Zahner Builds a Fantastic Façade for Miami Beach

For years, Zahner, a Kansas City, Missouri-based architectural metalwork producer, has worked alongside KVC Constructors and Faulders Studio. During that time, the trio has completed dozens upon dozens of construction projects across the United States, including 10 in Miami, Florida.

Due to this longstanding partnership, particularly in South Florida, KVC Constructors decided to work alongside Zahner and Faulders once again. For their next collaboration, the trio built a new parking garage on Miami’s Mount Sinai Medical Center’s campus.

Awarded the project in March 2022, the companies – while working with Netta Architects as well – completed their assignment in January 2024. Known officially as the Mount Sinai Medical Center Parking Garage, the six-story parking garage was created for up to 929 automobiles. Surrounded by a roughly 27,000-square-foot façade too, which covers three of its elevations, the parking structure is a prime example of Zahner’s mantra: “Innovation and Collaboration to Build the Extraordinary.”

“This mantra encapsulates our goals for every project we undertake,” said L. William Zahner, president and CEO of Zahner. “The Mount Sinai Medical Center Parking Garage, along with its façade, are projects we’re especially proud of.”

And rightfully so, as the façade features some of Zahner’s most renowned, highest quality materials, including its Drop & Lock metal panels and ImageWall perforated panels. 

“Zahner worked through multiple iterations of the façade during the project’s first six months,” Zahner explained. “The first iteration involved many folded plates to achieve deep shadows and reveals.”

Ultimately, Zahner decided to deploy its Drop & Lock metal panel attachment system, while also utilizing curved fins, which projected from the façade’s fins. In addition, the metalwork producer implemented its ImageWall perforated panel process. As a result, it enhanced the illusion of the façade’s depth and wave movement.

The ImageWall panels are comprised of 0.125-inch aluminum, while using the metalwork producer’s custom ImageWall pattern as well. All horizontal joints are staggered too, leading to the appearance of a continuous surface. 

At first, the ImageWall panels were fabricated. From there, they were then finished with an AAMA 2605-compliant paint, resulting in their high-quality, durable finishes.

Each ImageWall panel is attached to vertical aluminum mullions, while utilizing Zahner’s Drop & Lock system. Every mullion is anchored to the façade’s precast, either with an aluminum anchor or an outrigger, which is located at the curved section of the garage’s Southwest corner.

“Embeds in the precast led to a seamless erection process,” Zahner emphasized. “Curved fins were also included. The entire system is dead loaded at the top to eliminate horizontal expansion joints.”

To refine the façade’s structural support locations, Zahner team members worked with a structural team, too. The façade’s illumination was integrated into Zahner’s mullion system as well, via outriggers that are located at its bottom perimeter.

“The concept that Thom Faulders (of Faulders Studio) had for the façade required collaboration with project stakeholders throughout the entire project, in order to satisfy our desired aesthetic, meet Mount Sinai’s budget and deliver the final product within a tight schedule,” Zahner said.

While reflecting on the project’s end result, Zahner can’t stress the significance of the trio’s teamwork enough.

“Projects are ultimately successful, due to a larger team’s relationship,” he said. “We – Zahner, KVC Constructors and Faulders Studio – have built a trustworthy rapport that results in exceptional projects to be proud of.”

He added, “The Mount Sinai Medical Center Parking Garage is yet another example of the rapport we have and the success it leads to.”

Located near the ever-busy Julia Tuttle Expressway, the façade is aesthetically pleasing, too. Due to its design, from its broad horizontal lines to its geometric contours, the façade further enhances Mount Sinai Medical Center campus’s architecture. 

In doing so, it also engages Miami Beach visitors as they cross the Julia Tuttle Causeway Bridge, as everyone (not just the medical center’s visitors) can enjoy the structure’s beauty.

“Miami Beach now has a new gateway icon to greet its visitors,” Zahner said.

Not to mention, upon leaving Miami Beach, they’ll encounter yet another Zahner-produced structure, further proving the positive influences that the metalwork producer’s partnerships have.

“As they leave Miami Beach westbound, they’ll be welcomed by one more Zahner/KVC collaboration: the City View Garage that anchors the Miami Design District,” he concluded.