west haymarket arena
West Haymarket Arena Introducing Zahner projects featuring Design Assist, Arena and Curvilinear metalwork, for DLR Group, BVH Architects, The Clark Enersen Partners, Olsson Associates
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It gives me pride to introduce our team members for this iconic structure. This booklet is but a small window into the innovative museum-quality craft that we consistently provide. If you have the opportunity, take a closer look at one of our projects in person. We’ll exceed your expectations.
L. William Zahner
President & CEO A. Zahner Company
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To the owners and the design team for West Haymarket 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 West Haymarket Arena. We have reviewed the complexities of the project and the 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 system will meet the highest levels of sustainability while providing long-term performance. Our product will meet and surpass your expectations.
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We Lead the World.
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.
The Tacoma Museum of Glass, in Tacoma Washington.
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We Research & Develop. 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 on a day to day basis. And it shows: Zahner® has five registered U.S. Patents and four patents pending, a feat we attribute to collaborative problem-solving among the creative individuals in both our offices and fabrication plants. To the right are a few of the patented systems that Zahner has developed, as well as the products that use this research.
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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™ systems. These systems enable architects to construct anything 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 representation of an image to building surface. An image is received as an image file, converted to a raster file, scaled to the surface, and divided into a plurality of subcomponents.
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 Drop & Lock™ Roof & Siding systems, allow panels to be quickly and securely installed with virtually no visible hardware and maximum sustainability.
This is the fundamental basis for our custom Bold Batten Roofing system, providing a more sustainable product for historic and traditional applications.
This is the fundamental basis for the ZIRA™ system, allowing artists and architects to paint, draw, sculpt, and illustrate using the surface of metal panels.
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We give you budget control. One of the most powerful ways that an owner can control the budget for a complex project is by hiring a team that knows how to integrate custom components within the architecture of a project. This team is called the Design Assist Group, a diverse team of highly specialized engineers, architects, and designers. The function of the Design Assist Group is to fully define building systems to meet the architect’s intent, while working within a prescribed budget. The Design Assist Team at Zahner can be integrated into a project at any stage of development. However, the best way to ensure that a project performs well is to integrate Design Assist during the earliest stages of the design process.
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Above: Architects discuss the bumped pattern of the de Young panels.
Architects & owners during a Design Assist Meeting,
Left: Design Assist members meet with the artist for Art Wall at Doha.
discussing how to integrate lights into the panels.
Design Assist, and the Total Building Envelope. The Design Assist Group allows Zahner to completely own responsibility for a building’s envelope, including all exterior glazing, doors, and roof aspects of a project. The most successful projects produced by Zahner are in this vein, such as the de Young Museum, which Zahner was responsible for not only the metal-work, but for the total roof and glass system throughout the project. Below is a project currently in production, the McCoy Federal Building in Jackson, Mississippi. Similar to the de Young, the project owners employed Zahner’s Design Assist team to own the entire scope of the building envelope. This means that the glass system integrates exactly as the architect desires, and the owner can depend on the stability of the budget without unexpected expenses.
Rendering of the McCoy Federal Building, courtesy the
The McCoy Federal Building during the Design Assist
Physical mockup produced for the McCoy
architects at Schwartz & Silver.
Phase., Zahner design-engineers the surface.
Federal Building, Aluminum & Glass.
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We build with ZEPPS™ The ZEPPS™ Process is a series of Zahner Engineered Profiled Panel Systems designed for the specific purpose of building complex buildings and curvilinear forms. The rendering below shows the conceptual start for a ZEPPS™ Substructure on the Sheldon Haymarket. On top of this structure, the Stainless Steel skins will be attached to achieve the knife edged surface and museum quality interfaces with all the building’s components.
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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 coefficients, 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 & Opposite: Designs for Zaha Hadid’s upcoming Sheldon Haymarket Museum. Zahner will engineer the surface using ZEPPS™ Process. Above: Two adjacent ZEPPS™ Panels in the Zahner Facility in Kansas City.
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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 jobsite. 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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Sidra Medical Center (In Process) AECOM & Pelli Clarke Pelli Taubman Museum Randall Stout Architects Roanoke, Virginia; USA
Doha, Qatar 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 Cooper Union at 41 Cooper Square Morphosis New York City; USA Custom-Perf Angel Hair™ Stainless Fairmont Pacific Rim James KM Cheng Vancouver BC, Canada Custom Stainless Steel Finish & ZIRA™
Select Zahner projects featuring Design Assist
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The de Young Museum Herzog & de Meuron San Francisco, California; USA TECU® Classic
Tacoma Museum of Glass The Artwall at Doha
Arthur Erickson
Jan Hendrix + Legorreta & Legorreta
Tacoma, Washington; USA
Doha, Qatar ZIRA™ Painted Aluminum
Zahner Shop Expansion Art Gallery of Alberta
Crawford Architects
Randall Stout Architects
Kansas City, Missouri; USA
Edmonton, Alberta; Canada
Aluminum & Glass
Angel Hair™ Stainless Steel
Angel Hair™ Stainless & ZEPPS™
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Miami Intermodal Center Project:
Miami Intermodal Center (MIC) Transit Facility
Artist/Architect
Perez & Perez
Location:
Miami, Florida
Owner/Client: Date: Services:
Miami Dade County Est. 2011 Design Assist, Value Engineering, Scheduling, Fabrication, and Installation of the structure, form, and skin of the Miami transit facility.
