edmonton arena
Building With Design Assist & ZEPPS: Edmonton Downtown Arena Showcasing projects by Zahner featuring the Design Assist Group Presentation for the Evaluation Team: PCL Construction Edmonton Arena Corporation The City of Edmonton Icon Venue Group Project Consultants
Renderings courtesy of 360 Architecture
The design for the downtown Edmonton arena goes beyond anything we’ve seen, built, or imagined. The building’s exterior flows like a hurling puck on ice, a monument to motion. It is both a pleasure and an honour to be considered for the role of facade supply and installation. We’ll help you build it as you’ve imagined it.
–
L. William Zahner
CEO & President A. Zahner Company
Edmonton Downtown Arena Rendering courtesy of 360 Architecture.
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For 360 Architecture & the Evaluation Team for Edmonton Downtown Arena
We would like to briefly describe our organization and our accomplishments over the past decade. The following pages will showcase Zahner projects similar in scope and in complexity to the new Edmonton arena. We have reviewed the complexities of the project and the dignified aesthetic being designed. We have both the engineering know-how to define it and the expert fabricators who will produce the project. Our deliverable solutions for the total building envelope systems will meet the highest levels of sustainability while providing long-term performance. Our product will meet and surpass your expectations.
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NASCAR Hall of Fame in Charlotte, North Carolina.
Petersen Automobile Museum Rendering Courtesy KPF Associates
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Our Company
Zahner is internationally renowned and recognized for innovations in the field of metal and digital fabrication. We lead by developing new and sustainable metal applications, patinas, and their respective technologies; we recruit only the most dedicated and intelligent craftsmen and engineers; and we deliver the best, exceeding the exacting standards of our clients.
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L. William Zahner, president and Chief Executive Officer at Zahner, is a recognized expert in the field of architectural metals. The American Institute of Architects awarded him an honorary AIA membership in 2007 for his dedication to the architectural profession, his devotion to spreading his knowledge of metal, and his contributions to the world’s greatest architectural wonders.
We employ 35 personnel in our offices, and over 200 craftsmen in our fabrication facilities. Our engineers are divided into teams which manage each project from inception to completion. In our two factories in Dallas, Texas and Kansas City, Missouri, we produce the elements that compose the elegant buildings, public artworks, and design elements that you’re about to see.
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We Define Digitally. We first implemented digital definition and fabrication in 1992, and our digital definition model continues to evolve and become more sophisticated and comprehensive with each project. A digitally defined form is generated using a 3-dimensional computer model, which employs a fully parametric, spatial mathematical system. This powerful CAD system allows the engineers to accurately model the architect’s vision while testing real-world restraints, allowing the design to evolve as structural rationale, site constraints, and programmatic functions become apparent. Using these tools we can begin to evaluate the model for structural stability, testing the effects of wind, gravity, and the load transfer among structural components. The digitally defined model is used to provide data which instructs computer-guided machinery to fabricate parts and components of the model. Fabrication is fully engineered and quality controlled through shop fabrication of all panels and units. Any shape, irregular curve, or bend is possible. Digital Definition assists the building process by providing coordinated and precise instructions for the fabrication of primary and secondary structural steel members. These instructions continue into the field, directing the erection and installation of the entire structural system on the job site. Digital Definition provides a smooth and efficient installation of immensely complex projects.
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Below: Two images of the de Young, the left is a computer model; the right is the final built structure. Opposite & Bottom: The NASCAR Hall of Fame “Mobius” which wraps around the building was made possible by using digital definition.
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Building with ZEPPS™ The ZEPPS™ Process is a series of Zahner Engineered Profiled Panel Systems designed for the specific purpose of building complex facades and curvilinear forms.
10 Liverpool Department Store by Rojkind Architects during Construction.
Lightweight + Efficient The ZEPPS™ Process has a number of advantages over using other building systems: it is the most efficient building system available for the construction of curved facades. This means less waste, both physically and ecologically. Part of why the process is so efficient is because it is powerful and lightweight. It requires fewer vertical supports throughout the interior of the building. It uses significantly less structural steel, and despite the reduction in material, the ZEPPS™ Panels provide superior insulation, both in terms of the sound transmission co-efficients, and increased U-value (R-value) resistance. We regularly incorporate new technologies into the ZEPPS™ Process to ensure that it is the most advanced and efficient system at any given time. The ZEPPS™ Process has undergone three major upgrades over the past ten years, and continues to improve with every project we produce. The people at Zahner have a level of pride in their work that is unseen in the construction industry. This is because we are not just engineers and builders. We are artists, designers, architects, and expert craftsmen. The latest upgrade to the ZEPPS™ Process has enabled the production of curves that were previously deemed impossible. This is a result of our latest material research and development. Building with the ZEPPS™ Process ensures that the architectural result will meet or surpass the expectations of all parties.
Top: Designs for Zaha Hadid’s upcoming Sheldon Haymarket Museum. Zahner will engineer the surface using ZEPPS™ Process. Above: Two adjacent ZEPPS™ Panels in the shop for the Neiman Marcus Flagship store.
