Bill & Melinda Gates Hall at Cornell University
Gates Hall is a new computer science building for students of Cornell in Ithaca, New York. Designed by Morphosis Architects, the building features Zahner custom systems for the soffit, interior entry foyer, and exterior facade. The building, named for Bill & Melinda Gates, is a dedicated building for Cornell University's Computing and Information Science (CIS) program.
The project's facade is designed using generative processes developed by Morphosis. Its unique appearance also serves the building's environment performance, reducing heat gain while providing natural light into the offices and classrooms.
The complex facade appears to be made up of unique parts, but there are several typical forms which are cleverly spaced to give the appearance that each part is unique. This technique of using the negative space to create complex visuals is a hallmark of the architecture firm's genius, and can be seen on other Morphosis projects such as Emerson College LA and Bloomberg Center.
Emerson College LA is designed by Morphosis with a series of custom facade systems design-engineered, manufactured, and installed by Zahner. The new Emerson College campus in Los Angeles provides a landmark for film and performing arts students of the Boston-based college to study in an immersive environment. The innovative design by the esteemed architects at Morphosis provides an integrated and efficient experience for both visitors and students.Working with Zahner's Design Assist team of engineers, designers and fabricators, this generative design was developed for manufacturing. A team of Zahner installers completed the project in Los Angeles, providing the new campus with a visually compelling, efficiently envisioned, and rapidly completed building envelope system.The project was certified LEED Gold in 2014.
Zahner worked with Morphosis to optimize the frame panel system, reducing it to the fewest number of components. By switching from bulky hollow frames to a combination of angles and plates, Zahner minimized the leading edges and simplified its compound joint conditions, resulting in sharper lines and cleaner forms at a reduced cost.
Field time and layout were reduced immensely by using a three-point attachment scheme and coordinating anchor locations beforehand, which were fabricated into the mullions. There are 450 total framed panels using 90 panel types, fabricated by Zahner for the facade. Each panel was pre-designated and automatically numbered with its specific location and pre-installed mullion incorporated anchor-tabs awaiting their arrival.
The facade project team included Zahner working directly with glass installer W&W to optimize the panel system. Thornton Tomasetti provided the structure's engineering, and Welliver was the construction manager that coordinated and ensured the project's success. The project team’s delivery of the angular sunshades should contribute to the building's expected LEED Gold certification.
Reducing the cost of the Gates Hall facade with Design Assist
Because Zahner not only fabricates but also engineers its facades, Design Assist is often employed for complex facades such as Gates Hall at Cornell. By managing the project under a Design Assist contract, Zahner was able to refine the façade elements with Morphosis to arrive at a system that achieved the aesthetic intent and was streamlined for fabrication and installation.
Using Zahner's Design Assist process allowed Morphosis to hone the costs of their design while meeting its visual requirements. Once the design intent was solidified, Zahner clarified the forms, both aesthetically and functionally. This resulted in reduced waste and construction delays, as well as a reduction in the overall cost.
The facade was designed to create the illusion of movement through a series of rigid forms. By varying the shape and angle that panels integrated into the panel system, Morphosis was able to create smooth transitions across the surface. Each panel is mounted on a staggered galvanized steel frame, and skinned with perforated stainless steel.
Building the Entrance Soffit
In addition to the building's generative facade, Zahner also engineered and manufactured the bright orange soffit under the main entrance. The sloping curves of the painted aluminum soffit contrast against the angularities of its framed panels.
Zahner used the ZEPPS assemblies on the soffit to achieve this flowing surface. Systematic production of seven internal fin members per panel created the continuous curves and minimized the number of joints. Support members follow the profile of the soffit to ensure the efficiency of the final surface and optimal installation.
Building with Morphosis
Zahner has worked with Morphosis on several projects including Cooper Union and Clyde’s Wine and Dine in New York City, and the Eugene Federal Courthouse in Oregon, and Emerson LA in California. Because of these successful collaborations, Morphosis brought Zahner onboard during the planning stages to provide Design Assist.