In 2019, Productions Unlimited, Inc. completed a rigging renovation project for NC State in Raleigh, North Carolina. The project included the removal of the theatre’s antiquated rigging equipment, reinforcement of the building to support new loads, and the installation of a Tgrid+ Wire Grid System. Additionally, 25 ETC Prodigy Hoists, an ETC Foundation Control System, and all associated rigging equipment were integrated into the project.
The Stewart Theatre was built in 1973 and has served as the University’s main performance venue since its completion. Designed as a modified thrust with a full stage and lacking a physical proscenium arch, the theater's original rigging system comprised counterweight rigging, some dead-hung rigging, and a mix of motorized and manual winch sets. The rigging was in poor condition and in need of replacement. Additionally, the absence of a grid in the building posed challenges, making inspections and maintenance extremely difficult, especially given the elevated stage roof at approximately 60 feet.
Starting with the Talley Student Center renovation in 2011, Jason Prichard from Theatre Consultants Collaborative (TCC) partnered with NCSU staff. Their goal was to create safe access to the roof for inspections and rigging, as well as to design a safer and more user-friendly rigging system. Despite the initial postponement of the project due to funding constraints, TCC persisted in its collaboration with NCSU, conducting ongoing studies until funding was secured. Once was funding was secured, TCC began collaborating with Eric Sowers of Huffman Architects and structural engineering firm Lysaght & Associates. Together, they devised a lightweight yet versatile solution that not only provided the required access but also reinforced the roof structure to accommodate a motorized rigging system. The lightweight nature, easy installation, and cost-effective design of the proposed solution prompted TCC to engage Productions Unlimited in the design of the Tgrid+ system for the venue to provide the safe access required for the project.
Incorporating the T-grid+ wire grid, equipped with grid wells for point rigging above, was complemented by the strategic placement of ETC Prodigy hoists. These hoists were arranged side to side to optimize weight distribution and maintain tight lineset spacing. This concept allowed the structural engineers to create queen posts and use 3” diameter tie-rods and turnbuckle bodies to increase the capacity of the roof system at one of the theatre’s main trusses. Together, these elements would work in harmony to achieve the desired outcome for the NC State team.
The project, which was bid in late 2018 and subsequently awarded to BAR Construction of Greensboro, North Carolina, progressed with Productions Unlimited, Inc. serving as the primary subcontractor. PUI’s responsibilities encompassed various tasks, such as demolishing the existing rigging, implementing the Tgrid+ system, installing ETC rigging, constructing a new ladder with integrated fall protection for access to the grid area, and setting up and tensioning the 3" tie-rods. Notably, when these rods were tightened to the specified tension of 70,000 lbs., they lifted the center peak of the building by ¾ inch. The execution of these tasks required several days of welding, a feat accomplished efficiently by PUI's team of certified welders, completing the work in record time.
Construction began in late May. The trapped stage floor limited the load capacity compelling PUI to utilize several access solutions including their Denka Atrium Boom Lift, rope access, and Spider Staging, including swing stages and baskets.
For the project, PUI took on the fabrication of essential components like the Tgrid+, pipe battens, the new ladder, and guardrails. The installation of all equipment was executed by PUI's proficient team of rigging installers, which included two ETCP certified riggers specializing in theater rigging. Construction was completed in early September.
NC State’s Stewart Theatre has been upgraded to state-of-the-art rigging and with the Tgrid+ system in place they will be able to perform maintenance, inspections, and specialty rigging for years to come.
175 Old Airport Road | Roebuck, SC 29376
Productions Unlimited, Inc. [#this year :%Y]