musee zahner kme
Musée de Louvain-la-Neuve Introduction Solanum™ Preweathered Steel Perkins + Will & Emile Verhaegen
To the design team for the Musée de Louvain-la-Neuve I am proud to introduce our team members for this iconic structure. This booklet is but a small window into the innovative museum-quality surfaces that we consistently provide. If you have the opportunity, take a closer look at one of our projects in person. We’ll meet / surpass your expectations.
L. William Zahner
President Zahner-KME
To Perkins + Will, Emile Verhaegen and the Design Team for the Musée de Louvain-la-Neuve The following pages will showcase Zahner projects similar in scope and in complexity to the Musée de Louvain-la-Neuve in Belgium. We have reviewed the complexities of the project and the architectural aesthetic being designed. We have both the engineering know-how to define it and the expert fabricators who will produce and install the project. Our deliverable solutions for the weathering steel curving facade and sun screen elements will meet the highest levels of sustainability while providing long-term performance. The Musée de Louvain-la-Neuve will be as stunning as you’ve imagined it.
We Lead the World.
Zahner-KME is internationally renowned and recognized for its innovative engineering and construction in the field of metal. 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.
L. William Zahner, our president and Chief Executive Officer, leads the company as 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.
The Tacoma Museum of Glass, in Tacoma Washington.
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.
Patent No. US 7,434,366 B2
Patent No. US 7,210,273 B2
Date of Patent: October, 2008
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.
And it shows: Zahner® has five registered U.S. Patents and four patents pending, a feat we attribute to collaborative problemsolving among the creative individuals in both our offices and fabrication plants.
This is the fundamental basis of design for all of our ZEPPS™ systems. These systems enable architects to construct anything imaginable.
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 for the Inverted Seam™ system, the best roof that money can buy.
Patent No. US 7,212,688 B2
Patent No. US 5,394,666
Patent No. US 5,272,849
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 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.
Date of Patent: May, 2007
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.
Date of Patent: March, 1995
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.
Date of Patent: December, 1993
This is the fundamental basis for our custom Bold Batten Roofing system, providing a more sustainable product for historic and traditional applications.
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 3-dimensional computer modeling, employing a fully parametric, spatial mathematical system. This powerful CAD system allows the engineers to accurately model the architect’s vision while testing realworld restraints, allowing the design to evolve as structural rationale, site constraints, and programmatic functions become apparent. This is also the stage where the visual nature of the 3D model becomes structurally plausible, allowing 360º viewing of the form; here we can begin to evaluate the model for structural stability, testing the effects of wind, gravity, and the load transfer among structural components. Using CAD software, cross section cuts are made through the digital model’s “mass.” Through this method of sectioning, a primary 3-dimensional, structural frame is derived. The edges of these “framing” members, and the perimeter edges of the object’s form, digitally define a rational structural shape.
Below: Two images of the de Young, the left is a computer model; the right is the final built structure. Opposite: CAD drawing of the sub-structure mobius component for the NASCAR Hall of Fame.
The digitally defined model is then used to provide data which instructs computerguided machinery, thus beginning the process of fabricating the project. 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.
This is not just an museum. This is art.
Trinity River Audubon Center
Hunter Museum of American Art
de Young Museum
Art Gallery of Alb
berta
The Taubman Museum of Art
The Contemporary Jewish Museum
Museum of Glass
We build art to showcase art.
Metal becomes Art. select projects involving various metals
de Young Project: Location: Owner: Architect: General Contractor:
The new de Young Museum of Art San Francisco, California The Corporation of Fine Art Museums Herzog & De Meuron in association with Fong and Chang Architects Swinerton Builders, Mr. Michael Strong
Services Provided:
Design Assist, Value Engineering, Scheduling, Fabrication, and Erection of the monumental exterior metal and building envelope. The architects required a pattern on the wall to match that of sunlight streaming through a canopy of trees. Digital pictures and digital modeling images were converted into machine language and issued as the basis for 7,600 individually unique dimpled and perforated wall panels. Zahner’s digital model of the nine story twisting tower was also used by the concrete structure subcontractor. The entire façade was designed to resist seismic forces as well as all other structural requirements.
Project Duration:
Start of design assist June 2001; substantial completion: January 2005.