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Innovation We cultivate brilliant minds and gifted craftsmen, a group of people who strive to discover oceans of opportunity and untapped markets for their potential to transform the way we do business. We encourage and reward innovative thinking in a creative environment where collaboration occurs day in and day out. And it shows: Zahner has multiple design and manufacturing patents registered in the U.S., with a number of upcoming patents pending, a feat we attribute to collaborative problem-solving among the creative individuals in both our offices and fabrication plants.
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Patent No. US 7,434,366 B2 Date of Patent: October, 2008
Patent No. US 7,210,273 B2 Date of Patent: May, 2007
Two D-shaped flanges are connected by a web to create an I-beam. Each flange includes a planar segment and a curved segment, and a lip extends from the planar segment of each flange and is adapted and attached to the web.
Panel attachment system comprised of a plurality of covering panels, retaining members, and mounting structures. The mounting structures secure the retaining members through the use of protruding locking members formed on the panels which interlock with a slot on the retaining members.
This is the fundamental basis of design for all of our ZEPPS™ Processes. These processes enable architects to construct any form or shape imaginable.
This is the fundamental basis for the Inverted Seam™ system, the best roof that money can buy.
Patent No. US 7,212,688 B2 Date of Patent: May, 2007
Patent No. US 5,394,666 Date of Patent: March, 1995
Patent No. US 5,272,849 Date of Patent: December, 1993
A method of transferring a represented image to a building surface. The representation is received as an image file, converted to a raster file, scaled to the surface, and divided into a plurality of sub-components.
A metal roof panel attachment system for producing a finished roof surface exhibiting an smooth, planar configuration. Adjacent planar panels are attached to secondary support members which form a recessed joint, the concealing drainage channel.
An improved roof covering system which includes roof panels, joint areas, joint covers, and securing assemblies. The joint covers include transversely extending locking tabs. The securing assembly includes clips with vertically oriented slots to engage the tabs.
This is the fundamental basis for the ZIRA™ Process, allowing artists and architects to paint, draw, sculpt, and illustrate using the surface of metal panels.
This is the fundamental basis for the Drop & Lock™ Roof & Siding Systems, which allow panels to be quickly and securely installed with virtually no visible hardware, providing maximum sustainability.
This is the fundamental basis for our custom Bold Batten Roofing System, providing a more sustainable product for historic and traditional applications.
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Sidra Medical Center AECOM & Pelli Clarke Pelli Doha, Qatar
Taubman Museum Randall Stout Architects Roanoke, Virginia; USA
Ceramic Tile on ZEPPS™ Understructure
NASCAR Hall of Fame Pelli Clark Pelli Charlotte, North Carolina; USA Angel Hair™ Stainless Steel & ZEPPS™
Stainless Steel and Roano™ Zinc Neiman Marcus Elkus Manfredi Natick, Massachusetts; USA
Liverpool Department Store
Color Interference Stainless & ZEPPS™
Rojkind Architects Mexico City ZEPPS™ & Angel Hair™ Stainless
Portfolio / ZEPPS + DESIGN ASSIST Select projects completed by Zahner similar in scale and scope to the Edmonton Downtown Arena.
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The de Young Museum Herzog & de Meuron San Francisco, California; USA TECU® Classic
Tacoma Museum of Glass Arthur Erickson
Basra Stadium
Tacoma, Washington; USA
360 Architects Basra, Iraq Solanum™ Weathering Steel
BOK Arena Art Gallery of Alberta
HOK Architects
Randall Stout Architects
Oklahoma City, Oklahoma; USA
Edmonton, Alberta; Canada
Aluminum & Glass
Angel Hair™ Stainless Steel
Angel Hair™ Stainless & ZEPPS™
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NASCAR Hall of Fame Project:
NASCAR Hall of Fame
Architect:
Pei Cobb Freed
Location:
Charlotte, North Carolina
Completion: Services:
2011 Zahner provided Design Assist, engineering, fabrication, & installation. The project features a custom ZEPPS™ Engineered Panel System, used to create both the “Mobius” strip which wraps the building, as well as the exterior envelope.
A Single ZEPPS™ Panel is craned into position. The pre-fabricated panels integrate insulation, form, and structure in a single component.
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The ZEPPS™ Panel is lowered onto the building, where field installers fasten the large panel into place.
The individual panels create the greater form.
“We were able to efficiently build the structural facade as well as NASCAR’s finished surface by using the ZEPPS Process and Design Assist. We saved the owner $315,000 in material and design requirements without sacrificing quality. We estimate that owner saved four months of schedule by using ZEPPS™ in lieu of traditional stud framing because our panels were pre-fabricated and easily installed in the field.” — Jeff Mann A. Zahner Company
Next, installers zip the panels together to create a unified surface, and apply the stainless steel skins.