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Basrah Stadium Project:
360 Architects
Location:
Basrah, Iraq
Client: Current State: Date: Services Provided:
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Basrah Sports Center Stadium
Architect:
Abdullah A. Al-Jiburi Contracting Company In Production Est. 2012 Design Assist, Engineering, Fabrication, and Export.
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BOK Center Project:
BOK Center
Architect:
Pelli Clark Pelli
Location:
Tulsa, Oklahoma
Client/Owner: Date: Services Provided:
Tulsa Vision Builders 2008 Design Assist, Engineering, Fabrication, and Installation. The project uses the ZEPPS™ Process to build out the curvilinear shape of the exterior.
Individual ZEPPS™ assemblies between structural beams and columns.
View of the paneling, during construction
View of the Front entrance, completed.
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Zahner Campus Project:
The North Dock Expansion at the Zahner Campus
Architect:
Crawford Architects
Location:
Kansas City, Missouri
Client: Date: Services Provided:
Zahner 2011 Design Assist, Engineering, Fabrication, and Installation. Extruded aluminum ZEPPS™ System, with Glass Curtainwall. L. William Zahner worked with the architects at Crawford to come up with a design that evoked the topography of sand dunes in Qatar, and then developed a design and system to accomplish the desired surface. The final product is a bold design for a square building.
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Hunter Museum Project:
The Hunter Museum of American Art
Architect:
Randall Stout Architects
Location:
Kansas City, Missouri
Client: Date: Services Provided:
Zahner 2011 Design Assist, Engineering, Fabrication, and Installation. Extruded aluminum ZEPPS™ System, with Glass Curtainwall. L. William Zahner worked with the architects at Crawford to come up with a design that evoked the topography of sand dunes in Qatar, and then developed a design and system to accomplish the desired surface. The final product is a bold design for a square building.
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The Taubman Project:
The Taubman Museum of Art
Architect:
Randall Stout Architects, Inc
Location:
Roanoke, Virginia
General Contractor: Date: Services Provided:
Balfour Beatty; Mr. David Salzer 2008 Design Assist, Engineering, Fabrication, and Installation. Employed digital definition modeling and through coordination, we discovered and prevented errors that would not have been noticed at such an early stage were it not for the Design Assist Process.
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The Art Gallery of Alberta Project:
Randall Stout Architects, Inc
Location:
Edmonton, Alberta, Canada
Client
Flynn Canada
:Date:
2010
Services Provided:
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The Art Gallery of Alberta
Architect:
Design Assist, Engineering, Fabrication, Shipping, Zinc, Stainless, & Aluminum.
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Baja 600 Project: Architect: Location: Owner: Date of Completion: Services Provided:
Baja 600 Gastinger Walker Harden Architects Kansas City, Missouri Highwood Properties 2008 Design Assist, Engineer, Custom Patina & Shingle, Fabrication & Installation of new dome. Over twenty feet in diameter, the dome is clad with zinc panel shingling using one of our custom patinas. The curvature of the roof necessitates that every single row be a different size to maintain the alignment of each shingle to another.
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Key Profiles L. William Zahner is the President & CEO of Zahner® and is established in the architecture community as a leader and an innovator. He transformed what began as his great-grandfather’s regional sheet metal company into the international leader for engineered architectural metal. Zahner is the author of two textbooks used by metal experts throughout the world, and has written numerous articles on architectural metals, patinas, and systems.
Above: Honorary induction of L. William Zahner into the American Institute of Architects, May of 2007. Far Right: International Copper Medal, awarded by the Associazone Italiana di Metallurgica, located in Florence, Italy; March of 2006. 34
L. William Zahner [email protected]
President / CEO ZAHNER
Authorship Architectural Metals - A Guide to the Selection, Specification & Performance, Published by John Wiley and Sons, New York. 1995. Architectural Metal Surfaces, Published by John Wiley and Sons, New York. 2004.
Positions (Past & Present) Advisory Board for the Nerman Art Museum. Vice Chairman and current board member, KCAI Board of Trustees. Advisory Board for the School of Engineering at the University of KS. The Industry Liaison, National Architectural Committee of SMACNA. Past President of the National Association of Sheet Metal Contractors. Member of Fabricators and Manufacturers International Association. Trustee for the Sheet Metal Workers International Scholarship Fund. Member of the National Building Museum - Washington DC. Trustee of the Association of Specialty Contractors (ASC). Member of the American Society of Metals International. Past Board Member for Review Publication for the Arts. Past President, National Association of Sheet Metal Contractors. Past Board Member of SMACNA Research and Testing Institute. Past Board Member, Sheet Metal Occupational Heath Insurance Trust.
