As the Draftsperson for The Royale by Marco Ramirez, I was tasked by our Technical Director to 3D model and create construction drafts for the scene shop. My three units were the deck, the large arch wall center, and the mullion windows behind. These units were challenging because they were large, heavy, and required minimal structure.
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I broke the mullions window unit into eight pieces because of the physical limits of how we transport our scenery. The main construction was done with 1x pine, glue and staples with bolted connections at the seam during install.
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Specific parts of the unit had to support curved facing while remaining thin and open. This was done with angled pine on face where the lauan needed extra support. Furthermore, all of the holes for wire rope and bolted hardware were installed and completed in the shop prior to load-in.
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The arch wall was estimated to weigh a total of 1,800 pounds due to its size and amount of hard facing and framing required. Our arbors only allow for 900 pounds of weights on the lineset because it is a double purchase lineset. To accommodate this, we discussed marrying two arbors together but decided to max the arbor with 44 bricks and carry the remaining weight with chain hoists.
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The framing was laid out to fit like a puzzle in order to align the seams with the brick facing design of the wall. This proved to be difficult because some of the frames did not have enough support and were fragile. As we bolted the frames together and it took weight, the frame became strong and stacking each level was no problem.
This layout featured one deck track running stage left to right and a pair of tracks running upstage to downstage. The single track supported a few smaller units like a punching back and bell. The pair of tracks were reaved with one motor to maneuver a large boxing rink downstage. This deck used 95 stock platforms, 323 crown blocks, 21 stock track pieces, and 148 pieces of facing.
This is how I typically layout stock platforms for the shop to pull. It clearly shows the configuration of the lip and ledgers and helps to stay organized prior to loading in.