M | Zahner

McCoy Federal Building

August 15, 2016/in Exterior Architecture Government, LEED, Passive Security Jackson--Mississippi CDFL Architects, Hargreaves Associates, Schwartz/Silver Blue, Blue-grey, Grey, White M 2013 /by cmorris

Dr. A.H. McCoy Federal Building Modernization

This upgrade to the McCoy Federal Building includes infrastructure additions to the main building and an ancillary building which serves as a security entrance to the main structure. Designed by Schwartz/Silver architects, Zahner provided the glass facade design along with its structural support system.

In 2010, the General Services Administration (GSA) commissioned Schwartz/Silver to upgrade the McCoy Federal Building Courthouse and GSA Facilities in Jackson, Mississippi. Zahner was brought on to construct the building envelope for the structure, under design assist contract. Zahner provided engineering, fabrication, and installation of the curving glass facade in addition to the various architectural metal surfaces.

McCoy Federal Building in Jackson, Mississippi.

Glass and steel extrusions, each 10 to 25 feet long, thread into ZEPPS Sections to hold 1,078 lites of glass for the design by Schwartz/Silver for the Jackson, Mississippi Federal Courthouse and GSA Building. Locked into place by over 2,000 quills of varying heights, almost every single lite of glass is unique; the lites vary in width and height as specified by Zahner engineering and programming specialists.

New building codes designed to protect sensitive buildings and airports require security check-ins to be performed in a separate building. The addition to the McCoy Federal Building will also improve various functionalities and accessibility, as well as marketability for the value of the property and those around it, a benefit of its use as an example of passive security. It also is suggested that the building will help continue to improve the community interest in the downtown neighborhoods by freshening the street-level image of the Federal courthouse and the downtown area.

The project was completed in 2013, and is LEED Registered and slated to receive LEED Silver certification from the United States Green Building Council.

Panoramic view of the GSA Building in Jackson, Mississippi.

Night view of the glass lites on edge at the McCoy Federal Building.

McCoy GSA Federal Building at dusk in Jackson, Mississippi.

South view of the McCoy Federal Courthouse GSA in Jackson, Mississippi.

ZEPPS understructure visible as Zahner field operators prepare to install the lites of glass.

Zahner Field Operators install clips on the ZEPPS structure.

Detail of the McCoy Federal Building at the Zahner Headquarters.

Mockup for Schwartz/Silver architects at the Zahner Headquarters.

Zahner CAD rendering of the McCoy Federal Building.

LAPD Memorial

August 15, 2016/in Art & Sculpture Memorial Los Angeles--California Gensler Gold M, S 2009 /by cmorris

Los Angeles Police Department Memorial to Fallen Officers

The new LAPD Memorial to Fallen Officers stands as a testament to the strength and courage of the Los Angeles Police Department. The memorial is dedicated to the police officers and families who have sacrificed for the community of Los Angeles.

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We focused on the object most sacred to the LAPD: the brass badge.

David HerjeczkiPrincipal, Gensler

The project began after David Herjeczki and Christopher Keough of Gensler won a design competition for the new memorial. Working with a multi-layered concept, they developed meaning in both its design as well as its context.

“When you approach it from a distance, it will appear as a wall, reflecting the unity of the police force,” explains David Herjeczki of Gensler. “As you get closer, you will see it is an assemblage of individual pieces, each one paying tribute to a fallen officer. When contemplating an appropriate material for the memorial, we focused on the object most sacred to the LAPD: the brass badge.”

Los Angeles Police Department Memorial at the LAPD Headquarters.

The Memorial prior to installation at the LAPD Headquarters.

The LAPD Memorial dedication in Los Angeles, California.

Designing and Fabricating the Brass Memorial

To fabricate the 32′ long by 12′- 3” tall brass memorial, Kansas City-based fabricators at Zahner were enlisted to develop the team’s concept into reality. Of the 2000 shimmering brass plaques, 201 were engraved with the name, the rank and the date that each officer gave their life for a common cause.

Each plaque is staggered and set in relief. This both draws attention to the individual whose name is inscribed while allowing light from behind to illuminate each plaque. The memorial also features an abstracted badge design in the center of the memorial. The remaining plates are left blank. These plates are removable should additional names need to listed on the memorial.

