Court Theatre Case Study
Project Credits
Client: Christchurch City Council | Main Contractor: Hawkins Construction | Architect: Haworth Tompkins & Athfield Architects | Engineer: Ruamoko Solutions |
Mass timber installer: Kobe Construction | Mass timber BIM Co-ordinator: Offsite Design | Product: CLT, LVL, Glulam
Court Theatre Overview
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
Collaborative Design and Manufacturing
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.
Digital Fabrication
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.
Results
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 Sustainability
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.
Bio-Fuel Energy
Red Stag Timber utilises offcuts from sawing and planning as a bio-fuel to generate electricity and provide thermal energy to dry timber. Red Stag Timber is also a net exporter of electricity to the national grid to help power New Zealand’s growing energy needs.
Thermal Energy
Wood waste is used as the energy source for the kiln drying of timber. The thermal energy required to kiln dry timber can exceed 85% of the energy usage for a modern sawmill. Utilising its own wood offcuts as an energy source ensures that both CO2 emissions and landfill disposal requirements are minimised.
The project utilised approximately 109m3 of LVL, 39m3 of CLT, and 5m3 of Glulam, embodying approximately 101 tonnes of CO2.
Conclusion
Precise digital modelling and CNC fabrication allowed for efficient production processing and timely delivery of components to the site. This approach simplifies on-site assembly and reduces delays, facilitating smooth coordination, while also minimising labour costs and material waste. As a result, construction projects can progress seamlessly, making this digital fabrication approach a cost-efficient and sustainable solution.
Red Stag TimberLab’s leadership in the mass timber industry is exemplified by their high-quality engineered timber components, which have proven instrumental in realizing sustainable and innovative projects such as the Court Theatre. With cutting-edge digital fabrication capabilities and extensive production capacity, Red Stag TimberLab continues to push the industry forward, delivering exceptional products and unparalleled service to clients.
Case study written by Red Stag Timberlab: Court Theatre Case Study (redstagtimberlab.co.nz)