Location: College of the Holy Cross, Worcester, MA
Client: Sterling Miller Designs
Project Summary
ASR provided engineering support for the installation of Corian architectural elements within a performing arts theater and an associated architectural staircase at the College of the Holy Cross in Worcester, Massachusetts. Working in close collaboration with Sterling Miller Designs, ASR supported the realization of the architectural vision by translating complex interior geometries into precise, buildable Corian systems.
ASR’s role focused on resolving geometric complexity, tolerance stack-up, and installation planning challenges through high-fidelity modeling derived from 3D scan data of the installed structures. The scope included full Corian panel design, joinery development, and the design of fabrication molds and formwork used to manufacture the panels. Unlike other Corian projects, this installation did not require additional structural reinforcement, allowing ASR to focus on precision fit, alignment, and constructability.
Engineering Scope & Key Constraints
The primary engineering challenge was the installation of rigid Corian architectural elements onto existing, as-built structures where accumulated construction tolerances could not be accommodated through conventional fabrication assumptions. Key constraints included:
- Installation onto existing steel and architectural substrates
- Complex multi-level interior geometry within a theater environment
- Architectural requirements for smooth, continuous Corian surfaces
- Tight visual tolerances with minimal allowable panel gaps
- Cumulative tolerance stack-up from prior construction
- Coordination between architectural, fabrication, and installation teams
- Confined interior installation conditions within an active institutional facility
Meeting these requirements required accurate representation of as-built conditions and fabrication-aware installation planning.
ASR’s Approach
As-Built Modeling from 3D Scan Data
A high-resolution 3D scan of the installed structures was performed by others. ASR received the scan data and imported it into CAD to generate high-fidelity digital models representing the true as-installed geometry of the theater elements and staircase.
These models revealed deviations from nominal design geometry caused by fabrication and installation tolerances. Using the scan-derived data, ASR identified areas where direct translation of architectural geometry would result in misalignment, gaps, or installation challenges, enabling corrective strategies to be developed early in the process.
Corian Panel Design, Joinery, and Mounting Strategy
Using the high-fidelity as-built CAD models, ASR designed all Corian panels, including the complete panel geometry, interfaces, and panel-to-panel joinery required to achieve a seamless architectural finish. Joinery details were developed to accommodate local geometric variation while maintaining surface continuity and alignment.
ASR also developed panel-specific shimming and mounting methodologies tailored to each installation location based on local geometry, orientation, and adjacency to architectural features. This approach allowed the Corian elements to be installed accurately with minimal field adjustment while preserving the architectural intent.
Formwork, Mold Design, and Fabrication Support
To support fabrication, ASR designed all formwork and molds used to manufacture the Corian panels. These tooling designs ensured consistent panel geometry, repeatable fabrication quality, and reliable interface control across both the theater and staircase installations.
ASR supported fabrication and installation by providing:
- High-fidelity CAD models of all Corian panels and interfaces
- Detailed designs for formwork, molds, and fabrication tooling
- Fully defined joinery and edge conditions
- Guidance on shimming locations, mounting points, and installation sequencing
- Ongoing coordination with Sterling Miller Designs and fabrication partners
This level of engineering support enabled predictable fabrication outcomes and streamlined installation.
Collaboration
ASR worked closely with Sterling Miller Designs, Corian fabricators, and installation teams throughout the project. By acting as the technical bridge between architectural vision and as-built field conditions, ASR helped ensure that design intent was preserved while remaining grounded in constructability.
The use of scan-based modeling and fabrication-aware engineering allowed potential issues to be resolved proactively rather than during installation.
Outcome
ASR successfully enabled the installation of Corian architectural elements within both the performing arts theater and staircase at the College of the Holy Cross. The final installation achieved smooth, continuous surfaces with tight visual tolerances, no visible gaps, and a finish consistent with the architectural design intent.
This project demonstrates ASR’s ability to support architects, designers, and fabricators on complex interior architectural installations—particularly where precision materials such as Corian must interface with existing structures. ASR’s repeat collaboration with Sterling Miller Designs highlights the value of as-built modeling, detailed panel design, and fabrication-aware engineering in delivering high-quality architectural outcomes.
ASR’s Role
Engineering partner responsible for as-built modeling from 3D scan data; high-fidelity CAD development; Corian panel, joinery, formwork, and mold design; mounting and shimming methodologies; fabrication detailing and tooling support; installation planning; and coordination with architectural and fabrication teams.