What brings “star performance” to an insulating project? Members of the insulation manufacturing team working alongside partners at PCI and Bay Insulation recently delivered a performance quality installation on a massive scale, as they installed 2.5 million square feet of rigid fiberglass insulation on the walls and under the steel dome of the Las Vegas Sphere. 

While the luminescent exoskeleton featuring 580,000 square feet of LED display dominates the Las Vegas landscape, insulating materials installed behind the scenes support sound performance in a venue renowned for its acoustics. Sphere Immersive Sound, powered by HOLOPLOT, is billed as the world’s most advanced concert-grade audio system. Acoustic features tailored to the Sphere include a 3-D beam-forming sound system that can be transmitted to individual seats in the 18,000-seat venue. 

Selecting insulating products designed to absorb noise and support acoustics was an important consideration when specifying materials for the Sphere’s walls and ceiling areas.  

Additionally, team members including the contractor, distributor and manufacturer, had to manage the availability of product as well as coordinate shipping, storage and installation over a nearly three-year construction process. PCI, the specialty contractor managing framing, drywall and specialty finishes for the Sphere, performed BIM modeling services and generated jobsite schedules that were critical to successfully installing the rigid fiberglass insulation in the walls and under the steel dome.   

A key challenge for the project team was installing acoustic insulation that fit within the Sphere’s geodesic curves formed by hundreds of interlocking triangles. Curvature coupled with practical logistics, like assuring timely product delivery during a historically challenging time for supply chains, required a nimble, real-time approach to problem solving on the jobsite, while always prioritizing safety for workers. 

Solving for Complexity While Following the Curve 

BIM modeling helped turn the architectural drawings for the Sphere into practical working documents showing the precise placement of components in the walls.  

Double-curved framing elements form the Sphere’s “bowl” seating area and insulation pieces were sized and cut to follow the curvature. Because there are so many music hardware and speaker niches installed throughout, not every interlocking surface is coterminous. The design team needed a way to control for design interruptions when installing the insulation. As insulation is prolific throughout the space, modeling assisted in the constructability side of the install strategy. 

The volume of space, as well as an abundance of hard surfaces, meant that while sound quality had to be optimized, noise had to be controlled. The bowl is surrounded by a multi-storied atrium where visitors can circulate and enjoy bars and restaurants while appreciating décor that pays homage to the mathematics underlying the Sphere’s design. The 2.5 million square feet of rigid insulation installed throughout the structure help absorb noise and optimize sound quality.  

Planning, Product and People 

Teamwork on the project demonstrated that the right collaborators are essential for achieving success behind the scenes. Bay Insulation of Las Vegas served as the distributor for supplying 140 truckloads of sound acoustic board insulation and fiberglass insulation. James Adams, manager of Bay Insulation’s Las Vegas office says the project was the largest board insulation project in the company’s history. Managing such a massive project required careful coordination on paper and in action. The product wasn’t the only performer in this massive project.  

People and processes also played a role. A spreadsheet developed and maintained by an inside sales rep at Owens Corning’s Toledo headquarters, was key in managing the timely delivery of product. Rhonda’s organizational abilities earned her the title of “maestro.” Following completion, Rhonda was presented with an honorary photo plaque signed by team members recognizing her leadership in managing delivery times and communications throughout the massive project.  

Plans called for material to be prefabricated when it arrived on the jobsite where it was installed in the curved design with a combination of adhesives and impaling pins. Cut to specification, the pieces of rigid board insulation were installed in an array of different 4-inch and 2-inch thicknesses that included radial, dome and double-curved designs.  

The complex geometry required an acoustic insulation that was resilient and would maintain its performance following installation. Acoustic boards were installed to meet these demands. Made of inorganic glass fibers with a thermosetting resin binder and formed into rigid rectangular boards, the insulation is dimensionally stable and will not shrink or warp. The rigid boards are trusted to deliver acoustic properties and provide absorption, deflection and reduce sound transmission in multiplex theaters, sound studios and performing arts centers. Acoustic engineers evaluated the absorption and deflection properties needed throughout the massive venue. 

Insulating such a massive project can seem overwhelming but planning at the outset helped support efficiency. “It all comes down to communicating as much detail as possible when you’re working with thousands and thousands of moving parts on a jobsite,” says Bryan Bergquist, regional sales leader, Owens Corning.   

Construction of the Sphere took place as supply chains were tight and logistics were still adapting following the pandemic. The project was hit hard by the aftermath of Covid and the problems it caused for supply chains. Bergquist says that PCI and Bay Insulation’s communication with the insulation manufacturer assured that the right components were received on time, at the right location and in condition for install. 

The adage, “a place for everything and everything in its place” was part of planning how components would be stored upon arrival. The size of the Sphere proved to be an asset when it came to protecting insulating materials on the jobsite. Rigid insulation was stored on floors where less activity was taking place and staged in the appropriate areas as construction progressed. Selecting a durable, insulating material was also important.  

Processes to Support Safety and Efficiency 

Protecting people, and their safety on the jobsite, is always priority one. Processes were in place to protect workers on the jobsite. Given the height of the structure (367 feet) careful attention was paid to collaborating with the scaffolding suppliers on each of Sphere’s six levels. Components were staged on the ground for efficient access at the time of install.       

Every project yields insights and opportunities. The Sphere demonstrated how planning and modeling paired with prefabrication can support efficiency and safety on the jobsite. Relationships with others in the industry are also important. The manufacturer and supplier’s previous experience working with PCI and Bay Insulation on projects allowed team members to tap into a broad network of construction specialists. Insulation production plants coordinated efforts to support on-time delivery of product to the distributor who managed timely delivery. And the installers on the jobsite were the hands-on experts translating BIM plans into product installation.  

A project of such stature demands an opening of grand proportions. Legendary Irish rock band U2 opened its “U2: UV Achtung Baby Live” residency at the Sphere in September 2023. Several team members involved in the collaboration celebrated completion of the project by taking in a U2 performance. According to Bergquist, the performance was an opportunity to see the venue from an entirely different perspective, as a member of the audience. 

The Sphere continues to present new possibilities for immersive entertainment, and for the future of the construction sector. Such high-profile buildings can generate enthusiasm for the trades and be an asset in recruiting new entrants to the industry.