The memorial’s presence was felt throughout Kansas City. After the wall was manufactured and prepared for shipment, the Kansas City Police Department escorted the delivery truck to the city limits to begin its 1,600-mile journey to Los Angeles.

“Several of us here got choked up when we found out Kansas City Police would be escorting it to city limits,” said Linda Wagener CEO of the Los Angeles Police Foundation. “In law enforcement, we really are a brotherhood.”

KCPD Officers escort the Memorial to Kansas City limits.

Los Angeles Police Officer sees the LAPD Memorial for the first time during its arrival.

The wall is set in the public plaza which is adjacent to the new police headquarters. This space, that both the police and community share, was formally dedicated on October 14, 2009. Open 24 hours a day, the memorial allows visitors to show their respect and remember the officers who have given the ultimate sacrifice.

Brass plates adorned during the dedication in Los Angeles.

Design Engineering the Los Angeles Memorial

To intelligently build the project with the small available budget required some efficient choices in the design process. Zahner began working with Gensler early on to come up with a series of solutions that did not compromise the integrity of the design or the quality of construction. The solution for this is Design Assist, a service which provides custom design solutions.

Design Assist is the process of translating the architects model to a production-ready scheme. The Design Assist process is often a collaborative re-design of the project, an essential process to ensure the constructibility of the project later down the line.

In the case of the LAPD Memorial, the architects had several web meetings with Zahner, where they were able to digitally rotate and discuss the model, tearing parts away, and streamlining the design to its core structure. The resulting design is a sustainable and flexible memorial that will stand the test of time.

Location of the memorial adjacent to the Los Angeles Police building, marked in red.

Architect's diagram of the monument design.

Kansas City Zoo

August 15, 2016/in Exterior Architecture Zoo Kansas City BNIM Brown M 1995 /by cmorris

The Deramus Education Pavilion at the Kansas City Zoo

Designed by BNIM, the Deramus Education Pavilion was created to symbolize the Kansas City Zoo and provide a preparatory experience for every zoo visitor. Zahner provided the custom copper standing seam and bold batten roof panels. These featured built-in gutters which were formed to create a unique geometry on the surface.

The roof systems throughout the project were installed as raw sheet, and will be allowed to naturally age. Over the years, the project has developed a dark brown patina, and after a few decades, will develop a deep green-blue patina.

The copper sheets were developed as standing seam and bold batten roof panels. These were designed with custom built-in gutters formed to cap the roof’s unique geometry.

Related System

Canopy

Custom canopies fabricated with Zahner engineering benefit from high-quality craft and attention to detail. Zahner engineers work with designers and contractors to develop integrated systems which meet a range of desired aesthetics, from historic restorations and filigree to contemporary geometric forms.

Aerial imagery of the Deramus entrance pavilion at the Kansas City Zoo.

The design of the building integrates many sustainable strategies. The building plan takes advantage of the site’s solar orientation. Operable windows are a part of the building’s envelope on the south, east, and west facades, allowing for natural cross ventilation to occur when appropriate. A highly energy-efficient HVAC system was sought, and several energy efficiency measures were employed in the design to minimize the energy used throughout the building. Extensive use of natural daylighting is incorporated into the envelope of the building.

A few examples of the materials used in the building design are as follows: structure made completely of salvaged or sustainably managed wood products, a copper roof that is comprised of 80% post-consumer waste copper and ‘waste’ marble floors (that is, floors made from marble that has been rejected for other purposes).

Juilliard Stairs

August 15, 2016/in Interior Architecture Education New York City Diller Scofidio + Renfro, FXFOWLE Architects Grey, Red M 2009 /by cmorris

Slow Stairs at The Juilliard School in New York City

Zahner worked with the architects at Diller Scofidio + Renfro to develop a gliding red stairway for the recent renovations at The Juilliard School in New York City. Zahner was responsible to Turner Construction in New York City for producing the design engineered metal-work. The two staircases are located one after the other, on the eastern-most side of the school from the third to fifth floors. There the students can collect their thoughts around the adjacent study areas.

