During the design phase, comprehensive 3D modelling and analysis of tolerance and deflection was performed at critical interfaces between multiple trades. Premobilization, survey and point cloud scans were evaluated and 3d models reconciled to fit as-built conditions. Field support was provided for the installation of composite clerestory glazing (Benson Mitek) with stainless steel eyebrow overhangs (Zahner) as well as the stainless steel perimeter bullnose assemblies that wrapped the roof edge and supported the perimeter gutter.

We incorporated the canopy deflection criteria in our evaluation of survey information (translations in X,Y,Z as the building was loaded with more weight) to predict where our final position would be and respond appropriately. Once analysis was complete and positional data calculated, a spreadsheet of elevation values via jackbolt heights/unique shim packs was exported and sent to the field crews. This offered the installers the ability to set the positions of all the units while safe on the ground with assurance that prefabricated parts would align once the building was fully loaded.

Location: Mountain View, CA
Year Completed: 2022
Clients: Whiting Turner
Coordinated Trades: 10+
Part Count: 5k
Square Footage Installed: 100k (3 buildings)
*Work completed while with A Zahner Company. Photo credit J. Coleman.

The canopy is composed of a sinusoidal tubular steel spine with cantilevering mullions and prefabricated freeform patterned skins. The low tolerance of the steel superstructure created difficult conditions on which to install the high tolerance finished skin components, so a digital twin model was created from as-built scans and fabricator models. Reconciling the two allowed for adjustments to part orientations, created consistent edges and reveals, and assured that parts would fit before they arrived on site. The model was used to drive a directed survey installation in the field, which was complemented by a custom magnetic fixture to coordinate the relationship between prism and weld stud positions. The combination of as-built analysis, 3d model reconciliation, and on-site directed survey enabled an expedited installation not achievable using conventional methods.

Location: Scottsdale, AZ
Year Completed: 2023
Client: Willmeng Construction
Part Count: 500
Square Footage Installed: 5k
*Work completed while with A Zahner Company. Photo credit J. Coleman.

The fluid concrete geometry of this 20,000 sq ft residence is comprised of 100+ interconnected shotcrete and cast-in-place segments. The “watertight” nature of concrete formwork and the desired plywood liner forced a zero-tolerance connection between each of the 2,000 individual concrete forms. Ensuring continuous curvature between 30 ft arches, floating tree wells, and parabolic feature walls was achieved using a global orientation model consisting of over 100,000 pre-located reference survey point locations. An as-built model allowed surveyors to accurately align formwork project wide, allowing for disconnected segments to successfully interlock during the final pour.

Location: Montecito, CA
Year Completed: 2022
Architect: Shubin Donaldson
Client: MATT Construction
Part Count: 2,000
Square Footage Installed: 40,000
*Work completed while with C.W. Keller & Associates. Photo credit G. Coleman / A. Grove

The sculpture is composed of 225 laser cut aluminum 'leaves'; each requiring precise positioning on an existing 150’ tall cast-in-place concrete wall. Although the substrate appears flat, it deviated +/- 1.75” from the as-designed directives, resulting in challenges achieving an accurate layout. A digital-twin model defining 687 precise mounting anchor locations was produced from a jobsite scan. Each anchor point was modeled, named, and coordinated with both PENZID ASCII formatted points for the total station operator and physical stickers for quick reference by the installers. Directed survey was used to quickly guide the site team to drill locations for each anchor at the pre-determined locations.

Location: Charlotte, NC
Year Completed: 2023
Client: Nervous System, RafCo Properties
Coordinated Trades: 2
Part Count: 1k
Square Footage Installed: 4k
*Work completed while with A Zahner Company. Photo credit J. Coleman.