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NASCAR Hall of Fame Project:
NASCAR Hall of Fame
Architect:
Pei Cobb Freed
Location:
Charlotte, North Carolina
Completion: Services:
2011 Zahner provided Design Assist, engineering, fabrication, & installation. The project features a custom ZEPPS™ Engineered Panel System, used to create both the “Mobius” strip which wraps the building, as well as the exterior envelope.
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“As construction manager, we were impressed not only by the strict quality control process used in manufacturing, but also by the diligence and documentation of quality measures by the field staff. Zahner held to our budget, schedule, safety, and quality standards in delivering the project. The ribbon will indeed be the feature remembered by all who visit the NASCAR Hall of Fame. I highly recommend A. Zahner Company for any project which demands the qualities referenced above.”
— Tom Barnett, Project Manager Turner Construction Company, 2009.
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Basra Sport City Project:
Basra Stadium at Sport City
Architect:
360 Architects
Location::
Basra, Iraq
Completion: Services:
2013 Zahner provided design assist, engineering, fabrication, and shipment of the Solanum® Steel vertical metalwork.
The team takes a look at a panel mockup for Basra Sports City.
A single column rises during the project’s construction.
The Basra project, substantially complete.
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Liverpool Flagship Store Project:
Liverpool Flagship Department Store
Architect:
Rojkind Architects
Location:
Mexico City
Completion: Services:
2011 Zahner provided Design Assist, engineering, fabrication, & shipment. The project features the ZEPPS® Engineered Panel System, with Angel Hair® Stainless steel. Zahner exported the ZEPPS® Panels to local installers in Mexico City, and the panels were installed without issues.
Local installers in Mexico City hang the first two ZEPPS® Panels.
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Installers provide the final patches before peeling the blue protective film from the stainless steel.
The finished Liverpool Flagship Store in Mexico City.
“Even though we had never collaborated with them, Zahner’s credentials and experience clearly indicated that they were the ideal candidate for this project. The design and fabrication process we went through has been one of the most rewarding collaborations we have had in recent years. It is also an assurance when you are working with the best. Not only could they understand where we were coming from, but also, what we were trying to achieve – they helped contribute to the great result.” — Gerardo Salinas, AIA Partner Rojkind Arquitectos, 2013.
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Zahner Headquarters Project:
The North Dock Expansion at the Zahner Campus
Architect:
Crawford Architects
Location::
Kansas City, Missouri
Completion: Services:
2011 The facade’s glass curtainwall directly integrates into an aluminum ZEPPS™ substructure designed by Zahner. Inspired by the topography of sand dunes in Qatar, architects at Crawford worked closely with CEO/President L. William Zahner to match his desired aesthetic. Engineers at Zahner then developed a system to accomplish the desired surface. The final product is a bold design for a rectangular building.
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The iconic 19,199 seat downtown arena has spent nearly five years shattering expectations, selling out shows, attracting major artists and landing in national publications’ rankings of the nation’s top-performing venues. Since its first show on Sept. 6, 2008 - a sold-out concert by the Eagles - the BOK Center has sold 3.3 million tickets, collected $104.4 million in ticket revenue and generated more than $11.1 million in sales tax. — Zack Stoycoff
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Staff Writer
The Tulsa World 2013
BOK Center Project:
BOK Center
Architect
Pelli Clark Pelli
Location:
Tulsa, Oklahoma
Completion: Services:
2008 Zahner provided Design Assist, Engineering, Fabrication, and Installation. The building’s facade was produced using the ZEPPS® Process.
Photograph of the hundreds of ZEPP Assemblies during construction. Each ZEPP was installed between the structural steel framework.
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Taubman Museum Project:
The Taubman Museum of Art
Location:
Roanoke, Virginia
Architect:
Randall Stout Architects, Inc
Owner/Client: Services:
Balfour Beatty; Mr. David Salzer Design Assist, Engineering, Fabrication, and Installation. Employed digital definition modeling and through coordination, we discovered and prevented errors in other subcontractors work. The complex geometries of the Taubman replicate the hills and mountains to the west of Roanoke, Virginia.
Taubman Museum showing CAD layout with transparent skins.
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CAD Layout shows the aluminum framework of the ZEPPS components.
Installed ZEPPS components are prepared for final skinned surface.
Photograph of the finished stainless steel skins showing the uniform surface.
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“For many years now Bill Zahner has given support, energy, backbone, and technical assistance in realizing many of my works ... His firm provides exemplary craftsmanship in everything they undertake, and are seriously and extremely committed to Architecture, with a capital A.” — Frank Gehry, 2008 30
Pritzker Pavilion Project:
Pritzker Pavilion in Millennium Park
Architect:
Frank Gehry Partners
Location:
Chicago, Illinois
Completion: Services Provided:
2004 Design Assist, Engineering, Fabrication, and Installation. The Bandshell for this project was a highly complex engineering feat, the result of which is a very high-quality curvilinear form.