Architectural Metal Consultant
Selected architectural metal and metal art restoration projects Toledo Museum of Art, lead coated copper skin. Architectural metal work on the AJC Photo voltaic facility in California. Walt Disney Concert Hall skin system. Restoration of the Martin Puryear Sculpture – Getty Museum of Art. Restoration of the Donald Judd Sculptures – ‘the boxes’ & ‘Swimming Pool’ Construction, material selection for World Trade Center site work; Seattle Art Museum Building- Seattle, Washington.
Commissioned sculptural works as an artist “Balloons” 1999 – Wichita, KS. “Hands of Man” 2006 – Salvation Army Kansas City Headquarters. “Directions” 2006 – Economic Development Commission, Kansas City, MO. “Leaves” 2007 – Private collection, Kansas City, MO.
Recognition 2006 - Copper Metal, awarded by Associazione Italiana Di Metallurgia. 2007 - Honorary American Institute of Architects. 2000 - AFLCIO Labor Management Award – National Recognition. 2000 - Engineering News Record – Top 25 News Makers of the Year. 2002 - OCEA Award of Merit – American Society of Civil Engineers. 2007 - Entrepreneur Award from the Bloch School of Business.
Education Bachelor of Science Degree in Civil Engineering, University of KS 35
Robert Zahner [email protected]
Senior Vice President Zahner® 1997-Present
Key Profiles Robert Zahner is the Senior Vice President of Zahner® and is established in the metals industry as an expert on metal construction. Robert Zahner specializes in contract terms, conditions, and administration of the company. In the metal community Zahner is recognized as both a leader and an innovator. Anthony Birchler serves as the Vice President of Engineering & Sales. Birchler shared responsibility for the development and implementation of two out of the five patents that Zahner® holds. He works directly with the architects and the engineers as well as general contractors. He has an extensive knowledge of metal wall & fenestration systems. Jeff Mann is the Senior Project Manager of Team #1. Mann is responsible for the scheduling, costing, general project management, and on site review. Mann is the face of the project from start to finish.
Select Positions (Past & Present) Board Member for SMACNA Trustee, Sheet Metal Workers International Association (SMWIA) Advisor to the American Welding Society regarding Soldering Standards Co-Chairman, Joint Apprentice Trust for the Sheet Metal Workers Local Past Construction Career’s Subcommittee Chairman AGC of America Past Chairman of the SMACNA Architectural Steering Committee Past President of the SMACNA-KC Board of Directors
Relevant Industry Participation AGC of America develop project management training course Negotiating Committee, Teamster Collective Bargaining Agreement SMACNA task force to revise Architectural Sheet Metal Manual ITI to develop industry standard for soldering certification
Architectural Metal Consulting The Unidome in Cedar Rapids, Iowa The Walker Art Museum Sculpture Garden in Minneapolis, Minnesota 5th and Delaware Lofts in Kansas City, Missouri Stainless Steel Artwork for the 87th Street Bridge in Lenexa, Kansas Public Sculpture in St. Paul, Minnesota The Daniel Thomas Office Building In Overland Park, Kansas Stainless Steel Handrails for the Prairie Star Parkway in Lenexa, Kansas Lake of the Isles Residence in Minneapolis, Minnesota
Education Bachelor of Science Degree in Civil Engineering, University of Colorado
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Jeff W. Mann
Anthony E. Birchler [email protected]
Vice President of Engineering / Sales Zahner® 1997-Present
[email protected]
Senior Project Manager, Team #1 Zahner® April 2005-Present
Responsible for sales & development of company projects and products. Responsible for engineering and design produced by the company. Consults with existing and potential clients in achieving their designs through our active “Design/Assist” process. Oversees all design aspects of custom projects.
Previous Experience
Digital engineering, fabrication, installation, overall BIM modeling and coordination between client, architect, general contractor and other related sub-contractors. Development of project budget & estimate, schedules, and BOM. Responsible for project from Design process to project close-out.
Select Managed Projects
Zahner® / Director of Engineering / Boosted efficiency of the engineering department by reorganizing and implementing technology enhancements and starting an ongoing training program. Shared responsibility for the development and implementation of the ZEPP™ System and initial BIM programming. Harmon, Ltd. / Sales Manager – Northeast Region / Responsible for all Sales in Northeast Region of the US; consulted with owners, architects and consultants to determine their needs and priorities by applying advanced and creative design solutions to complex cladding problems. Created and presented technical reviews, training seminars and other presentations for corporate clients as well as inhouse clients. EFCO Corporation / Project Manager / Managed and designed numerous custom curtainwall and window projects. Designed and developed new curtainwall systems. Developed an automated manufacturing system providing prompt delivery of custom windows.
