Court Theatre Case Study

Red Stag TimberLab proudly supplied all mass timber components for the construction of the new Court Theatre in Christchurch. The project entails Cross Laminated Timber (CLT) for stair components and mezzanine floors, Laminated Veneer Lumber (LVL) for various structural elements such as roof rafters, columns, and trusses, and a few externally visible Glue Laminated Timber (Glulam) columns

The Court Theatre project is an excellent example of a hybrid structure, seamlessly integrating steel, concrete, and mass timber to optimize structural integrity. Given the use of multiple materials, a meticulous shop drawing process was essential. Red Stag TimberLab, Offsite Design, Hawkins Construction, and Kobe Construction collaborated closely throughout this phase to refine Design for Manufacture and Assembly (DfMA) principles.

Their joint efforts ensured precise 3D modelling to accommodate construction tolerances and material buildability. Offsite Design’s DigiBuild™ approach was instrumental in this endeavour, facilitating the coordination of structures and streamlining the fabrication process. It enabled simultaneous coordination and modelling for fabrication, seamlessly handing over a fully coordinated and machine-readable model to Red Stag TimberLab for digital fabrication. This entire process minimizes waste and reduces the risk of construction delays, resulting in successful on-site assembly without the need for modifications.

Once the shop drawings were approved, all elements underwent CNC fabrication based on the coordinated BIM model, a process known as digital fabrication. Large CNC machines milled every component to millimetre precision, guaranteeing the accuracy required for rapid on-site assembly. The upfront detail in meticulous shop drawings facilitated the perfect fitting of components during on-site assembly.

Engaging a single supplier for all the mass timber elements streamlined the co-ordination and 3D modelling process which ensured an accurate and organised delivery for the installation team. As New Zealand’s largest mass timber supplier, Red Stag TimberLab’s expertise in digital manufacturing made them the ideal partner for this project. Their ever-increasing capacity and ability to supply CLT, LVL, and Glulam products, further enhances the value Red Stag TimberLab can provide for hybrid structures.

The design incorporates visually exposed mass timber, contributing to a warm interior ambience, while enhancing occupants’ wellbeing. Additionally, mass timber acts as a natural humidity regulator, promoting a healthier indoor environment by absorbing and releasing atmospheric moisture as needed.

The Court Theatre mass timber superstructure stands as a testament to sustainable building practices. This is because, unlike traditional building materials, mass timber absorbs and stores carbon dioxide as embodied carbon throughout its lifespan. Red Stag TimberLab’s CLT is manufactured in our plant that runs on 100% renewable energy from biowaste products from the Red Stag sawmill. No one is better at telling your net zero carbon story than Red Stag TimberLab. 

Red Stag Timber is a market leader in terms of sustainable product innovation and manufacturing capacity. The company has been recognised as a leader in New Zealand for its contribution to Energy Efficiency and Conservation by receiving the 2018 EECA award for Large Energy User of the Year.

Innovation within the sawmill utilizes biomass waste material to produce electricity and to fuel the kilns required to dry the timber.

The project utilised approximately 109m3 of LVL, 39m3 of CLT, and 5m3 of Glulam, embodying approximately 101 tonnes of CO2.

Case study written by Red Stag Timberlab: Court Theatre Case Study (redstagtimberlab.co.nz)