Referencing LEED objectives, we use post-consumer and pre-consumer (postindustrial) recycled metal content in our copper and copper-alloy materials. Post-consumer = minimum 65% postconsumer scrap (or more if the appropriate quantities and grades are available). Pre-consumer = no more than 35% pre-consumer scrap (depending on the availability of appropriate quantities and grades). We use the newest generation of efficient copper refining and alloying furnaces that allow for maximum utilization of postconsumer scrap materials.
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Art Gallery of Alberta Project:
Art Gallery of Alberta (AGA)
Architect:
Randall Stout Architects
Location:
Edmonton, Alberta
Completion: Services:
2010 Zahner provided Design Assist, Engineering, Fabrication, and Shipment. Zahner used the architect’s 3D Model to engineer the sculptural from with the ZEPPS™ Process, and worked with Flynn Canada who provided installation of the interlocking panels and stainless steel skins.
The ZEPPS™ Panels are custom designed to meet the architect’s desired form.
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The ZEPPS™ Process is structural, installing onto the basic steel substructure.
ZEPPS™ configures directly into the 3D Model to precisely match the desired form.
The finished skin of a ZEPPS™ Project is highly consistency as expected from Zahner.
“AGA membership increased dramatically from 1,600 to nearly 5,300. At our first year anniversary celebration, Mayor Stephen Mandel praised our accomplishments and Lindsay Blackett, Minister of Culture and Community Spirit, told us that the investment in the AGA was the best $27 million the Government of Alberta has ever spent.“
— Barry Zalmanowitz, 2010 Chair, Board of Directors
Art Gallery of Alberta
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“When everyone else said that the operable double skin for the Cooper Union’s New Academic Building couldn’t be done, Zahner worked closely with us to make it happen.”
— Thom Mayne FAIA, 2008 Morphosis
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Cooper Union Project:
Cooper Union New Academic Building
Architect:
Morphosis
Location:
New York City
Date: Services Provided:
2009 Design Assist, Engineering, Fabrication & Shipment. Zahner’s Angel Hair® Stainless steel covers the majority of the building, perforated with to allow light through while providing thermal protection. The small window-like rectangles scattered across the surface are where the surface isn’t perforated.
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de Young Project:
The new de Young Museum of Art
Architect:
Herzog & de Meuron
Location:
San Francisco, California
Owner/Client: Completion: Services:
The Corporation of Fine Art Museums 2006 Design Assist, Value Engineering, Scheduling, Fabrication, and Erection of the exterior metal and building envelope. The architects required a pattern on the wall to match sunlight streaming through a canopy of trees. Digital images (below right) were converted into machine language and issued as the basis for 7,600 individually unique dimpled and perforated wall panels.
Over time, the patina has transformed the surface from a bright reflective red to a historic verdigris-tone.
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“Seldom has an architectural project been talked about so much in the world media. In the new age of folded, textured, and curvaceous buildings, Zahner has become a clinic for twisting and treating metal. The list of projects is impressive, reaching a pinnacle with the completion of the widely praised copper facade on the new De Young Museum in San Francisco.”
— Salvatore Orlando, 2007 President President KME-Group
The building features a perforated and bumped wall which references imagery of nearby forestry (pictured left).
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Key Profiles & Organization
L. William Zahner
Robert Zahner
CEO / President
Senior Vice President
Zahner
Zahner
[email protected]
[email protected]
L. William Zahner is established in the architecture community
Robert Zahner’s background in civil engineering and contract
as a leader and an innovator. He transformed what began as a
development provides the Zahner operations group with
small regional shop into the international leader for engineered
contractual oversight and peer review leadership. Zahner is
architectural metal. He sits on the Board for the US Secretary of
the Senior Vice President and presides over the operations and
Commerce, and is a leading expert on the science of metal.
contract responsibilities for the team.
Anthony Birchler P.E.
Randy Stratman
James Porter
VP of Engineering / Sales
Design-Engineer
Chief Operating Officer
Zahner
Zahner
Zahner
[email protected]
[email protected]
[email protected]
Anthony Birchler develops the initially design and engineering
Randy Stratman is the engineering director, responsible
Jim Porter brings over 14 years of experience in on-time
of a project with each client. Birchler shared responsibility for
for defining the scope of each project. Stratman designs
production management of each of the Zahner projects. Porter
the development and implementation of two out of the five
the details for both visual aesthetics as well as functional
implements strategic process improvements and coordinates
patents held by Zahner. He works directly with the engineers,
performance. Stratman oversees the early stages of designing
LEAN initiatives to maximize staff productivity and increase the
architects, and general contractors, and has an extensive
the project, guiding the operations team leader who manages
quality performance of each project produced by Zahner.
knowledge applied metal facade and fenestration systems.
the project through to completion.