Education: Bachelor of Science in Civil Engineering, University of Missouri, Rolla, 1984. Registered Professional Engineer, Missouri License No. 23332.
NASCAR Hall of Fame Museum (Charlotte, North Carolina); Architect – Pei Cobb Freed and Partners Architects, LLP; Contractor – Turner-FNT/ BE&K Building Group – Davis Joint Venture; Contract Value - $8.6 million; reference – Barton Plunkett – Turner/BE&K/Davis Project Executive Taubman Museum of Art (Roanoke, Virginia); Architect – Randall Stout Architects, Inc.; Contractor – Balfour Beatty; Contract Value - $5.4 million; reference – David Salzer – Balfour Beatty Senior Vice President Operations – 703-218-1354 Treasure Island Entry (Las Vegas, Nevada); Client – Carmel Architectural Sales; Architect – YWS Architects; Contract Value - $445,000; reference – Dave Traino – CEO – Carmel Architectural Sales – 714-630-7721
Previous Experience
Wood & Stuff Cabinetry / Foreman / Built custom cabinetry. Oversaw installation crew for cabinet and countertop installation. Bill Dye Builders II / Foreman / Lead crew in construction of residential home building and remodeling.
Education: Bachelor of Science in Engineering, Kansas State University, 1996. Associates in Accounting, Hutchinson Community College, May, 1989.
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Operational Structure Every project begins at the Design Assist Group, where the project is analyzed and amplified to meet the desired expectations of clients and architects. Design Assist translates the architect’s vision and scope to the abilities and aptitude of our engineers and craftsmen. When the project has been passed through an initial engineering analysis in Design Assist, the groundwork has been laid for Team #1 or Team #2. This allows them to manage the entirety of the project, from engineering to production to installation. Each team coordinates with individuals from the Production Facilities in Kansas City and in Dallas to produce the many components of a project. Each team also has a Field Superintendent who coordinates the installation of projects in the field. Jim Porter manages these production of the engineering solutions and directly collaborates with Anthony Birchler of the Design Assist Group to efficiently construct these projects.
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We play it safe. We operate in accordance with the Health and Safety at Work Act (1974) and all applicable regulations made under the Act. The management at Zahner® supports all programs which promote safety, good health and the well-being of the employees. Beginning in the Summer of 2009, we instituted a fitness awareness program for all employees with incentives to reach optimal body mass index figures. The program has been deemed successful, boosting the morale and health of employees, and in the long-term, this will lower what the company pays for insurance each year. We require safety training, equipment safeguards, and appropriate personal protective equipment when engineering controls are not adequate to minimize exposure. We are committed to providing a safe working environment and we take great precautions to prevent personal injury in the processes of design, production, and construction. It is the duty of all employees to act responsibly and to do everything they can to prevent injury to themselves and fellow workers. The following employees are responsible and accountable to ensure that we are operating safely at all levels of our operation: Senior Vice President .......................................... Robert Zahner Shop Foreman ........................................... assigned per project Vice President of Operations ...................................... Jim Porter Field Superintendent ................................................. Bob Pesek Director of Safety ......................................... Jo Ann Mendenhall Field Superintendent ............................................ Dennis Moore Shop Superintendent ............................................... Kevin Hidy Field Foreman ............................................ assigned per project 40
Above: Safety Leadership Award celebrating over 1 Million Safe Hours without a Lost-time injury. This award from Turner, BE & K, and Davis, accounts for over a year of production on the NASCAR Hall of Fame project, from 2008-2009.
The duties of the field safety representative include: •
•
• • • • •
•
•
•
Reviewing and fully understanding the site safety programs including documentation thereof Establishing first-aid procedures and coordination with the Project Medical Services (listed in project logbook) Maintaining safety and first-aid records Participating in weekly safety meetings Disseminating safety and health information Providing safety consultation Performing follow-up safety inspections on noncompliance issues and determining whether a “stop work” order is necessary Investigating accidents, evaluating and preparing accident reports Accompanying safety and compliance officers on-site Ensuring all Zahner® employees have proper safety orientation and training.
Zahner® is responsible for understanding and complying with all safety and health requirements affecting each project. It is each employee’s responsibility to support Zahner® and the project by providing a safe place to work, protecting themselves, and protecting coworkers from injury or illness. All employees must comply with all known federal, state and local regulations as well as all company safety and health policies. Each employee will be responsible for reporting identified safety or health hazards on the job to his/her supervisor and safety representative. Employees shall also report all accidents or incidents. Employees shall also cooperate and assist in determining proper safety measures for preventing recurrence. All accidents resulting in injury must have an accident report filled out.
