Form Off-Site Solutions by JE Dunn uses an approach to prefabrication integration that aims to collaboratively optimize the design, streamline scheduling, enhance safety, and maximize resource efficiency.
JE Dunn Construction recently worked to implement a complex prefabrication integration for the Starlight Theatre project, a renowned Kansas City landmark. Starlight Theatre recently launched their Uniquely KC campaign to raise money for their new renovation and addition project. The campaign’s mission is to connect the community through live arts experiences that entertain, inspire, and engage.
The first phase of this renovation involved constructing two nearly 70-foot-tall masonry towers that flank each side of the stagehouse, designed to replicate the exiting towers built in the 1950s. Each tower is topped with a patinated copper roof that matches the existing roof spires on the historic towers. In collaboration with Zahner, Form and JE Dunn designed and engineered two symmetrical halves for each roof structure. The structures were clad with copper at Zahner’s off-site facility before being shipped to the jobsite, where they were assembled, hoisted into placed, and capped with a decorative spire.
When considering whether to implement prefabrication, JE Dunn evaluates the pros and cons of the project at hand. For Starlight Theatre, the goal was to match the existing copper roofs, which passed a significant challenge given the 75 years of patina, wear, and character on the original copper. Fortunately, the design team had not yet selected a product, allowing for discussions around implementing prefabrication efforts. Knowing that Zahner has nearly 75 years of experience in manufacturing patinaed copper, the company was a perfect partner for this project.
Overcoming Challenges
The Starlight Theatre project had specific challenges to overcome, including a limited schedule, tight jobsite, and difficult buy out. Being primarily an outdoor space, Starlight Theatre runs on a seasonal basis – giving the team a limited schedule for construction. Furthermore, the logistics of the site are extremely tight. The laydown area is limited for materials around the stagehouse and most of the expanse is sloped. Building the roof structures on-site was near impossible in the timeframe.
By moving fabrication off-site, the team minimized downtime for critical path masonry activities and reduced the amount of time scaffolding needed for framing in place. In addition to the difficult site logistics of building these in place, the patinaed copper roofing was a scope that was difficult to buy out, as most roofing trades lacked the necessary expertise or were hesitant to take on the risk for such a pricy material.
Prefabricating the roofs in the manner JE Dunn implemented through Form helped overcome these buyout hurdles