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Contact Information
L. William Zahner
Robert Zahner
Anthony Birchler
President & CEO
Senior Vice President
Vice President Engineer / Sales
[email protected]
[email protected]
[email protected]
Zahner HQ 1400 E. 9th Street Kansas City, Missouri 64106 p 816.474.8882 f 816.474.7994 Zahner-Dallas 2860 Alouette Dr. Grand Prairie, TX 75052 p 816.423.8348
Renderings courtesy of 360 Architecture
The design for the downtown Edmonton arena goes beyond anything we’ve seen, built, or imagined. The building’s exterior flows like a hurling puck on ice, a monument to motion. It is both a pleasure and an honour to be considered for the role of facade supply and installation. We’ll help you build it as you’ve imagined it.
–
L. William Zahner
CEO & President A. Zahner Company
Edmonton Downtown Arena Rendering courtesy of 360 Architecture.
3
For 360 Architecture & the Evaluation Team for Edmonton Downtown Arena
We would like to briefly describe our organization and our accomplishments over the past decade. The following pages will showcase Zahner projects similar in scope and in complexity to the new Edmonton arena. We have reviewed the complexities of the project and the dignified aesthetic being designed. We have both the engineering know-how to define it and the expert fabricators who will produce the project. Our deliverable solutions for the total building envelope systems will meet the highest levels of sustainability while providing long-term performance. Our product will meet and surpass your expectations.
4
NASCAR Hall of Fame in Charlotte, North Carolina.
Petersen Automobile Museum Rendering Courtesy KPF Associates
5
Our Company
Zahner is internationally renowned and recognized for innovations in the field of metal and digital fabrication. We lead by developing new and sustainable metal applications, patinas, and their respective technologies; we recruit only the most dedicated and intelligent craftsmen and engineers; and we deliver the best, exceeding the exacting standards of our clients.
6
L. William Zahner, president and Chief Executive Officer at Zahner, is a recognized expert in the field of architectural metals. The American Institute of Architects awarded him an honorary AIA membership in 2007 for his dedication to the architectural profession, his devotion to spreading his knowledge of metal, and his contributions to the world’s greatest architectural wonders.
We employ 35 personnel in our offices, and over 200 craftsmen in our fabrication facilities. Our engineers are divided into teams which manage each project from inception to completion. In our two factories in Dallas, Texas and Kansas City, Missouri, we produce the elements that compose the elegant buildings, public artworks, and design elements that you’re about to see.
7
We Define Digitally. We first implemented digital definition and fabrication in 1992, and our digital definition model continues to evolve and become more sophisticated and comprehensive with each project. A digitally defined form is generated using a 3-dimensional computer model, which employs a fully parametric, spatial mathematical system. This powerful CAD system allows the engineers to accurately model the architect’s vision while testing real-world restraints, allowing the design to evolve as structural rationale, site constraints, and programmatic functions become apparent. Using these tools we can begin to evaluate the model for structural stability, testing the effects of wind, gravity, and the load transfer among structural components. The digitally defined model is used to provide data which instructs computer-guided machinery to fabricate parts and components of the model. Fabrication is fully engineered and quality controlled through shop fabrication of all panels and units. Any shape, irregular curve, or bend is possible. Digital Definition assists the building process by providing coordinated and precise instructions for the fabrication of primary and secondary structural steel members. These instructions continue into the field, directing the erection and installation of the entire structural system on the job site. Digital Definition provides a smooth and efficient installation of immensely complex projects.
8
Below: Two images of the de Young, the left is a computer model; the right is the final built structure. Opposite & Bottom: The NASCAR Hall of Fame “Mobius” which wraps around the building was made possible by using digital definition.
9
Building with ZEPPS™ The ZEPPS™ Process is a series of Zahner Engineered Profiled Panel Systems designed for the specific purpose of building complex facades and curvilinear forms.
10 Liverpool Department Store by Rojkind Architects during Construction.
Lightweight + Efficient The ZEPPS™ Process has a number of advantages over using other building systems: it is the most efficient building system available for the construction of curved facades. This means less waste, both physically and ecologically. Part of why the process is so efficient is because it is powerful and lightweight. It requires fewer vertical supports throughout the interior of the building. It uses significantly less structural steel, and despite the reduction in material, the ZEPPS™ Panels provide superior insulation, both in terms of the sound transmission co-efficients, and increased U-value (R-value) resistance. We regularly incorporate new technologies into the ZEPPS™ Process to ensure that it is the most advanced and efficient system at any given time. The ZEPPS™ Process has undergone three major upgrades over the past ten years, and continues to improve with every project we produce. The people at Zahner have a level of pride in their work that is unseen in the construction industry. This is because we are not just engineers and builders. We are artists, designers, architects, and expert craftsmen. The latest upgrade to the ZEPPS™ Process has enabled the production of curves that were previously deemed impossible. This is a result of our latest material research and development. Building with the ZEPPS™ Process ensures that the architectural result will meet or surpass the expectations of all parties.
Top: Designs for Zaha Hadid’s upcoming Sheldon Haymarket Museum. Zahner will engineer the surface using ZEPPS™ Process. Above: Two adjacent ZEPPS™ Panels in the shop for the Neiman Marcus Flagship store.