The stairway was designed to appear as though it were made from a single sheet of metal. In actuality, the stair is made possible by several plates of 3/4″ low-carbon steel, seamlessly welded and painstakingly ground to achieve the look of a unified single piece of metal. Each step is a separate plate, bent at a 90 degree angle on either side, and then welded to either side of the staircase. The stairs are placed at a non-standard height and depth, so that the effect is a “slow staircase” where each step is only slightly elevated from the last.

Juilliard Staircase designed by Diller Scofidio + Renfro.

One of the issues with welding metal is its tendency to warp itself towards the weld. When it came time to weld the long pipe which serves as the hand rail, Zahner identified this as a potential problem. If this wasn’t done correctly, the entire staircase would bow to the left or right as one looked up at it. After debating different ways to prevent warpage, the solution Zahner employed was an old ship building technique — we welded the handrail from both sides at the same time. The result is a highly accurate straight piece of steel with only three connections to the building.

Custom staircase loaded on a truck to be shipped to Juilliard School in New York City.

Detail of the staircase design's joints, ground to a seamless finish.

Hoi Polloi

August 15, 2016/in Art & Sculpture, Landscape Architecture Public Art, Sculpture, Urban Design St. Louis--Missouri HNTB Lindsey Stouffer L, M 2006 /by cmorris

Hoi Polloi at Forsyth Metrolink Station

Hoi Polloi is a public artwork by Lindsey Stouffer, located at the Forsyth Metrolink stop in the greater St. Louis area. The artwork was manufactured by Zahner in Kansas City.

The Forsyth St. Louis MetroLink stop is a below-grade, open-air station located at the intersection of Forest Park Parkway and Forsyth Boulevard on the border of University City and Clayton, Missouri in the greater St. Louis metro area. The public artwork is one of nine commissioned for the St. Louis railway extension as part of the HNTB-designed Cross County Metrolink Extension.

Related Project

Capitol Federal Hall

The building features various exterior and interior metalwork, design-engineered and manufactured by Zahner. The project was completed in 2015. Zahner worked with architects Gensler and Gastinger Walker, under the construction management of JE Dunn.

Hoi Polloi public artwork for the St. Louis Metrolink at Forsyth Station.

The artwork consists of four large metal screen assemblies which face one another, divided by the metro’s train tracks. Perforations in the screens create an optical illusion, a moire effect which appears to shimmer as viewers descend into the amphitheater-like space.

The Manufacturer Behind Public Art

Zahner was selected by the artist to produce this public artwork for the St. Louis Metrolink. The artist’s plans were translated to constructible schematics through Zahner’s Design Assist program, a process whereby Zahner engineers work within a budget to develop a customized plan for building art and architecture.

After the design assist phase, the project went through a more typical engineering for production, and was then manufactured at the Zahner plant in Kansas City. The parts were crated and shipped to the jobsite, where the sculpture was assembled and installed by Zahner’s fabrication team.

Related System

Guardrail

Custom guardrail systems are a critical component of providing a design which is both safe and friendly for unique architectural environments. Zahner works with designers to provide bespoke handrail and guardrail systems for their projects.

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It’s intended to feel intimate and monolithic, durable and penetrable, relevant and timeless, specific and general.

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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.

Hoi Polloi explores the way a person thinks and feels entering a public space. ”It’s intended to feel intimate and monolithic, durable and penetrable, relevant and timeless, specific and general.“ — Lindsey Stouffer, the artist behind Hoi Polloi, a large-scale public artwork for the Forysthe Metrolink Station.

Zahner created the two main artworks on the site, which measure 20’ h. x 15’ w. (South), and 26’ h. x 30’ w. (North). Zahner was also responsible for crafting a custom railing system which integrates into the hardware of the perforated metal artwork.

Zahner’s involvement with the art community for both public and private artworks has steadily increased as the company produces ever-more complex and artistically innovative works of architecture.

As many works of public art do, the Hoi Polloi environmental sculpture straddles the line between fine art and architecture, and pushes the boundaries of both in the process.

H&R Block Installation

August 15, 2016/in Art & Sculpture Sculpture Kansas City Dierk Van Keppel Blue M, S 2006 /by cmorris

‘Blue Sun’ Hanging Mobile for H&R Block Headquarters

In 2006, H&R Block commissioned artist Dierk van Keppel to produce a custom glasswork in the new headquarters for their downtown office in Kansas City. Blue Sun is a blown and fused glass mobile, hung in an aluminum armature.

