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  1. ArchDaily
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  3. Factory
  4. United States
  5. Crawford Architects
  6. 2011
  7. Zahner Factory Expansion / Crawford Architects

Zahner Factory Expansion / Crawford Architects

  • 01:00 - 19 September, 2011
Zahner Factory Expansion / Crawford Architects
Zahner Factory Expansion / Crawford Architects, Courtesy of  crawford architects
Courtesy of crawford architects

Courtesy of  crawford architects Courtesy of  crawford architects Courtesy of  crawford architects Courtesy of  crawford architects +22

  • Architects

  • Location

    Kansas City, MO, United States
  • Architects

    Crawford Architects
  • Structural Engineer

    Wallace Engineering
  • Mechanical Engineer

    M.E. Group, Inc
  • Electrical Engineer

    M.E. Group, Inc
  • Area

    6200.0 ft2
  • Project Year

    2011
  • Photographs

    Courtesy of crawford architects

From the architect. Zahner’s continuing success as one of the world’s foremost architectural metal manufacturers prompted the need for an expansion of their manufacturing facility at 8th and Paseo Blvd. in Kansas City, Missouri. The location for the expansion ties into the northern façade of a 30-year-old weathering steel clad facility and re-imagines a roughly paved concrete assembly yard surrounded by an unsightly chain link fence.

Site Plan
Site Plan

The design intent was to convert this underutilized area into a large column-free assembly space, with ample clear height to move material around on 2 large cranes, and make a seamless connection to the existing factory floor. Beyond pure utility, the facility sought to provide transparency, characterize where Zahner is headed in the future, and showcase their ability to produce highly engineered forms within.

Section
Section

Encapsulating these values means understanding that Zahner has built their reputation on knowing the intricacies of metal, its chemical properties, and how they can be manipulated. Following this notion through intensive design research, the form for the façade 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. Once the sketch was complete, a computer based algorithm converted the sketch’s tonal values into a 3-dimensional digital surface model of the façade. The resulting form grows out of the rigid, solid geometry of the existing building’s east façade with a single sweeping motion, and increases in complexity as it moves around the corner to the west, paying tribute to both Zahner’s past and future.

Courtesy of  crawford architects
Courtesy of crawford architects

Articulation of the abstractly based model was closely developed with Zahner’s engineers and utilizes a variation of the ZEPP (Zahner Engineered Proprietary Panel) system. The system’s key components are vertically oriented DT* fins made from a half-circle shaped aluminum extrusion riveted to a water jet cut 3/16” aluminum plate. These fins are commonly used as a structural backup system behind many of Zahner’s organic façades with a skin applied to their surfaces. In this case the skin is left absent both exposing and expressing the structural skeleton beneath. Placement of the fins is every 24 inches on center with an Inverted Seam™ dry-set glass panel system in-between producing a structural curtain wall set on a cast-in-place concrete base. The glass panel system not only provides transparency between the shop’s activities and the surrounding neighborhood, but also provides idealistic northern light into the assembly space. This light combined with a large structural bay (43.5’ wide) and the configuration of 2 (5 ton) cranes has led to increased productivity and production.

Courtesy of  crawford architects
Courtesy of crawford architects

The result is a dynamic, rippling surface that breathes new life into the surrounding urban environment and showcases Zahner’s ability to act as a bridge between art and science.

Courtesy of  crawford architects
Courtesy of crawford architects
Location to be used only as a reference. It could indicate city/country but not exact address. Cite: "Zahner Factory Expansion / Crawford Architects" 19 Sep 2011. ArchDaily. Accessed . <http://www.archdaily.com/169206/zahner-factory-expansion-crawford-architects/>
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36 Comments

vanesa jimenez · August 11, 2012

Zahner Factory Expansion / Crawford Architects | ArchDaily http://t.co/ups2r1Q3 vía @archdaily

Yudistira Julian A. · August 11, 2012

Zahner Factory Expansion / Crawford Architects http://t.co/DkiHQwcX

Claudio M Bentivenga · August 11, 2012

Zahner Factory Expansion / Crawford Architects | ArchDaily http://t.co/6t0RYIC0 via @archdaily

Allen Angle · July 05, 2012

Their work is amazing, now their factory is as well! @azahner Factory Expansion / Crawford Architects | ArchDaily http://t.co/NV9SGg9M

Crawford Architects · July 05, 2012

Their work is amazing, now their factory is as well! Zahner Factory Expansion / Crawford Architects | ArchDaily http://t.co/NV9SGg9M

Crawford Architects · July 05, 2012

Fantastic renderings and explanation of our new Zahner Facility designed by @CrawfordArch http://t.co/MYKIeSrF