11
Innovation We cultivate brilliant minds and gifted craftsmen, a group of people who strive to discover oceans of opportunity and untapped markets for their potential to transform the way we do business. We encourage and reward innovative thinking in a creative environment where collaboration occurs day in and day out. And it shows: Zahner has multiple design and manufacturing patents registered in the U.S., with a number of upcoming patents pending, a feat we attribute to collaborative problem-solving among the creative individuals in both our offices and fabrication plants.
12
Patent No. US 7,434,366 B2 Date of Patent: October, 2008
Patent No. US 7,210,273 B2 Date of Patent: May, 2007
Two D-shaped flanges are connected by a web to create an I-beam. Each flange includes a planar segment and a curved segment, and a lip extends from the planar segment of each flange and is adapted and attached to the web.
Panel attachment system comprised of a plurality of covering panels, retaining members, and mounting structures. The mounting structures secure the retaining members through the use of protruding locking members formed on the panels which interlock with a slot on the retaining members.
This is the fundamental basis of design for all of our ZEPPS™ Processes. These processes enable architects to construct any form or shape imaginable.
This is the fundamental basis for the Inverted Seam™ system, the best roof that money can buy.
Patent No. US 7,212,688 B2 Date of Patent: May, 2007
Patent No. US 5,394,666 Date of Patent: March, 1995
Patent No. US 5,272,849 Date of Patent: December, 1993
A method of transferring a represented image to a building surface. The representation is received as an image file, converted to a raster file, scaled to the surface, and divided into a plurality of sub-components.
A metal roof panel attachment system for producing a finished roof surface exhibiting an smooth, planar configuration. Adjacent planar panels are attached to secondary support members which form a recessed joint, the concealing drainage channel.
An improved roof covering system which includes roof panels, joint areas, joint covers, and securing assemblies. The joint covers include transversely extending locking tabs. The securing assembly includes clips with vertically oriented slots to engage the tabs.
This is the fundamental basis for the ZIRA™ Process, allowing artists and architects to paint, draw, sculpt, and illustrate using the surface of metal panels.
This is the fundamental basis for the Drop & Lock™ Roof & Siding Systems, which allow panels to be quickly and securely installed with virtually no visible hardware, providing maximum sustainability.
This is the fundamental basis for our custom Bold Batten Roofing System, providing a more sustainable product for historic and traditional applications.
13
Sidra Medical Center AECOM & Pelli Clarke Pelli Doha, Qatar
Taubman Museum Randall Stout Architects Roanoke, Virginia; USA
Ceramic Tile on ZEPPS™ Understructure
NASCAR Hall of Fame Pelli Clark Pelli Charlotte, North Carolina; USA Angel Hair™ Stainless Steel & ZEPPS™
Stainless Steel and Roano™ Zinc Neiman Marcus Elkus Manfredi Natick, Massachusetts; USA
Liverpool Department Store
Color Interference Stainless & ZEPPS™
Rojkind Architects Mexico City ZEPPS™ & Angel Hair™ Stainless
Portfolio / ZEPPS + DESIGN ASSIST Select projects completed by Zahner similar in scale and scope to the Edmonton Downtown Arena.
14
The de Young Museum Herzog & de Meuron San Francisco, California; USA TECU® Classic
Tacoma Museum of Glass Arthur Erickson
Basra Stadium
Tacoma, Washington; USA
360 Architects Basra, Iraq Solanum™ Weathering Steel
BOK Arena Art Gallery of Alberta
HOK Architects
Randall Stout Architects
Oklahoma City, Oklahoma; USA
Edmonton, Alberta; Canada
Aluminum & Glass
Angel Hair™ Stainless Steel
Angel Hair™ Stainless & ZEPPS™
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NASCAR Hall of Fame Project:
NASCAR Hall of Fame
Architect:
Pei Cobb Freed
Location:
Charlotte, North Carolina
Completion: Services:
2011 Zahner provided Design Assist, engineering, fabrication, & installation. The project features a custom ZEPPS™ Engineered Panel System, used to create both the “Mobius” strip which wraps the building, as well as the exterior envelope.
A Single ZEPPS™ Panel is craned into position. The pre-fabricated panels integrate insulation, form, and structure in a single component.
16
The ZEPPS™ Panel is lowered onto the building, where field installers fasten the large panel into place.
The individual panels create the greater form.
“We were able to efficiently build the structural facade as well as NASCAR’s finished surface by using the ZEPPS Process and Design Assist. We saved the owner $315,000 in material and design requirements without sacrificing quality. We estimate that owner saved four months of schedule by using ZEPPS™ in lieu of traditional stud framing because our panels were pre-fabricated and easily installed in the field.” — Jeff Mann A. Zahner Company
Next, installers zip the panels together to create a unified surface, and apply the stainless steel skins.
17
NASCAR Hall of Fame Project:
NASCAR Hall of Fame
Architect:
Pei Cobb Freed
Location:
Charlotte, North Carolina
Completion: Services:
2011 Zahner provided Design Assist, engineering, fabrication, & installation. The project features a custom ZEPPS™ Engineered Panel System, used to create both the “Mobius” strip which wraps the building, as well as the exterior envelope.
