Stand alone "room in a room" studio build in Orange NSW Australia

Document your build here: All about your walls, ceilings, doors, windows, HVAC, and (gasp!) floated floors...
gearjunk1e
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Joined: Sun, 2021-Mar-07, 19:19
Location: Orange Australia

Stand alone "room in a room" studio build in Orange NSW Australia

#1

Postby gearjunk1e » Tue, 2021-Jun-01, 06:31

Hi everyone

Documenting my build as I go
My design post is on
https://www.digistar.cl/Forum/viewtopic.php?f=5&t=915

Almost completed the first stage of the build - what is referred to as a "hay shed" - basically a galvanised steel frame with a corodek (galv iron) roof on a concrete slab. Just some work to do to finish the front gutter and barge flashing. I've installed insulation under the roof to address excessive noise from rainfall and condensation issues - just need to tape up joins.
20210531_155214.jpg
Anticon
20210601_161404.jpg
Shed frame side
20210601_161504.jpg
Shed front
Dug the trench for the electrical and ethernet cables; had to dig by hand given I was trying to dodge water pipe and sewer pipes and didn't have a plan for exactly where they'd been laid. All pipes found with no incidents :D
20210601_161330.jpg
trench
Next step is doing the damp proofing and flashing that will sit under the treated pine frames that will hold both the external skin (corodek) on the outside of that frame and the walls of the outer room - on the inside of that frame. We sit on top of the ridge here and the rain can come in sideways from any direction so I'm taking a dual approach to waterproofing the base - DPC selected is bitumen coated aluminium that can be folded to shape
image.png
sill plate and sills


Andrew



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gullfo
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Stand alone "room in a room" studio build in Orange NSW Australia

#2

Postby gullfo » Mon, 2021-Jul-19, 14:20

looking good!



Dr Space
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Stand alone "room in a room" studio build in Orange NSW Australia

#3

Postby Dr Space » Tue, 2021-Jul-20, 08:26

So far so good.. Exciting... 8-)



gearjunk1e
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Joined: Sun, 2021-Mar-07, 19:19
Location: Orange Australia

Stand alone "room in a room" studio build in Orange NSW Australia

#4

Postby gearjunk1e » Fri, 2021-Jul-23, 01:40

gullfo wrote:Source of the post looking good!
Glenn - I'm close to posting again in the design board re HVAC design - the ceiling design forced me to face into this and the weather here has given me a lot more research time - both :D and :(
Dr Space wrote:Source of the post So far so good.. Exciting... 8-)
Dr Space - thanks for looking in - it led me to your build posts - wow!!!...and I thought I had a tough time getting approvals and trades in :D
Andrew



gearjunk1e
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Posts: 46
Joined: Sun, 2021-Mar-07, 19:19
Location: Orange Australia

Stand alone "room in a room" studio build in Orange NSW Australia

#5

Postby gearjunk1e » Sat, 2021-Oct-16, 00:38

Bit of an update - I don't want to bore people with basic shed building updates so I've tried to keep pics to matters that have some impact on isolation.

Its been slow going - the rainfall has been frequent and above average this winter. That however, has been an ever present reminder that my damp course solution is VERY important - especially since we sit on a ridge line and the wind can be brutal - bringing rain in almost sideways at times and I DON'T want water seeping in between my rooms where I'll never see it until its too late!

