By: Kevin Lemieux, P.Eng, Struct.Eng, Principal, Weiler Smith Bowers Consulting Structural Engineers and

Dylan Bilinsky, Operations Manager, RiteTech Construction Ltd.

The Lake City Way project in Burnaby, British Columbia, is a significant achievement in the application of tilt-up construction techniques for large-scale developments. Comprising 21 advanced movie studio sound stages, the project integrates tilt-up panels with two levels of underground parking and production workshops constructed using cast-in-place (CIP) concrete and suspended slabs. The project’s execution highlights rigorous engineering and careful planning, addressing both structural and logistical challenges.

Located 20 minutes from downtown Vancouver and 30 minutes from the airport, the Lake City Studios facility spans an 18.6-acre site. The facility’s 21 soundstages, including one of Western Canada’s largest at nearly an acre in size, offer a range of ceiling heights and configurations to meet diverse production needs. Sustainable practices are central to the project, with renewable hydroelectric energy powering the facility and dedicated systems for recycling and waste management. Underground parking for over 1,000 vehicles and a mile of adjacent parking for production vehicles ensure operational efficiency. The campus is strategically situated next to the Skytrain rapid transit system, providing enhanced accessibility.

Scheduled to open in the summer of 2025, the master-planned campus includes extensive production facilities such as mill shops, props lock-ups, and naturally lit costume build areas. With seven production offices comprising over 100,000 square feet, the development fosters a collaborative environment by co-locating numerous film-related businesses.

Design and Functional Planning

The Lake City Way project was designed to optimize spatial efficiency while addressing the specific requirements of the film production industry. Site constraints included a sloping grade, environmental setbacks, and proximity to rapid transit infrastructure. The development features two primary structures: an L-shaped building with six 50ft clear soundstages, two 30ft clear soundstages, and an adjoining three-story office block, and a rectangular building with ten 40ft clear soundstages and three additional 35ft clear lower stages. These buildings are supported by up to two levels of a combined underground parking and workshop space.

Tilt-up construction was selected for its structural benefits, acoustic properties, and ability to meet tight construction schedules. The panels, tailored to soundstage requirements, provide essential isolation and durability, ensuring long-term functionality.

Integration of Construction Techniques

The project required three years of planning followed by a 14-month tilt-up construction phase. The overall construction phase is about 3 year. Tilt-up panels were integrated with CIP and suspended slab systems, anchored to the slabs via embedded steel plates. This approach provided stability while maintaining the flexibility needed for complex site conditions.

To address site-specific challenges, a crane was positioned below grade, utilizing the space between buildings as a temporary roadway. This innovative strategy minimized the need for extensive reshoring and allowed for efficient panel erection, ensuring adherence to the construction timeline.

Structural Challenges and Solutions

The project’s tilt-up panels, some reaching heights of 65 feet and weighing up to 148,000 pounds, posed significant engineering challenges. Constructed on suspended slabs, these panels required precise stacking and selective reshoring to accommodate weights exceeding 300 pounds per square foot.

During erection, robust bracing systems were employed to maintain panel stability. Braces, extending up to 52 feet, were anchored to the structural floor slab and remained in place until the roof structure provided additional support. This method ensured safety and structural integrity throughout the construction process.

Trade Coordination and Sequencing

The complexity of the Lake City Way project required meticulous coordination among multiple trades. Over six lift phases spanning 14 months, teams navigated overlapping schedules, site access limitations, and weather-related delays. Weekly coordination meetings facilitated alignment among the CIP contractor, tilt-up specialists, and structural steel teams.

Pre-lift safety briefings and adaptive planning addressed potential risks and ensured seamless progress. Challenges such as managing laydown areas and optimizing access routes were resolved through ongoing communication and collaboration.

Architectural and Environmental Considerations

The Lake City Way project demonstrates how tilt-up construction can meet architectural and environmental goals. The panels’ durability and low maintenance requirements align with sustainability objectives, while the use of hydroelectric energy and recycling systems further reduces the project’s environmental impact.

Architecturally, the design integrates functional and aesthetic elements, including naturally lit workspaces and expansive soundstages. The inclusion of film-related businesses within the campus fosters a collaborative ecosystem, supporting both creativity and industry growth.

Impact and Implications for Future Projects

The Lake City Way project highlights the adaptability of tilt-up construction for complex, large-scale developments. Its successful implementation demonstrates the importance of early planning, innovative engineering solutions, and cross-disciplinary collaboration. These lessons can inform future projects, emphasizing the value of integrating advanced construction methodologies with sustainable practices.

By addressing diverse challenges and setting new standards for efficiency and functionality, the Lake City Way project underscores the transformative potential of tilt-up construction in modern building design.