18
“As construction manager, we were impressed not only by the strict quality control process used in manufacturing, but also by the diligence and documentation of quality measures by the field staff. Zahner held to our budget, schedule, safety, and quality standards in delivering the project. The ribbon will indeed be the feature remembered by all who visit the NASCAR Hall of Fame. I highly recommend A. Zahner Company for any project which demands the qualities referenced above.”
— Tom Barnett, Project Manager Turner Construction Company, 2009.
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Basra Sport City Project:
Basra Stadium at Sport City
Architect:
360 Architects
Location::
Basra, Iraq
Completion: Services:
2013 Zahner provided design assist, engineering, fabrication, and shipment of the Solanum® Steel vertical metalwork.
The team takes a look at a panel mockup for Basra Sports City.
A single column rises during the project’s construction.
The Basra project, substantially complete.
21
Liverpool Flagship Store Project:
Liverpool Flagship Department Store
Architect:
Rojkind Architects
Location:
Mexico City
Completion: Services:
2011 Zahner provided Design Assist, engineering, fabrication, & shipment. The project features the ZEPPS® Engineered Panel System, with Angel Hair® Stainless steel. Zahner exported the ZEPPS® Panels to local installers in Mexico City, and the panels were installed without issues.
Local installers in Mexico City hang the first two ZEPPS® Panels.
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Installers provide the final patches before peeling the blue protective film from the stainless steel.
The finished Liverpool Flagship Store in Mexico City.
“Even though we had never collaborated with them, Zahner’s credentials and experience clearly indicated that they were the ideal candidate for this project. The design and fabrication process we went through has been one of the most rewarding collaborations we have had in recent years. It is also an assurance when you are working with the best. Not only could they understand where we were coming from, but also, what we were trying to achieve – they helped contribute to the great result.” — Gerardo Salinas, AIA Partner Rojkind Arquitectos, 2013.
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Zahner Headquarters Project:
The North Dock Expansion at the Zahner Campus
Architect:
Crawford Architects
Location::
Kansas City, Missouri
Completion: Services:
2011 The facade’s glass curtainwall directly integrates into an aluminum ZEPPS™ substructure designed by Zahner. Inspired by the topography of sand dunes in Qatar, architects at Crawford worked closely with CEO/President L. William Zahner to match his desired aesthetic. Engineers at Zahner then developed a system to accomplish the desired surface. The final product is a bold design for a rectangular building.
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The iconic 19,199 seat downtown arena has spent nearly five years shattering expectations, selling out shows, attracting major artists and landing in national publications’ rankings of the nation’s top-performing venues. Since its first show on Sept. 6, 2008 - a sold-out concert by the Eagles - the BOK Center has sold 3.3 million tickets, collected $104.4 million in ticket revenue and generated more than $11.1 million in sales tax. — Zack Stoycoff
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Staff Writer
The Tulsa World 2013
BOK Center Project:
BOK Center
Architect
Pelli Clark Pelli
Location:
Tulsa, Oklahoma
Completion: Services:
2008 Zahner provided Design Assist, Engineering, Fabrication, and Installation. The building’s facade was produced using the ZEPPS® Process.
Photograph of the hundreds of ZEPP Assemblies during construction. Each ZEPP was installed between the structural steel framework.
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Taubman Museum Project:
The Taubman Museum of Art
Location:
Roanoke, Virginia
Architect:
Randall Stout Architects, Inc
Owner/Client: Services:
Balfour Beatty; Mr. David Salzer Design Assist, Engineering, Fabrication, and Installation. Employed digital definition modeling and through coordination, we discovered and prevented errors in other subcontractors work. The complex geometries of the Taubman replicate the hills and mountains to the west of Roanoke, Virginia.
Taubman Museum showing CAD layout with transparent skins.
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CAD Layout shows the aluminum framework of the ZEPPS components.
Installed ZEPPS components are prepared for final skinned surface.
Photograph of the finished stainless steel skins showing the uniform surface.
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“For many years now Bill Zahner has given support, energy, backbone, and technical assistance in realizing many of my works ... His firm provides exemplary craftsmanship in everything they undertake, and are seriously and extremely committed to Architecture, with a capital A.” — Frank Gehry, 2008 30
Pritzker Pavilion Project:
Pritzker Pavilion in Millennium Park
Architect:
Frank Gehry Partners
Location:
Chicago, Illinois
Completion: Services Provided:
2004 Design Assist, Engineering, Fabrication, and Installation. The Bandshell for this project was a highly complex engineering feat, the result of which is a very high-quality curvilinear form.
Referencing LEED objectives, we use post-consumer and pre-consumer (postindustrial) recycled metal content in our copper and copper-alloy materials. Post-consumer = minimum 65% postconsumer scrap (or more if the appropriate quantities and grades are available). Pre-consumer = no more than 35% pre-consumer scrap (depending on the availability of appropriate quantities and grades). We use the newest generation of efficient copper refining and alloying furnaces that allow for maximum utilization of postconsumer scrap materials.
