Terracon’s responsive materials testing team helps Orlando realize ambitious dream

Project

Dr. Phillips Center for the Performing Arts

Location

Orlando, FL

Challenge

“Ambitious.” That’s the word you’ll hear when talking to anyone involved in building the Dr. Phillips Center for the Performing Arts. Nothing was easy about bringing Orlando’s vision to create a world-renowned performing arts center to life, from the downtown location across from city hall to the budget that relied heavily on community donations during times of economic upheaval to the 330,000 square-foot reinforced concrete and structural steel design that included an expansive cantilevered canopy, three distinct theater spaces, plus an outdoor plaza.

To help ensure the center’s foundation and structural elements were safe and reliable, Terracon performed hundreds of construction materials tests in two project phases over 10 years, with the uniquely transformable Steinmetz Hall completed in the final phase. At one point, excessive gaps between the 200-ton steel “backbone” of the canopy halted progress until we found a solution.

Solution

The project involved several complicated engineering solutions by Terracon and partners. The canopy roof supported by structural steel required extremely large trusses. Certified Terracon professionals performed a variety of fabrication shop inspections in Virginia and Canada to ensure the steel’s quality. 

Next, highly skilled welding techniques and testing went into securing the canopy to the trusses. When excessive gaps occurred, Terracon utilized an expert welding engineer to qualify welds to remedy the problem, and Terracon inspectors were on site to inspect throughout the successful 12-hour lift and placement. Radiography testing was suggested but meant no one could be within 250 feet of the structure during testing, effectively shutting down downtown. Terracon offered an alternative — ultrasonic testing — to ensure the fit was solid. 

The center’s deep foundation, like the roof, was massive. Concrete pours were planned carefully through excellent communication with partners and concrete lab testing, sometimes performed over the weekend to keep the project on schedule. Throughout the project, Terracon project managers analyzed the budget and the project needs to have just the right number and mix of professionals working to ensure safety, efficiency, and prudent use of funds.

Results

The first part of the arts center opened in 2014, and the second in 2022. Known as “the front porch of Orlando,” it’s won numerous awards and sold more than 3.3 million tickets to performances. In 2023, Architectural Digest named the center’s Steinmetz Hall one of the 11 most beautiful theaters in the world, along with the Sydney Opera House, the Vienna State Opera, and others. Ambitious dream, realized.