Light-gauge Steel Sub-system Closes the Gap Between Segmented Structure and a Smooth Curved Skin

Overview

Radius Track worked with Performance Contracting Inc. to deliver a light-gauge steel subsystem closing the gap between the segmented structural frame and smooth curved skin of the 800-seat egg-shaped theater:

• Engineered framing solution installable within constraints of existing historic building shell
• Adjustable system accommodating as-built structural steel variances
• Just-in-time deliveries meeting tight site logistics and 26-month schedule

Problem & Approach

Radius Track was brought into the project after the primary structure had already been designed and fabricated. The team had to respond to several non-negotiable constraints including a 26-month schedule driven by the DC Public Schools calendar and just-in-time deliveries due to tight site logistics.

The framing solution needed to adapt to as-built structural steel, including variances from the design model. To validate the approach before fabrication, Radius Track developed a comprehensive 3D model integrating the architect's geometry, a structural scan, and construction documents. This allowed conflicts to be resolved virtually.

From this coordination, Radius Track engineered a highly adjustable light-gauge framing system. Pre-curved box beams with adjustable outrigger assemblies achieved the required plan curvature. Pre-curved hat channels mounted to the box beams defined the cross-section geometry. This system provided flexibility to accommodate local deviations while fitting within extremely tight spatial constraints.

"On boarding Radius Track provided a 180-degree direction change on the theater skin scope of work. They started solving challenges right from the start and clearing the fog. Before Radius Track, making the jump from the theater structure to the finished skin was shaping up to be a nightmare.” – Gabe Oliver, Project Manager, GCS Inc. (General Contractor)

Solution & Results

A point-cloud scan of the erected steel was captured and imported into the 3D Rhino model. This allowed Radius Track to compare actual conditions with theoretical geometry and pinpoint discrepancies early.

Key technical achievements included:

• Developed cap-track and outrigger connection strategy for precise placement of pre-curved components
• Delivered geometric precision required for theater's complex design while retaining adjustability for as-built conditions
• Enabled installation crew to reach full proficiency within two days following material delivery
• Accommodated structural frame variances without compromising curved skin geometry
• Met aggressive schedule through coordinated just-in-time deliveries

The light-gauge framing system successfully bridged the gap between segmented structure and smooth theater skin within the historic building's constraints.

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Team

Architect Joint Venture: Cox Graae + Spack Architects and Lance Bailey Associates Inc.     

General Contractor: GCS | SIGAL

Framing & Finish Contractor: Performance Contracting Inc.

Distributor: Allied Building Products - Baltimore

Cold-formed Steel Framing System: Radius Track Corporation

Cold-formed Steel Engineer: Studio NYL

Awards

2018 ENR Mid-Atlantic Best K-12 Education Project 

2018 ENR Mid-Atlantic Project of the Year

2018 ENR Southeast Best Project - Cultural/Worship

2018 CFSEI Design Excellence

Additional Information

Featured presentation by the DC Preservation League

Article in Architect Magazine, 2018