So I've spend a truckload of time getting my waterproofing right at the base. It starts with a layer of bitumen coated aluminium on the slab edge held in place by some treated pine (base plate 1) with a metal sill on top. The base plate of the framing will sit on this.
20210721_171427.jpg
Profile shot of damp course system - you can almost see the bottom plate which is clearer in other shots
20210713_122442.jpg
I also sealed the join of the slab and the inside turn up of the bitumen coated aluminium with some SIKA FC11+ sealant. (photo bomb!)
20210713_144253.jpg
The concrete frog who's lost his head is doing its job in this shot
20210713_144301.jpg
Below is a mock up of how the metal sheeting with sit over the sill - before I made up the sills that sit in front of the columns and the next pic, a shot of one of the detailed cut outs around the columns
20210707_165646.JPG
20210901_155048.jpg
Headless concrete frog doing stuff all!
20210901_122314.jpg
I went a bit overboard with the sealant...anything that moved
Very pleased that my brother-in-law (builder) re-arranged his round the country road tour and turned up to accelerate the framing work - two are sooo much better than one!
Here's some framing shots and the start of hanging the wall wrap...Ametalin VapourTech Brane VHP Vapour Permeable Wall Insulation - its there in part to give me some rain protection pending cladding but most importantly to provide some insurance against condensation - it lets moisture out but not in. I can vouch for it not letting water in over the past week - we've had rain and wind coming in from all sides. Per feedback from Stuart, I'm putting some low GFR insulation on the inside of it to dampen any potential vibration in the cladding.
20211008_175543.jpg
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20211009_135319.jpg
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and with the wall wrap on all unprotected sides
20211009_190122.jpg
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20211009_190211.jpg
20211013_102935.jpg
One day it might stop raining again so I can get some cladding on and start actually building the studio :D
Andrew



Dr Space
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Stand alone "room in a room" studio build in Orange NSW Australia

#6

Postby Dr Space » Sat, 2021-Oct-16, 06:54

Looks great Andrew... Some things can be really difficult in Portugal... at the moment as fall and winter get going I still can't manage to get my windows put in.. Ordered in April and the frames are made but no glass has been delivered even though both companies said they would be ready in September.. Crazy sometimes but we will get there... both of us!!



gearjunk1e
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Posts: 46
Joined: Sun, 2021-Mar-07, 19:19
Location: Orange Australia

Stand alone "room in a room" studio build in Orange NSW Australia

#7

Postby gearjunk1e » Thu, 2021-Oct-21, 06:41

Dr Space
Yes - we have had quite a lot of COVID impact on supply of goods here - in our case due to lockdowns mostly which has meant production is down...trying to get LVL, framing timber or insulation is hard work...so I feel your pain.
Andrew



gearjunk1e
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Posts: 46
Joined: Sun, 2021-Mar-07, 19:19
Location: Orange Australia

Stand alone "room in a room" studio build in Orange NSW Australia

#8

Postby gearjunk1e » Fri, 2022-Aug-05, 08:12

Wow

I can’t believe how long it’s been since I last posted – much has happened since but most of that is to do with the external skin of the shed and steps to gain Council approval, rather than any studio building per se. I ended up excavating an area behind the shed and building a retaining wall so that I could install a 2nd water tank that will take the stormwater off my new structure. That’s occupied the better part of 6 months of building time. :blah: While this has nothing to do with isolation or acoustics - no Council approval means there is NO STUDIO. Anyway, Council have signed off on the key structural issues this week and I’m now free to get on with the fun stuff.
Here are some shots of the external work since I’ve invested so much time in it.
Pre excavation.jpg
tank site before work
Retaining wall build.jpg
building the retaining wall
Tank site ready.jpg
site ready
Front.jpg
My brother in law helped with the cladding - he built a couple of temporary platforms that we shifted around to lift and fix the material to the frame
Front right.jpg
lock up!
east wall.jpg
Fyrchek trolley.jpg
made this up to shift the piles of fyrchek (drywall) round to the shed
Rear view rear tank.jpg
Side pipe run.jpg
Run to 2nd tank.jpg
Rear pipe run 2nd tank.jpg
overflow to north.jpg
In between cladding, trenching, excavating, levelling and hanging and laying gutters/stormwater pipes, I have been busy on the prep work to allow me to complete the construction of what will form the outer room walls. Most of that is bridging the gap between the loose tolerances of the steel framed structure and those required to get a consistent isolation outcome to the target level – for example, packing out the frame so the outer leaf of the studio will sit flat, laying the base plates and setting up the metal frame to hold my C section steel joists.