For the complete Safety manual, please contact us. 41
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 816.423.8348 f 816.474.7994 Zahner-Dallas 2860 Alouette Dr. Grand Prairie, TX 75052 p 816.423.8348 Zahner-KME Klosterstraße 29 Osnabruck, Germany 49074 p +49 (0) 541 321-2002 f +49 541 321-2111
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It gives me pride to introduce our team members for this iconic structure. This booklet is but a small window into the innovative museum-quality craft that we consistently provide. If you have the opportunity, take a closer look at one of our projects in person. We’ll exceed your expectations.
L. William Zahner
President & CEO A. Zahner Company
3
To the owners and the design team for West Haymarket 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 West Haymarket Arena. We have reviewed the complexities of the project and the 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 system will meet the highest levels of sustainability while providing long-term performance. Our product will meet and surpass your expectations.
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We Lead the World.
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.
The Tacoma Museum of Glass, in Tacoma Washington.
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We Research & Develop. 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 on a day to day basis. And it shows: Zahner® has five registered U.S. Patents and four patents pending, a feat we attribute to collaborative problem-solving among the creative individuals in both our offices and fabrication plants. To the right are a few of the patented systems that Zahner has developed, as well as the products that use this research.
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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™ systems. These systems enable architects to construct anything 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 representation of an image to building surface. An image is received as an image file, converted to a raster file, scaled to the surface, and divided into a plurality of subcomponents.
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 Drop & Lock™ Roof & Siding systems, allow panels to be quickly and securely installed with virtually no visible hardware and maximum sustainability.
This is the fundamental basis for our custom Bold Batten Roofing system, providing a more sustainable product for historic and traditional applications.
This is the fundamental basis for the ZIRA™ system, allowing artists and architects to paint, draw, sculpt, and illustrate using the surface of metal panels.
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We give you budget control. One of the most powerful ways that an owner can control the budget for a complex project is by hiring a team that knows how to integrate custom components within the architecture of a project. This team is called the Design Assist Group, a diverse team of highly specialized engineers, architects, and designers. The function of the Design Assist Group is to fully define building systems to meet the architect’s intent, while working within a prescribed budget. The Design Assist Team at Zahner can be integrated into a project at any stage of development. However, the best way to ensure that a project performs well is to integrate Design Assist during the earliest stages of the design process.
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Above: Architects discuss the bumped pattern of the de Young panels.
Architects & owners during a Design Assist Meeting,
Left: Design Assist members meet with the artist for Art Wall at Doha.
discussing how to integrate lights into the panels.
Design Assist, and the Total Building Envelope. The Design Assist Group allows Zahner to completely own responsibility for a building’s envelope, including all exterior glazing, doors, and roof aspects of a project. The most successful projects produced by Zahner are in this vein, such as the de Young Museum, which Zahner was responsible for not only the metal-work, but for the total roof and glass system throughout the project. Below is a project currently in production, the McCoy Federal Building in Jackson, Mississippi. Similar to the de Young, the project owners employed Zahner’s Design Assist team to own the entire scope of the building envelope. This means that the glass system integrates exactly as the architect desires, and the owner can depend on the stability of the budget without unexpected expenses.
Rendering of the McCoy Federal Building, courtesy the
The McCoy Federal Building during the Design Assist
Physical mockup produced for the McCoy
architects at Schwartz & Silver.
Phase., Zahner design-engineers the surface.
Federal Building, Aluminum & Glass.
11
We build with ZEPPS™ The ZEPPS™ Process is a series of Zahner Engineered Profiled Panel Systems designed for the specific purpose of building complex buildings and curvilinear forms. The rendering below shows the conceptual start for a ZEPPS™ Substructure on the Sheldon Haymarket. On top of this structure, the Stainless Steel skins will be attached to achieve the knife edged surface and museum quality interfaces with all the building’s components.
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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 coefficients, 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 & Opposite: Designs for Zaha Hadid’s upcoming Sheldon Haymarket Museum. Zahner will engineer the surface using ZEPPS™ Process. Above: Two adjacent ZEPPS™ Panels in the Zahner Facility in Kansas City.
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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 jobsite. 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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Sidra Medical Center (In Process) AECOM & Pelli Clarke Pelli Taubman Museum Randall Stout Architects Roanoke, Virginia; USA
Doha, Qatar 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 Cooper Union at 41 Cooper Square Morphosis New York City; USA Custom-Perf Angel Hair™ Stainless Fairmont Pacific Rim James KM Cheng Vancouver BC, Canada Custom Stainless Steel Finish & ZIRA™
Select Zahner projects featuring Design Assist
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The de Young Museum Herzog & de Meuron San Francisco, California; USA TECU® Classic
Tacoma Museum of Glass The Artwall at Doha
Arthur Erickson
Jan Hendrix + Legorreta & Legorreta
Tacoma, Washington; USA
Doha, Qatar ZIRA™ Painted Aluminum
Zahner Shop Expansion Art Gallery of Alberta
Crawford Architects
Randall Stout Architects
Kansas City, Missouri; USA
Edmonton, Alberta; Canada
Aluminum & Glass
Angel Hair™ Stainless Steel
Angel Hair™ Stainless & ZEPPS™
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Miami Intermodal Center Project:
Miami Intermodal Center (MIC) Transit Facility
Artist/Architect
Perez & Perez
Location:
Miami, Florida
Owner/Client: Date: Services:
Miami Dade County Est. 2011 Design Assist, Value Engineering, Scheduling, Fabrication, and Installation of the structure, form, and skin of the Miami transit facility.
