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Theatre Flooring:
It’s Not Just for Standing On

By Allan T. Duffin

Whether your performers stroll, step, stand or dance on your venue’s stage, selecting the right type of floor can make all the difference in performance quality and, consequently, ticket sales. At the Marjorie Luke Theatre in Santa Barbara, Calif., a recent $3 million renovation of the entire facility included a remodeling and extension of the stage. “We built out an area from the proscenium arch where we could store our steel deck under the front lip of the stage,” explains Mark Robley Johnson, the theatre’s technical director. In a unique agreement, the theatre—located on the grounds of Santa Barbara Junior High School—is operated by a nonprofit organization as a dual-use facility. When not being used by the school, the facility hosts a wide variety of entertainment including children’s theatre, acting workshops, dance presentations and musical acts.

Obtaining proper funding and finding time in a busy schedule can be huge roadblocks in the effort to overhaul your stage floor. For some theatres this means raising money through various means and then going dark for a while as the work gets underway. The 10-month renovation of the Marjorie Luke Theatre—which was originally built during the Great Depression—was a grassroots effort that blended private and corporate donations with funding from a state initiative. Like the theatre itself, the new stage floor is multipurpose. “It’s wood over concrete,” explains Johnson. “Then we laid a masonite cover on it. When we have dance presentations or groups that request it, we lay down a Harlequin sprung floor.” A “sprung” or “floating” floor is engineered to provide appropriate cushion or “bounce” for certain types of performances. Moorestown, N.J.-based American Harlequin produces portable sprung floor panels that can be stored when not in use.

On the other hand, perhaps your theatre needs a floor that stays put, or maybe you’re looking for an easy-to-clean surface to cover an existing concrete subfloor. Whatever the case, flooring vendors offer a wide variety of surface types, from black linoleum to hardwood hewn from solid oak. Randy Swartz, president of Philadelphia’s Stagestep, Inc., provides a few examples: “Our Rave flooring comes in lots of colors and is very lightweight,” he says. “Timestep, a heavy-duty flooring, is used for tap, hip-hop and theatrical productions where sets and props are used onstage. Quietstep is used primarily for ballet.”

Is it time to replace your floor? If it’s old and brittle, damaged or stained beyond repair, or no longer lies flat, it’s probably time to call a flooring contractor. According to Tracey Cosgrove, product manager for Rosco Laboratories in Stamford, Conn., theatres need to focus on several key questions when hunting for a company to install a new stage floor: “First, what kinds of activities are going to happen on the floor? Will there be dancing, classes, or scenery moved across it? And second, is the floor a permanent install, or will it be a temporary floor that will be moved on and off the stage, or in and out of a facility?” Adds Claire Londress of American Harlequin, “We need to know about the current subfloor in the facility. Is it a hard subfloor like concrete, wood or tile? Or is it a sprung floor instead?”

Your most useful tool in choosing a new floor is to talk to those who will use it the most. Of course, opinions will vary depending on whom you’re asking. “Lighting designers like non-reflective floors and generally like black,” says Randy Swartz of Stagestep. “On the other hand, dancers usually prefer gray flooring, which gives them a horizon.” Renae Williams, the director of dance presentation at the Los Angeles Music Center, took a democratic approach to choosing a new stage floor for her facility: “Our Technical Director researched several different options and also spoke with the production staff from the companies we present. We want our visiting artists to feel comfortable and well taken care of while here.”

At the Chautauqua Institution, an educational facility and resort in New York, the newly christened Bratton Theatre sports a brand-new stage. “The old theatre was a very small converted space,” says Mike Sullivan, director of institution relations. “It didn’t have a real stage, and it had temporary seating. Our theatre company was very good at putting on these wonderful plays and really needed a space to match their talent.” Funded through a capital campaign, consultants Davis Crossfield Associates and architect Mitchell Kurtz reworked the space into a true theatre.

According to Kurtz, the Bratton Theatre’s new stage was crafted with ordinary carpentry materials. “Whatever you might carve up, you can simply get a replacement piece from a lumber yard,” he says. The top quarter-inch of the floor is “sacrificial” or replaceable. “So as you screw into the floor over the years,” explains Kurtz, “you can peel the layers apart and toss them away without undermining the structure.” Adds Robert Davis of Davis Crossfield Associates, “If you paint on the surface with a thick paint that won’t come off, you don’t have to spend hours scraping it. You just have to replace the panels.”