References:
General Contractor: Mr. Michael Strong (415) 421-2980 Owner: Ms. Patty Lacson (415) 750-3511 Architect: Herzog & De Meuron (011) 41 61 385-5757
The Taubman Project: Location: Architect: General Contractor: Services Provided:
References:
The Taubman Museum of Art Roanoke, Virginia Randall Stout Architects, Inc Balfour Beatty; Mr. David Salzer Design Assist, Engineering, Fabrication, and Installation. Employed digital definition modeling and through coordination, errors caught in time and prevented in other subcontractors work. The complex geometries of the Taubman replicate the hills, and the Blue Ridge Mountains to the west of Roanoke, Virginia. General Contractor: David Salzer (703) 218-1354 Architect: Randall Stout (310) 827-6876
We Meet, Surpass, and Precede LEED Certification We’ve committed ourselves to improving the environment and cutting the carbon footprint of both our own working environment as well as the buildings we create. Before Leadership in Energy and Environmental Design even existed, we were awarded in 1995 the Environmental Excellence Award from Kansas City because of our diligence to meet the standards now known as LEED.
The New Cooper Union Academic Building incorporates environmentally sophisticated technologies that bolster the new academic building’s standards to LEED Gold, with the possibility of achieving LEED Platinum, the highest rating awarded by the U.S. Green Building Council system. Using our perforation patterns, a semi-transparent mesh was engineered to create coolness during the Summer, and warmth in the Winter by controlling daylight, energy use, and natural ventilation.
Cooper Union Project: Location: Architect: Project Duration: Services Provided:
References:
Cooper Union New Academic Building New York City Morphosis 2006-2009 Design Assist, Engineering, Fabrication, Shipping. Stainless covers the majority of the building, allowing light to filter through while providing thermal protection. The small window-like rectangles scattered across the surface are actually bare Angel Hair™ Stainless steel without perforation. Architect: Morphosis (212) 675-1100 Facade Installation: Les Young, W&W Glass (703) 218-1354
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.
Solanum™ Preweathered Steel Zahner has more than 40 years of experience and over a hundred projects successfully installed using weathering steel surfaces for architecture and art. We operate out of a facility that is clad in architectural weathering steel, (pictured on page seven), and there is no other company in the world with as much experience and expertise in the applied use of weathering steel. Zahner’s systematic and scientific research has been instrumental in the development of an accelerated patination process. We develop our patina on preformed steel with an artistic natural color and texture like no other. This is our Solanum™ Patina. The density of our patina layer and its adherence to the surface is the reason for our steel’s durability and longevity over time. Our process for preweathered Solanum™ Weathering Steel accelerates the natural weathering process to arrive at a highly protective, durable mineral layer, and we have the science to prove it.
The science of steel.
It begins at the source. We work with our steel mill to ensure that the raw steel ingot is derived from specific alloying components. The base raw material is cast to exacting specifications. Next, we work with a rolling mill that understands the finesse required when working with bare weathering steel. If you don’t influence the base metal sources, the mill will treat the material like any other metal: it will be oiled, scratched, and scarred. Such contaminated metal will reveal itself in the final product as streaks, rings, and discolorations in the finished surface.
We inspect each and every plate surface. Each surface is cleaned and prepared to eliminate oxides, greases, and oils. If this step is not carefully, the finish will corrode. Next we shock the surface to an initial ferric oxide. This finish is slightly orange in color and is characterized by a crusty texture. At this point the metal is crusty and orange. An orange patina is not a permanent patina (pictured above right). Yellow and orange patinas on weathered steel will continue to flake, darken, bleed, and stain adjoining surfaces. Orange is soluble. At this stage, we allow this orange-toned oxide to grow to a point, and then remove most of it from the surface. The surface is then exposed to a proprietary solution and specific atmospheric conditions to develop a hydrated oxide form of ferrous oxide or ferrous hydroxide. This is insoluble. We cultivate the growth of the hydrated oxide form until it reaches a certain point. We arrest the surface with a chemical solution that inhibits and slows oxidation to a standstill. The material is in its final stage of development (pictured bottom right). This is Solanum™ Steel.
