Off-site Fabricators and Customization in History and Practice

The application of new technologies in conjunction with visionary businesspractices has allowed a select group of fabricators to fundamentally influencethe built environment. Examining the contemporary metal fabricatorZahner, with supporting historic research on James Bogardus and FrancoisHennebique for comparison, this paper reveals systemic approaches to customization,detailing, proprietary control, and labor relations.Off-site fabricators who deliver total customization in conjunction with precisionof detailing allow architects to subvert the appearance of repetitionwithin prefabricated systems. In the 19th century, the architect and fabricatorJames Bogardus produced innovative cast iron façades. Each installation wasinfinitely differentiable utilizing customized components to produce a varietyof widths of window openings, depths of façade, and detailing of ornament.At the turn of the 20th century, Francois Hennebique’s patented reinforcingsteel system provided a refined and versatile method for developing reinforcedconcrete structures that revolutionized building construction across the globe.Today, Zahner designs and fabricates metal skin systems which allow eachunit to be customized in x y and z planes. In addition, Zahner has developedsystemic connections to structure that provide further customization, precision,and integration of performative capabilities such as concealed drainage.Patented fabrication processes secure advances in technology, but are alsooften used as a method of advertising. Both Bogardus and Hennebique distinguishedthe quality of their products by marketing the exclusive ownershipof their fabrication processes. By utilizing workmen who were either directlyemployed or licensed by these firms, trade secrets were maintained. Today,Zahner holds patents and trademarks on a wide range of services and products:a digital design interface, a structural calculations system, a patterningprogram, and many proprietary coatings. All expertise is maintained in housethrough the control of fabrication and installation.Prefabricated units often allow the use of less skilled labor during installation.If a prefabricated system is highly customized then it becomes necessary forthe fabricator to maintain control of labor. James Bogardus, as a fabricator,outsourced production of his cast iron components to independent foundries,but utilized his own workforce for installation. Hennebique ensured qualitycontrol through an innovative business model built of franchised offices andlicensed contractors that, while typical in today’s market, was unique amonghis contemporaries. Today, Zahner’s workforce completes installations acrossthe globe, requiring the negotiation of labor contracts with localized unions. AsZahner has broadened its scope beyond sheet metal installation to erection ofstructure, these negotiations now span between trades, instituting a unique relationshipbetween iron workers, sheet metal workers, and Zahner’s operations.Zahner, Bogardus, and Hennebique are each distinguished by their profoundunderstanding of marketing to an audience of designers and clients seekinginfinite customization while requiring warrantee for the quality performance oftheir products. This understanding in conjunction with their advancement ofinnovative technology distinguishes these fabricators as instrumental in evolvingthe built environment.

Volume Editors
John Quale, Rashida Ng & Ryan E. Smith

ISBN
978-0-935502-85-5