Zahner worked in both an art fabricator capacity, as well as a collaborator to Dierk Van Keppel. Keppel used glass blowing and fusing to create a number of fused glass pieces in flat form.

Zahner cut the glass and produced the frames and stainless steel armatures for the artwork. Zahner also provided engineering-design to create the sculpture’s balance and leveling mechanisms that keep the mobile stable.

Detail of the metal ceiling system made for the Starlight Theatre Donor's Circle

Related Project

Starlight Donor’s Circle

Zahner engineers and artisans worked with Gastinger Walker Harden, with Bob Rohlf and the Starlight Theatre Association of Kansas City to engineer, fabricate, and install the artwork. The surface features glass cast by local Kansas City artist Dierk Van Keppel.

Dierk Van Keppel installation at the H&R Block in Kansas City.

Dierk studied art glass at the University of Kansas from 1983 to 1987, assisting with lectures and demonstrations for artists including Dale Chihuly, Stephen D. Edwards, Ken Carder, Fritz Driesbach, and Wes Hunting.

In 1984, Dierk studied under Richard Marquis and Thermon Statom at Pilchuck Glass Studio in Stanwood, WA, joining the staff at Pilchuck in 1985. In 1986, Dierk founded his first private glass studio, Free State Glass, in Lawrence, KS. In 1991, the artist moved closer to his hometown near Kansas City, and established Rock Cottage Glassworks in Merriam, Kansas.

Dierk Van Keppel sculptural installation at the H&R Block Space in Kansas City.

Gulf Islands

August 15, 2016/in Exterior Architecture, Interior Architecture Residential Vancouver BC AA Robins Brown, Orange, Red M 2012 /by cmorris

Gulf Islands Residence, Pacific Northwest

With jutting lines of burnt umber flying across the horizon, this remote single-family house is situated in rocky southern shores of the Pacific Ocean near Vancouver, British Colombia. Tony Robins of AA Robins Architect took on this 6,500 sq ft cladded challenge as lead architect and gave this hidden gem a contemporary style reminiscent of the modern sculptor Alexander Calder.

The exterior and interior cladding of the home is done primarily with A. Zahner Company’s trademarked patina, Solanum Steel weathering steel. This pre-weathered steel surface provides a vibrant and warm color to complement the surrounding blue ocean and sky. Comparative to raw weathering steel, Solanum Steel offers a stable surface which reduces runoff from the natural patina on its surface.

Related Surface

Gulf Islands

The Solanum Steel exterior of the Gulf Islands Residence appears bright umber in the afternoon light.

Photo of the interior Solanum Steel application. Light flows through the perforations on metal's surface.

Zahner engineered a CAD layout of the panels on the Gulf Islands Residence.

Fabricating the Weathered Steel Facade

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

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

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

Guggenheim Hermitage Museum

August 15, 2016/in Art & Sculpture, Interior Architecture Museum Las Vegas--Nevada OMA, REX Architecture Brown M 2002 /by cmorris

The Guggenheim Hermitage Museum in Las Vegas

The Guggenheim Hermitage Museum was designed by Rem Koolhaus and Joshua Prince-Ramus of OMA as a center for Impressionist Art.

Zahner developed a preweathered patina on weathering steel for the gallery walls. The materials was used to create five-thousand square feet of wall space for the historic artworks. This preweathered steel material was used throughout the Guggenheim Hermitage Museum.

Today the weathering steel material is known as Solanum Steel, and uses a steel alloy which has replaced COR-Ten in popular usage. Many areas of the gallery were clad in this material, and served as a unique tone to back the acclaimed artworks of the nineteenth century.

Related Surface

Guggenheim Hermitage Museum

Three of the walls clad in Zahner’s Solanum Steel were engineered to rotate, allowing curators to change the size and proportion of the four intermediary spaces within seconds. The wood floor and ceiling were produced using a finished maple surface.

A museum installer places a custom-magnet wall connection to hang a painting.