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Art Gallery of Alberta Project:
Art Gallery of Alberta (AGA)
Architect:
Randall Stout Architects
Location:
Edmonton, Alberta
Completion: Services:
2010 Zahner provided Design Assist, Engineering, Fabrication, and Shipment. Zahner used the architect’s 3D Model to engineer the sculptural from with the ZEPPS™ Process, and worked with Flynn Canada who provided installation of the interlocking panels and stainless steel skins.
The ZEPPS™ Panels are custom designed to meet the architect’s desired form.
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The ZEPPS™ Process is structural, installing onto the basic steel substructure.
ZEPPS™ configures directly into the 3D Model to precisely match the desired form.
The finished skin of a ZEPPS™ Project is highly consistency as expected from Zahner.
“AGA membership increased dramatically from 1,600 to nearly 5,300. At our first year anniversary celebration, Mayor Stephen Mandel praised our accomplishments and Lindsay Blackett, Minister of Culture and Community Spirit, told us that the investment in the AGA was the best $27 million the Government of Alberta has ever spent.“
— Barry Zalmanowitz, 2010 Chair, Board of Directors
Art Gallery of Alberta
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“When everyone else said that the operable double skin for the Cooper Union’s New Academic Building couldn’t be done, Zahner worked closely with us to make it happen.”
— Thom Mayne FAIA, 2008 Morphosis
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Cooper Union Project:
Cooper Union New Academic Building
Architect:
Morphosis
Location:
New York City
Date: Services Provided:
2009 Design Assist, Engineering, Fabrication & Shipment. Zahner’s Angel Hair® Stainless steel covers the majority of the building, perforated with to allow light through while providing thermal protection. The small window-like rectangles scattered across the surface are where the surface isn’t perforated.
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de Young Project:
The new de Young Museum of Art
Architect:
Herzog & de Meuron
Location:
San Francisco, California
Owner/Client: Completion: Services:
The Corporation of Fine Art Museums 2006 Design Assist, Value Engineering, Scheduling, Fabrication, and Erection of the exterior metal and building envelope. The architects required a pattern on the wall to match sunlight streaming through a canopy of trees. Digital images (below right) were converted into machine language and issued as the basis for 7,600 individually unique dimpled and perforated wall panels.
Over time, the patina has transformed the surface from a bright reflective red to a historic verdigris-tone.
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“Seldom has an architectural project been talked about so much in the world media. In the new age of folded, textured, and curvaceous buildings, Zahner has become a clinic for twisting and treating metal. The list of projects is impressive, reaching a pinnacle with the completion of the widely praised copper facade on the new De Young Museum in San Francisco.”
— Salvatore Orlando, 2007 President President KME-Group
The building features a perforated and bumped wall which references imagery of nearby forestry (pictured left).
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Key Profiles & Organization
L. William Zahner
Robert Zahner
CEO / President
Senior Vice President
Zahner
Zahner
[email protected]
[email protected]
L. William Zahner is established in the architecture community
Robert Zahner’s background in civil engineering and contract
as a leader and an innovator. He transformed what began as a
development provides the Zahner operations group with
small regional shop into the international leader for engineered
contractual oversight and peer review leadership. Zahner is
architectural metal. He sits on the Board for the US Secretary of
the Senior Vice President and presides over the operations and
Commerce, and is a leading expert on the science of metal.
contract responsibilities for the team.
Anthony Birchler P.E.
Randy Stratman
James Porter
VP of Engineering / Sales
Design-Engineer
Chief Operating Officer
Zahner
Zahner
Zahner
[email protected]
[email protected]
[email protected]
Anthony Birchler develops the initially design and engineering
Randy Stratman is the engineering director, responsible
Jim Porter brings over 14 years of experience in on-time
of a project with each client. Birchler shared responsibility for
for defining the scope of each project. Stratman designs
production management of each of the Zahner projects. Porter
the development and implementation of two out of the five
the details for both visual aesthetics as well as functional
implements strategic process improvements and coordinates
patents held by Zahner. He works directly with the engineers,
performance. Stratman oversees the early stages of designing
LEAN initiatives to maximize staff productivity and increase the
architects, and general contractors, and has an extensive
the project, guiding the operations team leader who manages
quality performance of each project produced by Zahner.
knowledge applied metal facade and fenestration systems.
the project through to completion.
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Contact Information
L. William Zahner
Robert Zahner
Anthony Birchler
President & CEO
Senior Vice President
Vice President Engineer / Sales
[email protected]
[email protected]
[email protected]
Zahner HQ 1400 E. 9th Street Kansas City, Missouri 64106 p 816.474.8882 f 816.474.7994 Zahner-Dallas 2860 Alouette Dr. Grand Prairie, TX 75052 p 816.423.8348