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Basrah Stadium Project:
360 Architects
Location:
Basrah, Iraq
Client: Current State: Date: Services Provided:
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Basrah Sports Center Stadium
Architect:
Abdullah A. Al-Jiburi Contracting Company In Production Est. 2012 Design Assist, Engineering, Fabrication, and Export.
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BOK Center Project:
BOK Center
Architect:
Pelli Clark Pelli
Location:
Tulsa, Oklahoma
Client/Owner: Date: Services Provided:
Tulsa Vision Builders 2008 Design Assist, Engineering, Fabrication, and Installation. The project uses the ZEPPS™ Process to build out the curvilinear shape of the exterior.
Individual ZEPPS™ assemblies between structural beams and columns.
View of the paneling, during construction
View of the Front entrance, completed.
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Zahner Campus Project:
The North Dock Expansion at the Zahner Campus
Architect:
Crawford Architects
Location:
Kansas City, Missouri
Client: Date: Services Provided:
Zahner 2011 Design Assist, Engineering, Fabrication, and Installation. Extruded aluminum ZEPPS™ System, with Glass Curtainwall. L. William Zahner worked with the architects at Crawford to come up with a design that evoked the topography of sand dunes in Qatar, and then developed a design and system to accomplish the desired surface. The final product is a bold design for a square building.
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Hunter Museum Project:
The Hunter Museum of American Art
Architect:
Randall Stout Architects
Location:
Kansas City, Missouri
Client: Date: Services Provided:
Zahner 2011 Design Assist, Engineering, Fabrication, and Installation. Extruded aluminum ZEPPS™ System, with Glass Curtainwall. L. William Zahner worked with the architects at Crawford to come up with a design that evoked the topography of sand dunes in Qatar, and then developed a design and system to accomplish the desired surface. The final product is a bold design for a square building.
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The Taubman Project:
The Taubman Museum of Art
Architect:
Randall Stout Architects, Inc
Location:
Roanoke, Virginia
General Contractor: Date: Services Provided:
Balfour Beatty; Mr. David Salzer 2008 Design Assist, Engineering, Fabrication, and Installation. Employed digital definition modeling and through coordination, we discovered and prevented errors that would not have been noticed at such an early stage were it not for the Design Assist Process.
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The Art Gallery of Alberta Project:
Randall Stout Architects, Inc
Location:
Edmonton, Alberta, Canada
Client
Flynn Canada
:Date:
2010
Services Provided:
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The Art Gallery of Alberta
Architect:
Design Assist, Engineering, Fabrication, Shipping, Zinc, Stainless, & Aluminum.
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Baja 600 Project: Architect: Location: Owner: Date of Completion: Services Provided:
Baja 600 Gastinger Walker Harden Architects Kansas City, Missouri Highwood Properties 2008 Design Assist, Engineer, Custom Patina & Shingle, Fabrication & Installation of new dome. Over twenty feet in diameter, the dome is clad with zinc panel shingling using one of our custom patinas. The curvature of the roof necessitates that every single row be a different size to maintain the alignment of each shingle to another.
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Key Profiles L. William Zahner is the President & CEO of Zahner® and is established in the architecture community as a leader and an innovator. He transformed what began as his great-grandfather’s regional sheet metal company into the international leader for engineered architectural metal. Zahner is the author of two textbooks used by metal experts throughout the world, and has written numerous articles on architectural metals, patinas, and systems.
Above: Honorary induction of L. William Zahner into the American Institute of Architects, May of 2007. Far Right: International Copper Medal, awarded by the Associazone Italiana di Metallurgica, located in Florence, Italy; March of 2006. 34
L. William Zahner [email protected]
President / CEO ZAHNER
Authorship Architectural Metals - A Guide to the Selection, Specification & Performance, Published by John Wiley and Sons, New York. 1995. Architectural Metal Surfaces, Published by John Wiley and Sons, New York. 2004.
Positions (Past & Present) Advisory Board for the Nerman Art Museum. Vice Chairman and current board member, KCAI Board of Trustees. Advisory Board for the School of Engineering at the University of KS. The Industry Liaison, National Architectural Committee of SMACNA. Past President of the National Association of Sheet Metal Contractors. Member of Fabricators and Manufacturers International Association. Trustee for the Sheet Metal Workers International Scholarship Fund. Member of the National Building Museum - Washington DC. Trustee of the Association of Specialty Contractors (ASC). Member of the American Society of Metals International. Past Board Member for Review Publication for the Arts. Past President, National Association of Sheet Metal Contractors. Past Board Member of SMACNA Research and Testing Institute. Past Board Member, Sheet Metal Occupational Heath Insurance Trust.
