Maybe you’ve walked through the Sacramento airport and noticed the 56 foot long red rabbit leaping through the terminal.
Or maybe you’ve visited Cologne, Germany, and spotted the enormous ice cream cone that seems to have dropped from the sky and onto a building.
The 36-foot blue bear that’s peering into the Colorado Convention Center in Denver?
These are just a few of the large and unique projects that American Canyon-based Kreysler & Associates (K&A) create with composites, a substance that people tend to think of as fiberglass. It is essentially a very high performance material based on a combination of a resin and a glass fiber. It’s used to make shower stalls, airplanes, fly fishing rods, tennis rackets, mountain bikes, yachts, and formula one cars.
But K&A use the material to make things that, basically, other people can’t.
“We pride ourselves on being the guys to call who will look at just about anything. People may know what they want, but not how to get there. We rely on our innovation, experience, tools and skills, and we use all of that to try an offer a unique fabrication resource to the design, and engineering community,” said William Kreysler, the company founder and president.
K&A uses composites to manufacture one-of-a-kind creations like giant works of art, building facades, movie sets, and even furniture. The company’s long list of projects includes the acoustic panels in the Bing Concert Hall at Stanford University, a giant bowling ball crashing into bowling pins in a park in Germany, horses for P.F. Chang restaurants, and recently the wavy façade on the exterior of an addition to the San Francisco Museum of Modern Art.
Kreysler’s team enjoys the challenge each project brings. The company operates on five acres in American Canyon, with 30,000 square feet under roof. The company has 30 employees, and about 25 of them have been with Kreysler for more than 20 years. They control the entire process, from making the composites, creating the molds, and coordinating installation. It’s the same process for each project, but the amount of material used, how many layers, and how they form the composite is varied.
The material is created with glass fiber almost exclusively, as opposed to a carbon fiber, and a polyester resin, the most cost-effective and commonly used. The molds are made of foam, which are ground up and shipped back to the foam company when the project is completed.
One of the advantages of working with composites is the ability to create curved surfaces, unlike with traditional building materials. You can’t bend an I-beam, Kreysler likes to say.
“The vernacular and the whole world of building is based on flat surfaces, which is boring,” he said. “We’re unique because we’ll use these materials, but we’ll make one of a kind, or maybe 10, and most people in the composites business don’t think that way.”
K&A’s products are considered architectural, but the material could be used structurally, Kreysler said, noting composites are used that way elsewhere in the world. Several years ago, there were plans to build structural beams for part of a girder system to build a 2-lane automobile bridge in San Diego.
Per pound composites are fairly expensive. Rarely does K&A make anything that costs less than $50 a square foot to fabricate, and they have made sculptures and pieces for museums that cost more than $300 a square foot.