Set Design and Construction: Rehearsal Stage

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Rehearsal Stage

Printed From: Community Theater Green Room
Category: Producing Theater
Forum Name: Set Design and Construction
Forum Discription: Post your questions or suggestions about designing or building a set here.
URL: http://www.communitytheater.org/forum/forum_posts.asp?TID=3710
Printed Date: 11/24/24 at 2:23pm
Software Version: Web Wiz Forums 8.05 - http://www.webwizforums.com

Topic: Rehearsal Stage

Posted By: thrillwill
Subject: Rehearsal Stage
Date Posted: 1/04/09 at 9:53am

Hola all at the Green Room. Hope you had a lovely holiday!

We at Classic City Arts certainly did as a patron has 'donated' a 5000 sq ft warehouse for our use. The place is in pretty rough shape but should be more than useful for our needs. You can see a couple of pics at www.classiccityarts.com.

The building has a concrete floor that is hell on our feet after about five minutes so I have to build a rehearsal stage for our productions. It will simply be 9 4 x 8 platforms but I am stuck on what to cover them with. I know 3/4" ply is the way to go but my options at the local big box are a little overwhelming. I need something cheap (of course) but at the same time people need to be able to dance on this stage without killing themselves.

Anyt material suggestions would be greatly appreciated. P.S. what on earth does Lowes mean by 'sheathing'...

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Will Leamon
http://www.classiccityarts.com

Replies:

Posted By: Topper
Date Posted: 1/04/09 at 2:47pm

"Sheathing" is a construction term for builders. It refers to the "skin" or layer of material placed over the 2x stud framing of walls and roofs. Typically (depending on building codes in your area) it can refer to 3/4 plywood, particle board, OSB or other sheets of solid material (4'x8' or larger). It is generally "rough" in texture as it is meant to be covered up by siding, insulation, Tyvek wrap etc, etc.

When it is placed over floor joists it is called "sub-flooring" but is essentially referring to the same thing. It is likewise rough because it will be covered up with other material.

Smooth-sided plywood in comparison is much more expensive. One-sided plywood (smooth on one side) is reasonably cheaper, but I propose another solution:

Insteand of building platforms (which can be costly and noisy) you may want to consider laying plywood on top of some kind of soft underlayment (rubber or thin foam) that is used in the installation of hardwood flooring.

Covering your cement with heavy mil plastic will act as a water barrier (in case there's a danger of seepage). A layer of thin foam is placed on top of that and then the plywood.

For a much softer and sturdier floor, you could "sandwich" another layer of foam between two layers of sheathing (or subfloor).

On top of the plastic/foam combo I previously mentioned, lay exterior quality 1/2 plywood, OSB, or particle board (it's cheaper). You could even use tongue-and-groove material, but that is more difficult to work with.

Then a second layer of foam on top of that followed by one-sided 3/4 ply in an alternate pattern (smooth side up, of course), screwing it down firmly into the 1/2 inch material below (NOT the concrete!), staggering and overlapping the seams.

If don't recommend doing the ENTIRE floor (of a 5000 sq ft warehouse) because that would be cost-prohibitive, but merely map out a section of floor that replicates the size of the performance space.

Frame the perimeter with green-treated 2x4's bolted and glued directly into the concrete below. The plywood flooring would then be layed within this framework and "float" (meaning it is unattached to the concrete or 2x4 frame). Making a sandwich of material would ensure the plywood would remain in place, and not curl or shift at the seams.

Good luck!

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"None of us really grow up. All we ever do is learn how to behave in public." -- Keith Johnstone

Posted By: jungle16jim
Date Posted: 1/09/09 at 1:24pm

We had the exact same problem with our warehouse. (not donated--sigh) After tap dancing for Oklahoma, we all had shin splints. We did an "Adopt a Board" drive and had 80 donors pony up $20 each for the floor.

We built directly on foam covered by 2 layers of 1/2" ply. Because the floor is so low to the ground though, almost everyone trips on it at some point. But we wanted to keep it low for rolling platforms on and off (which ironically has never happened. Good luck with your project!

Posted By: thrillwill
Date Posted: 1/09/09 at 2:50pm

I still haven't really decided what to do at this point but I've gone ahead and started framing out some 4 x 8 platforms because either way we're going to need them. Money's so tight right now (just dropped the cash on the venue) that I'll probably just follow junglejim's lead and go with foam sandwiched in 1/2" ply.

Any specifics on the foam?

On a tangent could one cover the top of the foam with 1/4" luan. I get a pretty good deal on those as I buy a lot for the flats. But not only would it be cheaper but it would provide a paint-able surface. Too thin?

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Will Leamon
http://www.classiccityarts.com

Posted By: dboris
Date Posted: 1/12/09 at 12:52pm

"On a tangent could one cover the top of the foam with 1/4" luan. I get a pretty good deal on those as I buy a lot for the flats. But not only would it be cheaper but it would provide a paint-able surface. Too thin? "

This is exactly how I built the last stage at my theater. We started out with 3/4 plywood on top the framing. We then covered that with 1/4 foam insulation (you will find it in fanfold form). Finally on top of that I put 1/4" luan for a smooth surface.

Dan