Architectural Metal Consultant
Selected architectural metal and metal art restoration projects Toledo Museum of Art, lead coated copper skin. Architectural metal work on the AJC Photo voltaic facility in California. Walt Disney Concert Hall skin system. Restoration of the Martin Puryear Sculpture – Getty Museum of Art. Restoration of the Donald Judd Sculptures – ‘the boxes’ & ‘Swimming Pool’ Construction, material selection for World Trade Center site work; Seattle Art Museum Building- Seattle, Washington.
Commissioned sculptural works as an artist “Balloons” 1999 – Wichita, KS. “Hands of Man” 2006 – Salvation Army Kansas City Headquarters. “Directions” 2006 – Economic Development Commission, Kansas City, MO. “Leaves” 2007 – Private collection, Kansas City, MO.
Recognition 2006 - Copper Metal, awarded by Associazione Italiana Di Metallurgia. 2007 - Honorary American Institute of Architects. 2000 - AFLCIO Labor Management Award – National Recognition. 2000 - Engineering News Record – Top 25 News Makers of the Year. 2002 - OCEA Award of Merit – American Society of Civil Engineers. 2007 - Entrepreneur Award from the Bloch School of Business.
Education Bachelor of Science Degree in Civil Engineering, University of KS 35
Robert Zahner [email protected]
Senior Vice President Zahner® 1997-Present
Key Profiles Robert Zahner is the Senior Vice President of Zahner® and is established in the metals industry as an expert on metal construction. Robert Zahner specializes in contract terms, conditions, and administration of the company. In the metal community Zahner is recognized as both a leader and an innovator. Anthony Birchler serves as the Vice President of Engineering & Sales. Birchler shared responsibility for the development and implementation of two out of the five patents that Zahner® holds. He works directly with the architects and the engineers as well as general contractors. He has an extensive knowledge of metal wall & fenestration systems. Jeff Mann is the Senior Project Manager of Team #1. Mann is responsible for the scheduling, costing, general project management, and on site review. Mann is the face of the project from start to finish.
Select Positions (Past & Present) Board Member for SMACNA Trustee, Sheet Metal Workers International Association (SMWIA) Advisor to the American Welding Society regarding Soldering Standards Co-Chairman, Joint Apprentice Trust for the Sheet Metal Workers Local Past Construction Career’s Subcommittee Chairman AGC of America Past Chairman of the SMACNA Architectural Steering Committee Past President of the SMACNA-KC Board of Directors
Relevant Industry Participation AGC of America develop project management training course Negotiating Committee, Teamster Collective Bargaining Agreement SMACNA task force to revise Architectural Sheet Metal Manual ITI to develop industry standard for soldering certification
Architectural Metal Consulting The Unidome in Cedar Rapids, Iowa The Walker Art Museum Sculpture Garden in Minneapolis, Minnesota 5th and Delaware Lofts in Kansas City, Missouri Stainless Steel Artwork for the 87th Street Bridge in Lenexa, Kansas Public Sculpture in St. Paul, Minnesota The Daniel Thomas Office Building In Overland Park, Kansas Stainless Steel Handrails for the Prairie Star Parkway in Lenexa, Kansas Lake of the Isles Residence in Minneapolis, Minnesota
Education Bachelor of Science Degree in Civil Engineering, University of Colorado
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Jeff W. Mann
Anthony E. Birchler [email protected]
Vice President of Engineering / Sales Zahner® 1997-Present
[email protected]
Senior Project Manager, Team #1 Zahner® April 2005-Present
Responsible for sales & development of company projects and products. Responsible for engineering and design produced by the company. Consults with existing and potential clients in achieving their designs through our active “Design/Assist” process. Oversees all design aspects of custom projects.
Previous Experience
Digital engineering, fabrication, installation, overall BIM modeling and coordination between client, architect, general contractor and other related sub-contractors. Development of project budget & estimate, schedules, and BOM. Responsible for project from Design process to project close-out.
Select Managed Projects
Zahner® / Director of Engineering / Boosted efficiency of the engineering department by reorganizing and implementing technology enhancements and starting an ongoing training program. Shared responsibility for the development and implementation of the ZEPP™ System and initial BIM programming. Harmon, Ltd. / Sales Manager – Northeast Region / Responsible for all Sales in Northeast Region of the US; consulted with owners, architects and consultants to determine their needs and priorities by applying advanced and creative design solutions to complex cladding problems. Created and presented technical reviews, training seminars and other presentations for corporate clients as well as inhouse clients. EFCO Corporation / Project Manager / Managed and designed numerous custom curtainwall and window projects. Designed and developed new curtainwall systems. Developed an automated manufacturing system providing prompt delivery of custom windows.
