but it was only a recent advancement by Zahner’s research and development team that allowed the firm to match naturally aged copper.

Typically, architectural copper panels are installed as raw or ‘red’ copper sheets, and while this color will quickly morph from reflective reflective pinks and reds to a matte brown surface, it will still take another few decades before the metal fully patinates into the blues and greens.

An example of this slow patination process is the de Young Museum in California, which Zahner manufactured and installed in 2003-2005 as unpatinated copper panel system. Ten years later, the surface is now starting to show signs of green along the panel seams, but the overall tone is still a deep matte burnt umber tone. It is likely another ten to twenty years before the de Young will take on a green hue.

For the new CMA building, Zahner sped up the process. Zahner engineers manufactured pre-weathered custom blue-green copper using a rapid patina process. A process that normally takes twenty to thirty years was achieved in the span of a few weeks.

Zahner fabricated the building’s custom flashing and standing seam roof and supplied the pre-patinated copper sheets for the copper wall panels. Keith Panel Systems (KPS) engineered and fabricated the wall panels on their KPS System ‘A’ which provides a compartmentalized and pressure-equalized rainscreen. Phinney Industrial Roofing coordinated the work with KPS and successfully completed the installation as the sub-contractor to Corna Kokosing Construction.

Columbus Museum of Art, view from the main entrance.

Columbus Museum of Art, detail of the custom metalwork.

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.

Five threaded rods support each rib. The central columns do not hold the weight of the panels.

Aluminum fabricated-metal forms with custom printed and mounted graphics.

Installation process at Clyde Frazier's Wine and Dine

Installation of the printed aluminum fabrications.

Chihuly Bridge of Glass

August 15, 2016/in Exterior Architecture, Landscape Architecture Bridge, Exhibit, Museum, Pedestrian Bridge Tacoma--Washington Andersson-Wise Architects Dale Chihuly Blue, Grey M 2002 /by cmorris

Chihuly Bridge at the Museum of Glass in Tacoma, Washington

The Chihuly Bridge is a destination feature for Tacoma, Washington. Designed by Andersson-Wise Architects as an addition to the Tacoma Museum of Glass, the project provides a pedestrian bridge to downtown Tacoma. Made possible by a donation from Jim and Carolyn Milgard, the bridge crosses over major rail lines and links the Museum of Glass to Union Station and the State History Museum.

Zahner served as both the sole contractor and manufacturer in the production of the Chihuly Bridge of Glass. This construction included all structural steel, glazing and cladding elements as well as fiber optics and vacuum HVAC system within the cases.

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 system that Zahner used for the glass encasement of the artworks is the Drop Lock glass installation system, which allows for easy installation and sustainable maintenance. The system builds on Zahner’s patented Inverted Seam system for creating co-planar metal facades and roofs. The assembled panels provide rapid installation, require no silicone, and result in a visually clean edge with a dry look.

Visitors who walk across the bridge get a closer look at the work of artist Dale Chihuly. The bridge is divided into three sections:

— Seaform Pavilion: a glass ceiling and canopy system showcasing 2,364 works of Chihuly glass from his Seaform and Persian series.
— Crystal Towers: a permanent art installation by Chihuly, rising 40 feet above the bridge deck and serve as beacons of light.
— Venetian Wall: an eighty-foot long installation displaying 109 sculptures from three of Chihuly’s series: Venetians, Ikebana, and Putti.

Venetian Wall for the Chihuly Bridge of Glass, with Museum of Glass in the background

Pedestrians cross the Chihuly Bridge of Glass

Venetian Wall at the Chihuly Bridge of Glass

Seaform Pavilion at the Chihuly Bridge of Glass

Chihuly Bridge Seaform Pavilion, designed by Andersson Wise

Zahner field construction crew delivers the Seaform Pavilion for the Chihuly Bridge of Glass

Zahner field construction crew installs the Seaform Pavilion for the Chihuly Bridge of Glass

Plaque for the Venetian Wall at the Chihuly Bridge of Glass

Chihuly Bridge designed by Andersson Wise.

Press

US Glass Magazine – Chihuly Connections: New Bridge Creates A Link to Museum of Glass.
ArchNewsNow – Chihuly Bridge of Glass By Arthur W. Andersson, AIA/Andersson-Wise Architects

Cerner Headquarters

August 15, 2016/in Art & Sculpture, Exterior Architecture Flagship, Workplace Kansas City Gould Evans Associates Silver M, S 2005 /by cmorris

Signage for Cerner Headquarters Vision Center Forum Portals

The Cerner Corporation World Headquarters is designed by Gould Evans and features Zahner-manfufactured signage systems. Zahner produced this uniquely perforated stainless steel sculpture and sign for the Cerner Corporation in North Kansas City.

