The Ray and Maria Stata Center at MIT, Building 32
Designed for the Computer, Information, and Intelligence Sciences programs at MIT, Frank Gehry and his architectural team at Gehry Partners envisioned a sprawling academic complex of visually amorphous structures which provide a combination of study and social space for students. The project is comprised of 47 unique elements, using a variety of materials, from brick to glass and architectural metals.
Zahner developed the geometry and cladding the structure with rain screen panels in stainless steel, aluminum, and titanium. As the facade provider, Zahner designed the structural forms to match the designer's aesthetic, fabricated the forms, skins, and window units, and installed the facade onsite at the Cambridge, Massachusetts campus.
The Richard B. Fisher Center for the Performing Arts is the latest addition to the Bard College campus. Featuring a curving roof and structure manufactured by Zahner, the building is nestled amongst the foothills of the Catskill Mountains. 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.
Designing the Building Envelope for Stata Center
Because of the complex nature of the project, the designers used ZEPPS, the Zahner-patented structural system for building complex forms. Using ZEPPS allows the engineers to simplify the design into buildable components using 3D fabrication processes. Parts were then assembled either at the Zahner shop or in the field depending on their complexity and ease of shipment.
An onsite team of installers lifted and secured each ZEPPS assembly. In total there were 1,500 individual ZEPPS assemblies manufactured for the project. Each of these assemblies was lifted into place for this project and then surfaced with a metal skin in one of several specified metal surfaces. More than 10,000 individual skins were installed to the surface and roof.
One of the distinct advantages of the ZEPPS is that it allows fully functional window boxes, over six feet in height, to be pre-installed on these panels. For that reason, the system is often described as prefab for custom buildings.