Education: Bachelor of Science in Civil Engineering, University of Missouri, Rolla, 1984. Registered Professional Engineer, Missouri License No. 23332.
NASCAR Hall of Fame Museum (Charlotte, North Carolina); Architect – Pei Cobb Freed and Partners Architects, LLP; Contractor – Turner-FNT/ BE&K Building Group – Davis Joint Venture; Contract Value - $8.6 million; reference – Barton Plunkett – Turner/BE&K/Davis Project Executive Taubman Museum of Art (Roanoke, Virginia); Architect – Randall Stout Architects, Inc.; Contractor – Balfour Beatty; Contract Value - $5.4 million; reference – David Salzer – Balfour Beatty Senior Vice President Operations – 703-218-1354 Treasure Island Entry (Las Vegas, Nevada); Client – Carmel Architectural Sales; Architect – YWS Architects; Contract Value - $445,000; reference – Dave Traino – CEO – Carmel Architectural Sales – 714-630-7721
Previous Experience
Wood & Stuff Cabinetry / Foreman / Built custom cabinetry. Oversaw installation crew for cabinet and countertop installation. Bill Dye Builders II / Foreman / Lead crew in construction of residential home building and remodeling.
Education: Bachelor of Science in Engineering, Kansas State University, 1996. Associates in Accounting, Hutchinson Community College, May, 1989.
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Operational Structure Every project begins at the Design Assist Group, where the project is analyzed and amplified to meet the desired expectations of clients and architects. Design Assist translates the architect’s vision and scope to the abilities and aptitude of our engineers and craftsmen. When the project has been passed through an initial engineering analysis in Design Assist, the groundwork has been laid for Team #1 or Team #2. This allows them to manage the entirety of the project, from engineering to production to installation. Each team coordinates with individuals from the Production Facilities in Kansas City and in Dallas to produce the many components of a project. Each team also has a Field Superintendent who coordinates the installation of projects in the field. Jim Porter manages these production of the engineering solutions and directly collaborates with Anthony Birchler of the Design Assist Group to efficiently construct these projects.
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We play it safe. We operate in accordance with the Health and Safety at Work Act (1974) and all applicable regulations made under the Act. The management at Zahner® supports all programs which promote safety, good health and the well-being of the employees. Beginning in the Summer of 2009, we instituted a fitness awareness program for all employees with incentives to reach optimal body mass index figures. The program has been deemed successful, boosting the morale and health of employees, and in the long-term, this will lower what the company pays for insurance each year. We require safety training, equipment safeguards, and appropriate personal protective equipment when engineering controls are not adequate to minimize exposure. We are committed to providing a safe working environment and we take great precautions to prevent personal injury in the processes of design, production, and construction. It is the duty of all employees to act responsibly and to do everything they can to prevent injury to themselves and fellow workers. The following employees are responsible and accountable to ensure that we are operating safely at all levels of our operation: Senior Vice President .......................................... Robert Zahner Shop Foreman ........................................... assigned per project Vice President of Operations ...................................... Jim Porter Field Superintendent ................................................. Bob Pesek Director of Safety ......................................... Jo Ann Mendenhall Field Superintendent ............................................ Dennis Moore Shop Superintendent ............................................... Kevin Hidy Field Foreman ............................................ assigned per project 40
Above: Safety Leadership Award celebrating over 1 Million Safe Hours without a Lost-time injury. This award from Turner, BE & K, and Davis, accounts for over a year of production on the NASCAR Hall of Fame project, from 2008-2009.
The duties of the field safety representative include: •
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Reviewing and fully understanding the site safety programs including documentation thereof Establishing first-aid procedures and coordination with the Project Medical Services (listed in project logbook) Maintaining safety and first-aid records Participating in weekly safety meetings Disseminating safety and health information Providing safety consultation Performing follow-up safety inspections on noncompliance issues and determining whether a “stop work” order is necessary Investigating accidents, evaluating and preparing accident reports Accompanying safety and compliance officers on-site Ensuring all Zahner® employees have proper safety orientation and training.
Zahner® is responsible for understanding and complying with all safety and health requirements affecting each project. It is each employee’s responsibility to support Zahner® and the project by providing a safe place to work, protecting themselves, and protecting coworkers from injury or illness. All employees must comply with all known federal, state and local regulations as well as all company safety and health policies. Each employee will be responsible for reporting identified safety or health hazards on the job to his/her supervisor and safety representative. Employees shall also report all accidents or incidents. Employees shall also cooperate and assist in determining proper safety measures for preventing recurrence. All accidents resulting in injury must have an accident report filled out.
For the complete Safety manual, please contact us. 41
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 816.423.8348 f 816.474.7994 Zahner-Dallas 2860 Alouette Dr. Grand Prairie, TX 75052 p 816.423.8348 Zahner-KME Klosterstraße 29 Osnabruck, Germany 49074 p +49 (0) 541 321-2002 f +49 541 321-2111