Top: Microscope photo showing flakes and loose oxide on the surface of 2-year-weathered COR-TEN steel. Bottom: microscope photo of Solanum™ Steel, insoluble surface.
Our steel stains less. Our finish does not come off when rubbed, nor does it come off and stain adjoining surfaces over time. Weathering steel is known for staining adjacent surfaces with iron oxide as the material continues to age. Our preweathering process reduces and often eliminates staining of surrounding surfaces. We will guarantee it.
Telluride House; Architect: Architecture Research Office (ARO) 16ga Solanum™ Weathering Steel shingles.
Guggenheim Hermitage Museum; Architect: OMA. ½” Solanum™ Steel.
Zahner used the Solanum™ Steel process on the interior walls of the Guggenheim Hermitage Museum in Las Vegas, Nevada. Over 100 tons of oxidized and preweathered steel was used to produce this project. Because it was used as the interior walls of the museum, Rem Koolhaus and the architects at OMA required a surface that would perform better than any weathering steel product produced in the history of the material. They came to us to create it.
Trinity River Project: Location: Architect: Services Provided:
References:
Trinity River Audubon Center Dallas, Texas Antoine Predock Associates Design Assist, Engineering, Fabrication, and Installation. The subtly curving skin was punctured by multiple idiosyncratically placed apertures and the metal panel joints were carefully designed to work into the overall design effect. Architect: Antoine Predock (505) 843-7390
Screen Gates Project: Location: Owner: Architect: Services Provided:
Project Duration: References:
Kansas City Art Institute Screen Gates Kansas City, Missouri; KCAI Campus The Kansas City Art Institute Gastinger Walker Harden Architects Design Assist, Engineering & Fabrication, Delivery & Installation. Working with the Gastinger, we translated the pattern into machine language to custom perforate the panels. March 2006 - July 2006 Architect: Kirk Gastinger (816) 569-0813
The Nelson Project: Location: Architect: Services Provided:
Reference:
The Nelson-Atkins Museum of Art Kansas City, Missouri Steven Holl Architects Design Assist, Engineering & Fabrication, Delivery & Installation. Solanum™ Weathering steel panels were installed in the garage addition at the Nelson-Atkins Museum of Art. James Dayton (612) 338-0005
Vail Residence Project: Location: Architect: Services Provided: References:
Vail Residence Vail Colorado James Dayton Design Design Assist, Engineering, Fabrication, and Installation. Architect: James Dayton (612) 338.0005
Key Profiles L. William Zahner is the President & CEO of Zahner® and the president of Zahner-KME. Zahner 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.
L. William Zahner [email protected]
President
ZAHNER-KME
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.
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
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.
Anthony E. Birchler [email protected]
Vice President of Engineering / Sales Zahner® 1997-Present
Key Profiles 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. Randy Stratman is the Director of Engineering. He is a member of Design Assist Group. He moves between both the clients and the project teams to define the scopes, analyze the alternatives, and establish a prudent course of action to bring the project to fruition. 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.
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 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.
Jeff W. Mann
Randy G. Stratman
[email protected]
[email protected]
Engineering Director Zahner® 1998-Present
Senior Project Manager, Team #1 Zahner® April 2005-Present
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.
LEED® AP Works directly with clients to distill design directives & intent. Responsible for overseeing the implementation of creative design solutions for complex architectural cladding projects. Implementation of automated BIM modeling solutions that further facilitate the design, manufacturing, and installation sequences.
Previous Experience
Managed Projects 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
March Incorporated / Design Engineer / Designed plastic and metal products for manufacturing. Operated directly with customers and vendors. B/E Aerospace, Inc. / Designer / Designed new products (concept to production) with focus on reliability, minimum weight and ease of manufacturing and assembly. Employed latest technological services to produce rapid prototypes, molds and production assembly fixtures. Fasco Industries / Specification Technician / Designed new fractional horsepower electric products per client requirements. Facilitated the incorporation of new facilities and acquired product lines into firm’s engineering and manufacturing standards.
Education: Bachelor of Design / Drafting, Southwest Missouri State University, 1989 / Minor in Industrial Management.
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.
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.
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-KME supports all programs which promote safety, good health and 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
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-KME employees have proper safety orientation and training.