The Solanum Steel surface is a durable steel surface whose iron content enables magnetic properties. For this reason, the gallery opted for magnetic connections to the artworks, which meant that artworks could be easily installed and de-installed with minimal effort and clean-up. All of the paintings were hung from custom-made magnets, able to withstand several hundred pounds of vertical load.

The museum closed its doors in 2008 and was re-opened as an automobile museum. Zahner has since worked with OMA and REX (Ramus) on projects such as the Wyly Theatre in Dallas.

Festival of Arts

August 15, 2016/in Exterior Architecture Museum, Performance Center Laguna Beach--California, Los Angeles--California Bauer Architects Brown, Red, Violet M 2015 /by cmorris

Festival of Arts and Pageant of the Masters, Laguna Beach

Combining both natural and built elements from the surrounding environment, the Festival of Arts renovations link both the City of Laguna Beach with its surrounding canyon landscape. Zahner’s scope consisted of fabricating a series of five stand-alone wall sections, the tallest of which rises to nearly 20’. These act as both a decorative feature wall and a place-holder for signage regarding various events and exhibitions.

The existing concrete signage wall was demolished as part of the proposed renovation. Bauer Architects sought to reimagine the wall as art. They started with the image of tree branches, a link to the forested setting using the words of the philosopher Seneca, “All art is but an imitation of nature”.

For the perforations, a standard circular punch shape was used to create imagery of trees on the form’s copper surface. These shapes were then cut from the metal using a punch. When assembled in unison, the panels read as an entire image. To create additional texture and add rigidity to the panels, a series of embossed and debossed bumps were applied to the surface.

Related Surface

Festival of Arts

Growing a Stable Patina on Architectural Copper

The architects wanted to use a natural material with an aged look. Zahner’s Dirty Penny patinated copper was selected as the base material. This oxidized copper material was developed by Zahner to expedite the natural weathering process of copper. Rather than taking years to develop a rich, dark patina, the Dirty Penny process results in a stable patinated surface using a rapid chemical-based treatment. The panels for Festival of Arts were pre-patinated and shipped directly to the jobsite for installation.

The unsealed patinated panels will continue to age with time. The metal’s surface acts as a living protective barrier, similar to the way moss grows on stone. Unlike paint or anodization, which will deteriorate with time, the custom copper patina will continue to grow stronger as the surface oxidizes.

Manufacturing Accurately-Curved Architectural Forms

Creating the curvature for the panels proved to be a unique challenge. Some of the walls were derived from a single radius, while other sections included more than one radius in a single wall. All of these were tangent to one another. Due to the embossed and debossed bump pattern, the usual method of processing the entire sheet through a roll former could not be used. This compression would damage the bumps. Zahner’s solution was to crimp roll the top and bottom legs of each panel.

Crimp rolling the edges gave the sheets a gentle curve, but the process is not entirely precise. So to increase precision, Zahner also created a series of aluminum templates at the desired radius. Zahner was able to match the copper panels to the aluminum templates during the crimping process, resulting in a highly accurate architectural form.

The resulting geometry matches identically to the each of the radii provided in the architect’s model.

Simplifying the Concealed Attachments

Copper rolled angles were used as attachment hardware on the backs of each panel and fastened to existing mullions. In order to fit the curvature, these angles were also stretched to the appropriate radius. Coordination of fasteners to the copper rolled angles became key.

To disguise fasteners, Zahner assisted with coordinating the location for a series of aluminum “hats” on the mullions. Each piece of hat hardware lines up with a perforated hole. Fasteners were run through the perforations, to the back hardware. This allows for panels to be removed with ease, so that signage could be easily installed, and maintenance remains uncomplicated.

Designing concealed hardware is one of the advantages of using Zahner’s engineering and design team for projects like this. Contact Zahner to see what kinds of assistance we can provide for your project, or learn about how you can get your team started early with Zahner using Design Assist.

Fairmont Pacific Rim

August 15, 2016/in Exterior Architecture Hospitality, Parking Structure Canada, International, Vancouver BC James KM Cheng Architects L, M 2010 /by cmorris

Fairmont Pacific Rim in Downtown Vancouver BC, Canada

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

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

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

Fairmont Pacific Rim designed by James KM Cheng.

Translating the Image to Metal

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

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

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

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

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