When talking with a flooring contractor, make sure you’ve decided how much surface coverage you require. “We’ve done stages as small as 750 square feet for high school theatres,” says Michael Sean Graves, president, Entertainment Flooring Systems, “and as large as 20,000 square feet for concert halls.” Larger venues require additional flooring because of their multipurpose requirements, wings, and the like. Keep an eye on cost as you add up your space requirements. According to Swartz, floors by Stagestep can run between $1.22 to $3.89 per square foot, with additional costs for shipping, subfloors, and adhesives.

Protecting your investment
While the major manufacturers all provide some type of warranty for new floors, a theatre’s first line of defense is to maintain the surface with care. “If it isn’t maintained properly,” cautions Graves, “a new floor can be destroyed fairly quickly”—sometimes in as little as three years. Entertainment Flooring Systems provides a one-year warranty for hardwood floors due to their propensity for easy wear and tear. Vinyl and linoleum, on the other hand, come with a seven-year warranty. At Rosco Laboratories, the typical warranty is five years against manufacturing defects, while American Harlequin offers a lifetime warranty.

The materials used in the construction of the floor play a large role in its lifespan. Graves notes that while hardwood can last for many years, vinyl and linoleum floors exist in a constant state of wear-and-tear and will eventually dry out. “Vinyl hardens and becomes brittle,” says Graves, “because the plasticizers, which keep the surface flexible, are constantly curing. Linoleum eventually dries out too.” He estimates that well-maintained vinyl can last eight to 15 years under normal wear conditions. Adds Davis, “There are many serviceable floors that are 50 years old or older. It depends on how you use them.”

Is your theatre part of the green building movement? If you prefer to use as many ecology-friendly products as possible, you have some additional items to consider when choosing your new stage floor. Linoleum (a canvas or burlap base covered with linseed oil and other materials) and vinyl (a synthetic plastic composed of chlorine and ethylene derivatives) are less expensive than natural wood. Critical to choosing a “green” floor are the materials used in manufacturing and installation, as well as factors like toxicity, recyclability and longevity.

Speaking of recycling, the Cleveland Public Theatre took an interesting approach when it resurfaced the stage of its Gordon Square Theatre several years ago. “We are slowly renovating the properties,” says Executive Artistic Director Raymond Bobgan, “and are now undertaking a major capital campaign in cooperation with a community development organization and another theatre.” Volunteers and several designers visited a nearby racquetball court that was being torn down. “We took the racquetball floor apart so it wouldn’t be destroyed,” recalls Bobgan, “and then installed it over the floor of the Gordon Square Theatre.”

To keep your new floor sparkling, soap- and wax-based cleaners are not recommended for surfaces like vinyl because the cleaner will make the floor slippery—which spells certain disaster for the performer. “For vinyl surfaces, we recommend the use of a pH-neutral vinyl floor cleaner,” says Claire Londress of Harlequin. “This type of cleaner can be found at almost any hardware or home supply store.” Londress cautions that while buffing machines are useful for large areas, the equipment must be used carefully to avoid damaging the non-slip surface. According to Graves, hardwood floors, despite their longevity, can require refinishing up to twice a year—an additional cost for the theatre.

Installing a new floor
At Entertainment Flooring Systems, Graves supervises the installation of each floor, usually with a team of stagehands with whom he’s worked for the last two decades. “Sometimes we use local labor as well,” he says. “It depends on where the space is and the availability of my experienced labor.” On average the team can install approximately 1000 square feet of flooring per day. However, if two layers are required—for example, a sprung subfloor topped with a vinyl surface—the installers need twice the time to cover the same amount of surface area. For hardwood floors, Graves says that coverage decreases to 750 square feet per day because the crew needs to apply a coat of polyurethane to seal the new surface.

Once the stage is installed, it needs curing, or drying, time. According to Graves, glue used in linoleum or vinyl flooring typically takes at least a day to cure: “You need to wait 24 hours before you walk on it, and 48 hours until there’s any major traffic on the surface.” Heavy or rolling loads must wait one week before traversing the new stage.

For smooth installation of a new floor, Graves makes sure to chat with the client as well as the architect. “A lot of the time we deal with the architect or consultant, but we also need to consult with the owner of the facility.
Sometimes with renovations, they way things are designed and the way they’re used are totally different.” Says Claire Londress, “We work with our customers to ensure that the design of the new floor suits existing space or, if we’re looking at a new building, meshes with the architect’s plans.” For a great performance, the right environment can make all the difference.

Put your best foot forward and keep the discussion going on flooring at the DramaBiz Magazine forum, visit www.dramabiz.com/forum.