Zahner-KME is responsible for understanding and complying with all safety and health requirements affecting each project. It is each employee’s responsibility to support Zahner-KME 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.
To the design team for the Musée de Louvain-la-Neuve I am proud to introduce our team members for this iconic structure. This booklet is but a small window into the innovative museum-quality surfaces that we consistently provide. If you have the opportunity, take a closer look at one of our projects in person. We’ll meet / surpass your expectations.
L. William Zahner
President Zahner-KME
To Perkins + Will, Emile Verhaegen and the Design Team for the Musée de Louvain-la-Neuve The following pages will showcase Zahner projects similar in scope and in complexity to the Musée de Louvain-la-Neuve in Belgium. We have reviewed the complexities of the project and the architectural aesthetic being designed. We have both the engineering know-how to define it and the expert fabricators who will produce and install the project. Our deliverable solutions for the weathering steel curving facade and sun screen elements will meet the highest levels of sustainability while providing long-term performance. The Musée de Louvain-la-Neuve will be as stunning as you’ve imagined it.
We Lead the World.
Zahner-KME is internationally renowned and recognized for its innovative engineering and construction in the field of metal. 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.
L. William Zahner, our president and Chief Executive Officer, leads the company as 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.
The Tacoma Museum of Glass, in Tacoma Washington.
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.
Patent No. US 7,434,366 B2
Patent No. US 7,210,273 B2
Date of Patent: October, 2008
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.
And it shows: Zahner® has five registered U.S. Patents and four patents pending, a feat we attribute to collaborative problemsolving among the creative individuals in both our offices and fabrication plants.
This is the fundamental basis of design for all of our ZEPPS™ systems. These systems enable architects to construct anything imaginable.
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 for the Inverted Seam™ system, the best roof that money can buy.
Patent No. US 7,212,688 B2
Patent No. US 5,394,666
Patent No. US 5,272,849
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 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.
Date of Patent: May, 2007
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.
Date of Patent: March, 1995
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.
Date of Patent: December, 1993
This is the fundamental basis for our custom Bold Batten Roofing system, providing a more sustainable product for historic and traditional applications.
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 3-dimensional computer modeling, employing a fully parametric, spatial mathematical system. This powerful CAD system allows the engineers to accurately model the architect’s vision while testing realworld restraints, allowing the design to evolve as structural rationale, site constraints, and programmatic functions become apparent. This is also the stage where the visual nature of the 3D model becomes structurally plausible, allowing 360º viewing of the form; here we can begin to evaluate the model for structural stability, testing the effects of wind, gravity, and the load transfer among structural components. Using CAD software, cross section cuts are made through the digital model’s “mass.” Through this method of sectioning, a primary 3-dimensional, structural frame is derived. The edges of these “framing” members, and the perimeter edges of the object’s form, digitally define a rational structural shape.
Below: Two images of the de Young, the left is a computer model; the right is the final built structure. Opposite: CAD drawing of the sub-structure mobius component for the NASCAR Hall of Fame.
The digitally defined model is then used to provide data which instructs computerguided machinery, thus beginning the process of fabricating the project. 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.
This is not just an museum. This is art.
Trinity River Audubon Center
Hunter Museum of American Art
de Young Museum
Art Gallery of Alb
berta
The Taubman Museum of Art
The Contemporary Jewish Museum
Museum of Glass
We build art to showcase art.
Metal becomes Art. select projects involving various metals
de Young Project: Location: Owner: Architect: General Contractor:
The new de Young Museum of Art San Francisco, California The Corporation of Fine Art Museums Herzog & De Meuron in association with Fong and Chang Architects Swinerton Builders, Mr. Michael Strong
Services Provided:
Design Assist, Value Engineering, Scheduling, Fabrication, and Erection of the monumental exterior metal and building envelope. The architects required a pattern on the wall to match that of sunlight streaming through a canopy of trees. Digital pictures and digital modeling images were converted into machine language and issued as the basis for 7,600 individually unique dimpled and perforated wall panels. Zahner’s digital model of the nine story twisting tower was also used by the concrete structure subcontractor. The entire façade was designed to resist seismic forces as well as all other structural requirements.
Project Duration:
Start of design assist June 2001; substantial completion: January 2005.