Zahner · July 03, 2012

Fantastic renderings and explanation of our new Zahner Facility designed by @CrawfordArch http://t.co/MYKIeSrF

Allen Angle · July 01, 2012

Their work is amazing, now their factory is as well! Zahner Factory Expansion / Crawford Architects | ArchDaily http://t.co/NV9SGg9M

Allen Angle · July 01, 2012

Their work is amazing, not their factory is as well. Zahner Factory Expansion / Crawford Architects | ArchDaily http://t.co/NV9SGg9M

Zahner · April 14, 2012

Best article I&#39ve seen yet explaining our factory expansion: http://t.co/I6BFnGFt

Gavin Construction · February 23, 2012

How fantastic is this? Its hard to believe it houses an industrial workshop! #Architecture #construction http://t.co/y6CF3iJ2

Jonas Hällgren · January 18, 2012

Arkitektur! http://t.co/NRZnKROK

Vart · January 17, 2012

Aqua

Nour Alqahtani · October 06, 2011

The elevation seems like a continuum wave. The structure looks effort less and light regarding its coloumless large spans. Nice

sena · October 06, 2011

this dude got to balance function with aesthetic.big ups

Hill-PCI Group · September 29, 2011

RT @Urbanverse: Zahner #Architecture Metal Fabricators Extraordinaire manufacturing facility expansion, Kansas City http://t.co/AMuZYTbV

Crawford Architects · September 28, 2011

Zahner #Architecture Metal Fabricators Extraordinaire manufacturing facility expansion, Kansas City http://t.co/e6J1xyr0

Crawford Architects · September 28, 2011

“@Urbanverse: Zahner #Architecture Metal Fabricators Extraordinaire manufacturing facility exp Kansas City http://t.co/fhDt8HrC” a+ facade

Crawford Architects · September 28, 2011

RT @miloszlodowski: Not every factory should be a piece of unlikely cubature ;) http://t.co/WvsVx0VQ

Crawford Architects · September 28, 2011

Thank you! RT @3RRRarchitects: cool solar shading... Zahner Factory Expansion / Crawford Architects http://t.co/AR6ZaVwU via @ArchDaily

Gunthercito · September 27, 2011

“@Urbanverse: Zahner #Architecture Metal Fabricators Extraordinaire manufacturing facility exp Kansas City http://t.co/fhDt8HrC” a+ facade

John Galloway · September 27, 2011

Zahner #Architecture Metal Fabricators Extraordinaire manufacturing facility expansion, Kansas City http://t.co/e6J1xyr0

Cindy FrewenWuellner · September 27, 2011

Zahner #Architecture Metal Fabricators Extraordinaire manufacturing facility expansion, Kansas City http://t.co/e6J1xyr0

Vlatka & Visnja · September 23, 2011

Mmmmm #Zahner #Factory #Expansion / #Crawford #Architects | ArchDaily http://t.co/B9N8PbNU via @archdaily

Crawford Architects · September 22, 2011

Our Zahner Factory expansion project featured on ArchDaily&#39s site. http://t.co/6gC7uDmQ

Scott Abercrombie · September 21, 2011

@longerjohn This is what I should have designed for my PgDip! Zahner Factory / Crawford Architects | http://t.co/WNcq9n9B via @archdaily

iainp@[3RRR] · September 20, 2011

cool solar shading... Zahner Factory Expansion / Crawford Architects http://t.co/lSKRGQaH via @archdaily

Tulsa Architecture · September 20, 2011

Wallace Engineering, owned by TFA advisory board member Tom Wallace, were the engineers for this expansion for... http://t.co/N0v2VVJK

Modern Tulsa · September 20, 2011

Wallace Engineering, owned by TFA advisory board member Tom Wallace, were the engineers for this expansion for... http://t.co/281LvypP

Brittany · September 20, 2011

RT @ArchDaily: Zahner Factory Expansion / Crawford Architects http://t.co/RLOL8s71 #architecture

Milosz Lodowski · September 20, 2011

Not every factory should be a piece of unlikely cubature ;) http://t.co/HTPRaBWN

CordobArquitectos · September 19, 2011

Zahner Factory Expansion / Crawford Architects http://t.co/fbLvYehX vía @archdaily #Arquitectura

Crawford Architects · September 19, 2011

Our Zahner Factory Expansion project is featured on Arch Daily&#39s site today. http://t.co/bCnnPS2z

RENarch · September 19, 2011

Zahner Factory Expansion / Crawford Architects | ArchDaily http://t.co/zbvaT5Hd via @archdaily

this_is_it · September 19, 2011

its kansas city, missouri

up_today_arch · September 19, 2011

this waved elevation looks so good!....

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