zahner
factory expansion
zahner factor y expansion project brief :: The new addition for the world’s foremost metal manufacturer is utilitarian, innovative, and sustainable. The 6,200 SF expansion is more than a simple assembly and loading space—it is a testament to the work taking place inside. The façade, made of aluminum fins, glass, and concrete, brings in ample natural light to illuminate the interior during the day while at night the glazing allows the entire building to glow, making the drab, industrial area a little more vibrant. The façade utilizes a variation of the ZEPP (Zahner Engineered Proprietary Panel) system, but strays from the traditional project in which a metal “skin” is applied to the steel backup system. Here the skin is absent, thereby exposing and expressing the structural skeleton beneath. Clients also benefit by visiting the building where they can see first hand, Zahner’s ability to engineer complicated forms with their ever-expanding use of materials. The following book is a walk through the process from concept to execution that culminated in Zahner’s North Dock Expansion.
check out more images of the project at : : http://azahner.com/portfolio/zahner-campus/
existing factory & outline of the proposed expansion (looking southeast from of 8th St. & Paseo Blvd., Kansas City, MO)
To understand Zahner and their unique brand is to understand METAL. Following this notion through intensive design research the form for the facade was derived from metal oxidation patterns inspired by those found on Zahner’s campus. The final graphite concept sketch drew inspiration from multiple patterns to create a form that was specific to the proportions and context of the expansion.
oxidation pattern at Zahner’s fabrication plant
weathering steel pattern
abstract concept sketch based on metal oxidation patterns
digital wireframe created by converting the tonal values of the previous sketch into 3-dimensional points and slicing the surface model every 2’
study models used to refine the form
I am a DT*
Zahner DT* extrusion; used as a common structural backup in many of their facades. The concept exposes & celebrates this extrusion to create an architectural billboard for Zahner’s brand. example of architecture reinforcing a company’s brand (5th Avenue Apple Store by: Bohlin Cywinski Jackson )
*patent no.: US 7,434,366 B2 & US 7,784,243 B2
5 ton movable crane
the front edge of DT is rolled to define the fin’s form
open assembly floor
the first DT fin mockup
sectional sketchup model showing the DT fins and interior assembly space
a physical model used to sell the design to the client
physical model, showcasing the building transparency and ability to act as a beacon for the neighborhood at night
8th & Paseo Blvd. corner
photograph from the corner of 8th & Paseo Blvd.
interior assembly floor filled with natural light from the glazing system; no artificial lighting is required
daylit assembly floor
1801 McGee Street - Suite 200 Kansas City, MO 64108 T 816 421 2640 F 816 421 2650