References:
General Contractor: Mr. Michael Strong (415) 421-2980 Owner: Ms. Patty Lacson (415) 750-3511 Architect: Herzog & De Meuron (011) 41 61 385-5757
The Taubman Project: Location: Architect: General Contractor: Services Provided:
References:
The Taubman Museum of Art Roanoke, Virginia Randall Stout Architects, Inc Balfour Beatty; Mr. David Salzer Design Assist, Engineering, Fabrication, and Installation. Employed digital definition modeling and through coordination, errors caught in time and prevented in other subcontractors work. The complex geometries of the Taubman replicate the hills, and the Blue Ridge Mountains to the west of Roanoke, Virginia. General Contractor: David Salzer (703) 218-1354 Architect: Randall Stout (310) 827-6876
We Meet, Surpass, and Precede LEED Certification We’ve committed ourselves to improving the environment and cutting the carbon footprint of both our own working environment as well as the buildings we create. Before Leadership in Energy and Environmental Design even existed, we were awarded in 1995 the Environmental Excellence Award from Kansas City because of our diligence to meet the standards now known as LEED.
The New Cooper Union Academic Building incorporates environmentally sophisticated technologies that bolster the new academic building’s standards to LEED Gold, with the possibility of achieving LEED Platinum, the highest rating awarded by the U.S. Green Building Council system. Using our perforation patterns, a semi-transparent mesh was engineered to create coolness during the Summer, and warmth in the Winter by controlling daylight, energy use, and natural ventilation.
Cooper Union Project: Location: Architect: Project Duration: Services Provided:
References:
Cooper Union New Academic Building New York City Morphosis 2006-2009 Design Assist, Engineering, Fabrication, Shipping. Stainless covers the majority of the building, allowing light to filter through while providing thermal protection. The small window-like rectangles scattered across the surface are actually bare Angel Hair™ Stainless steel without perforation. Architect: Morphosis (212) 675-1100 Facade Installation: Les Young, W&W Glass (703) 218-1354
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.
Solanum™ Preweathered Steel Zahner has more than 40 years of experience and over a hundred projects successfully installed using weathering steel surfaces for architecture and art. We operate out of a facility that is clad in architectural weathering steel, (pictured on page seven), and there is no other company in the world with as much experience and expertise in the applied use of weathering steel. Zahner’s systematic and scientific research has been instrumental in the development of an accelerated patination process. We develop our patina on preformed steel with an artistic natural color and texture like no other. This is our Solanum™ Patina. The density of our patina layer and its adherence to the surface is the reason for our steel’s durability and longevity over time. Our process for preweathered Solanum™ Weathering Steel accelerates the natural weathering process to arrive at a highly protective, durable mineral layer, and we have the science to prove it.
The science of steel.
It begins at the source. We work with our steel mill to ensure that the raw steel ingot is derived from specific alloying components. The base raw material is cast to exacting specifications. Next, we work with a rolling mill that understands the finesse required when working with bare weathering steel. If you don’t influence the base metal sources, the mill will treat the material like any other metal: it will be oiled, scratched, and scarred. Such contaminated metal will reveal itself in the final product as streaks, rings, and discolorations in the finished surface.
We inspect each and every plate surface. Each surface is cleaned and prepared to eliminate oxides, greases, and oils. If this step is not carefully, the finish will corrode. Next we shock the surface to an initial ferric oxide. This finish is slightly orange in color and is characterized by a crusty texture. At this point the metal is crusty and orange. An orange patina is not a permanent patina (pictured above right). Yellow and orange patinas on weathered steel will continue to flake, darken, bleed, and stain adjoining surfaces. Orange is soluble. At this stage, we allow this orange-toned oxide to grow to a point, and then remove most of it from the surface. The surface is then exposed to a proprietary solution and specific atmospheric conditions to develop a hydrated oxide form of ferrous oxide or ferrous hydroxide. This is insoluble. We cultivate the growth of the hydrated oxide form until it reaches a certain point. We arrest the surface with a chemical solution that inhibits and slows oxidation to a standstill. The material is in its final stage of development (pictured bottom right). This is Solanum™ Steel.
Top: Microscope photo showing flakes and loose oxide on the surface of 2-year-weathered COR-TEN steel. Bottom: microscope photo of Solanum™ Steel, insoluble surface.