By way of reminder,

• I am building a live room 4.77m x 6.93m x 3.1m and a control room 5.2m x 4.2m x 3.1m within an outer shell that covers 70% of the overall shed area
• I’m aiming for 60dB TL at 1m – but can accept 50dB;
• For the outer shell I am using 1 layer of part 16mm ply/part 16mm Frychek (drywall) then one layer of Frychek (drywall) for the outer leaf - with green glue between the leaves;
• There is then an air gap of 200mm filled with fluffy; and
• 2 layers of 16mm Frychek (drywall) with green glue between for the inner room walls

I was toying with a ducted mini-split but have since decided to go with 2 ductless mini- splits. I will post my HVAC and insulation plan on my design thread.

Per post 33 in my design thread - with some good advice - I’ve established that while the metal cladding on the very outside has the potential to be a third leaf, the risk is very low and I have mitigated that risk by putting fluffy in the wood frame that holds the metal cladding.

Pics below of some of the internal work that I have progressed.
West side ply.jpg
My outer wall is part drywall/part ply as I had to have ply shear bracing at intervals around the perimeter - it was convenient to finish this first leaf on this wall section in ply
Mullion context.jpg
wide shot of the next pic
Mullion integration.jpg
The metal frame mullion columns are part of the outer wall - 2.4mm of steel plus 45mm of timber equates to the rest of my wall mass
packing for rafters 2.jpg
Couple of shots of the packing that sits in the C section of the frame - the ceiling steel rafters will sit on this - they are temporarily on their sides
packing for rafters 3.jpg
packing for rafters.jpg

Next steps
My workflow for the next few weeks will be centred on getting enough floor space back so I can utilise my drywall lift to hang the outer ceiling. At the moment I have piles of fyrchek (drywall) covering almost ½ the floor area. I have a plan for the walls and ceiling construction that will minimise the moving around of materials while leaving me adequate workspace to manage hanging 3.0m and 3.6m lengths of 16mm material. To do this I need to finish up the packing in the middle metal frame to hold the metal C- section steel rafters that the 2 layers of 16mm Fyrchek.

I promise to be more diligent with documenting the build diary now the work has turned to studio building :)

But in the meantime will post some more progress pics - hit the limit for this post

Andrew



gearjunk1e
Active Member
Posts: 46
Joined: Sun, 2021-Mar-07, 19:19
Location: Orange Australia

Stand alone "room in a room" studio build in Orange NSW Australia

#9

Postby gearjunk1e » Fri, 2022-Aug-05, 09:37

Extra pics per last post - hope these descriptions make sense
Base plates.jpg
My design post talks about the need to have "inside" base plates - these have multiple tubes of caulk (sealant) underneath and between (per Stuart's instructions)
packing west.jpg
Lots of packing to cater for variations in metal frame and wood framing that had to follow any variations in the metal frame
Packing east.jpg
More packing - fortunately, the back wall was dead straight and perpendicular
packing east 1.jpg
This one shows some of the blocking I needed to do behind/next to the steel columns so that the backer rod has something to push on to and to pack out any variations between the steel columns and frame
Rafters.jpg
Some of the outer wall ceiling rafters are sitting up there - for now so I could get a level between the outside frames and the middle one for the ceiling (to work out packer thickness) - the middle frame actually sits up to 30mm below the outside ones as it moves towards the apex
Rafters.jpg[/attachment]
Central frame.jpg
another angle on the rafters and the middle frame
Lift vertical 2.jpg
I had to include this - I made a frame from one of the drywall pallets - added some casters to the base that allows me to lift the 3.0 and 3.6m 16mm frychek into place by myself - although my wife prefers that I get her to "spot" me
Lift horizontal.jpg
lay it flat, slide them on, lift the frame and wheel them into place - the base of the frame when upright is set to just above the base plates so its an easy slide into place
blocking behind posts.jpg
another variation on the blocking behind/beside columns - not for isolation but gives the backer rod that will go in between the steel column and drywall sheets something to push against




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