Two sculptural navigational displays were built: a small corner entrance sign adjacent to the building’s main entrance, and a large signage system visible from the nearby highway. This larger sign features an illuminated Cerner logo mounted on the perforated stainless steel screen wall.

Each of the displays were fabricated by Zahner using ZIRA, a patented technology developed by Zahner creating perforated imagery. The architects and client designed a non-repeating pattern of 1’s and 0’s, binary code in a non-repeating pattern. Zahner developed a process to rapidly punch the numbers using multiple dies.

Detail of the perforated metal signage system at Cerner Headquarters.

Cerner signage wall at the Cerner World Headquarters.

Detail of the perforated metal system used for Cerner Headquarters.

Detail of the Cerner World Headquarters signage wall.

The larger of the two displays, visible from the end of 210 Highway in North Kansas City, was produced with lighting systems embedded in the aluminum and stainless steel framework. Pictured above and below are photos of the signage at night, and during the day. As cars drive by, it appears to flash and animate due to the lights parallactic relationship with the perforations.

The complete system for the 61′ long sign structure comprises 72 panels supported vertically by stainless steel structural fins of varying depth and shape. Each panel is constructed from 18-gauge stainless steel, with a perforation pattern generated from a random sequence of binary code.

The display closest to the building features a DNA strand within the sign, visible as an orange tube. The structure was built with 1/4″ aluminum fins, attached to square tubes which create the sign’s profile. The face of the fins were installed with 14 gauge Angel Hair Stainless steel panels.

Additional metal signage at Cerner Headquarters.

Fabricating the Cerner Signs

The sculptural sign was custom perforated from stainless steel plates using binary code to create the pattern. The surface is an array of 1’s and 0’s randomly placed across the plates of stainless steel.

Below are photos from the Zahner shop in Kansas City, where the material for each display was formed. Each panel was perforated using dies custom-made for the project. Together with the automated punches allowed the fabricators on the shop floor to quickly assemble components after being produced on the computer-controlled punch.

Backlit perforated metal system at Cerner Headquarters.

Cerner signage during fabrication at Zahner .

SUNY New Paltz

August 15, 2016/in Exterior Architecture Education New Paltz--New York ikon.5 architects Blue, Green M 2010 /by cmorris

SUNY Campus Commons at New Paltz

The State University of New York (SUNY) Campus Commons addition in New Paltz is a centerpiece for the school’s audacious program. Designed by ikon.5 architects, the glass and metal ‘crystalline palisade’ was ‘grown’ on the plinth of an existing concrete building. The new construction is designed for LEED Silver certification, incorporating radiant heating and cooling, photo-optic lighting controls, and substantial natural day lighting and views.

The muted turquoise surface is made using a pure copper alloy, preweathered and patinated (the process of developing a patina on metal) using a proprietary process developed by Zahner. The process results in an insoluble protective patina on the copper panel’s surface, variegated and eccentric.

The patinated copper surface was chosen by the architects because of the color’s association to nature and how it complements the glass shard. Zahner provided the sheets to local fabricators to create the flat-lock seam. The architects were already working with a manufacturer to fabricate the metal panel system, so the Zahner team supplied pre-patinated flat copper sheet and had a local team produce the panel system.

The ikon.5 architects-designed SUNY New Paltz Student Union Building

Interior view of the Star Blue™ copper panels at SUNY New Paltz Student Union Building

Star Blue™ copper panels at SUNY New Paltz Student Union Building

Detail of the Star Blue™ copper panels at SUNY New Paltz Student Union Building

Creating an Architectural Identity

The new design references the surrounding landscape of the Hudson River Valley and the Catskills. The building’s form was inspired by the nearby Shawangunk palisade, and its jade hue influenced by the Wallkill River’s muted blues.

The building also takes notes from the surrounding campus architecture. While the expanded student center stands in stark contrast to the neutral-toned concrete and brick buildings nearby, its angled roof continues the upward trajectory of an adjacent building’s ascending staircase. This attention to the building’s immediate context gives the new construction an integrated appeal, all-the-while maintaining its contemporary aesthetics.

The new building’s design has become a symbol for SUNY New Paltz, whose logo now incorporates the glass and metal pyramid. The exposed and triangulated framing underneath the glass zigzags across its fractal silhouette. Reflecting this exposed framing is the outdoor seating with its contemporary wireframe where students can enjoy the fresh air and sun while studying.