Our steel stains less. Our finish does not come off when rubbed, nor does it come off and stain adjoining surfaces over time. Weathering steel is known for staining adjacent surfaces with iron oxide as the material continues to age. Our preweathering process reduces and often eliminates staining of surrounding surfaces. We will guarantee it.
Telluride House; Architect: Architecture Research Office (ARO) 16ga Solanum™ Weathering Steel shingles.
Guggenheim Hermitage Museum; Architect: OMA. ½” Solanum™ Steel.
Zahner used the Solanum™ Steel process on the interior walls of the Guggenheim Hermitage Museum in Las Vegas, Nevada. Over 100 tons of oxidized and preweathered steel was used to produce this project. Because it was used as the interior walls of the museum, Rem Koolhaus and the architects at OMA required a surface that would perform better than any weathering steel product produced in the history of the material. They came to us to create it.
Trinity River Project: Location: Architect: Services Provided:
References:
Trinity River Audubon Center Dallas, Texas Antoine Predock Associates Design Assist, Engineering, Fabrication, and Installation. The subtly curving skin was punctured by multiple idiosyncratically placed apertures and the metal panel joints were carefully designed to work into the overall design effect. Architect: Antoine Predock (505) 843-7390
Screen Gates Project: Location: Owner: Architect: Services Provided:
Project Duration: References:
Kansas City Art Institute Screen Gates Kansas City, Missouri; KCAI Campus The Kansas City Art Institute Gastinger Walker Harden Architects Design Assist, Engineering & Fabrication, Delivery & Installation. Working with the Gastinger, we translated the pattern into machine language to custom perforate the panels. March 2006 - July 2006 Architect: Kirk Gastinger (816) 569-0813
The Nelson Project: Location: Architect: Services Provided:
Reference:
The Nelson-Atkins Museum of Art Kansas City, Missouri Steven Holl Architects Design Assist, Engineering & Fabrication, Delivery & Installation. Solanum™ Weathering steel panels were installed in the garage addition at the Nelson-Atkins Museum of Art. James Dayton (612) 338-0005
Vail Residence Project: Location: Architect: Services Provided: References:
Vail Residence Vail Colorado James Dayton Design Design Assist, Engineering, Fabrication, and Installation. Architect: James Dayton (612) 338.0005
Key Profiles L. William Zahner is the President & CEO of Zahner® and the president of Zahner-KME. Zahner 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.
L. William Zahner [email protected]
President
ZAHNER-KME
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.
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
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.
Anthony E. Birchler [email protected]
Vice President of Engineering / Sales Zahner® 1997-Present
Key Profiles 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. Randy Stratman is the Director of Engineering. He is a member of Design Assist Group. He moves between both the clients and the project teams to define the scopes, analyze the alternatives, and establish a prudent course of action to bring the project to fruition. 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.
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 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.
Jeff W. Mann
Randy G. Stratman
[email protected]
[email protected]
Engineering Director Zahner® 1998-Present
Senior Project Manager, Team #1 Zahner® April 2005-Present
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.
LEED® AP Works directly with clients to distill design directives & intent. Responsible for overseeing the implementation of creative design solutions for complex architectural cladding projects. Implementation of automated BIM modeling solutions that further facilitate the design, manufacturing, and installation sequences.
Previous Experience
Managed Projects 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
March Incorporated / Design Engineer / Designed plastic and metal products for manufacturing. Operated directly with customers and vendors. B/E Aerospace, Inc. / Designer / Designed new products (concept to production) with focus on reliability, minimum weight and ease of manufacturing and assembly. Employed latest technological services to produce rapid prototypes, molds and production assembly fixtures. Fasco Industries / Specification Technician / Designed new fractional horsepower electric products per client requirements. Facilitated the incorporation of new facilities and acquired product lines into firm’s engineering and manufacturing standards.
Education: Bachelor of Design / Drafting, Southwest Missouri State University, 1989 / Minor in Industrial Management.
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.
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.
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-KME supports all programs which promote safety, good health and 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
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-KME employees have proper safety orientation and training.
Zahner-KME is responsible for understanding and complying with all safety and health requirements affecting each project. It is each employee’s responsibility to support Zahner-KME 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.
