Soundman2020 - Studio Design Forum

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.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 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

Andrew

looking good!

So far so good.. Exciting...

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 and

Dr Space wrote:Source of the post So far so good.. Exciting...

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
Andrew

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. 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 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. and with the wall wrap on all unprotected sides One day it might stop raining again so I can get some cladding on and start actually building the studio
Andrew

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!!

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

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. 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.
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.
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

Extra pics per last post - hope these descriptions make sense Rafters.jpg[/attachment]

So much for regular posts!

Plenty happening but much of it not markedly visible other than to those who have been through the painstaking process of ensuring every part of the build hits the continuous mass requirements.

The last two months have been dedicated to:
1. Completing three sides of layer 1 of the outer wall (I’ll frame and clad the 4th side once I’ve got most of the drywall (plasterboard) sheet off the floor to give me some working room)
2. Marking up the screw positions for Layer 2
3. Mounting the 22 C section steel purlins that hold the outer ceiling;
4. Building out the central steel beam to the mass requirements (37.5kg/m2) I need as the two sections of outer ceiling butt up against either side of this beam as it is providing the mass for this part of the ceiling;
5. Bolstering the mass of the C section columns that form part of the outer wall; and
6. Doing some design work around ventilation (silencer sizing, mounting and duct design) that I will post in my design thread

I look forward to getting past working with and around the steel frame – if I ever did this again (and I won’t) I’d use masonry walls for the outer structure and get A frame trusses made to support the roof cladding. Of course the grass is always greener….and part of my complexity resulted from trying to squeeze every ounce of internal space out of the footprint.

Pics below

3 almost completed walls – couple of gaps just hanging out for some offcuts of the right size/orientation
The outer ceiling purlins in place – just need to fix the over battens to stop any “roll”
The much “loved” centre beam with all the added extras to get the mass up to the target level and some overhanging pieces to provide a solid surface to push the backer rod into once the ceiling is hung.
This month is all about hanging the ceiling sheets and getting most of layer 2 of the outer wall/ceiling off the floor and hung!

Andrew

Good stuff. Will you be making use of the extra space offered by the peaked roof when building the inner room?

Cheers,
Jennifer

endorka wrote:Good stuff. Will you be making use of the extra space offered by the peaked roof when building the inner room?

Cheers,
Jennifer

Jennifer
Thanks for your support...this stuff gets hard sometimes - takes forever . So any little bit of encouragement is welcomed.
On the "peaked" roof - yep inside rooms follow the same line - just 200mm lower. In my live room I get to a peak acoustic height of 3.2m on the flat bit and about 3.0 and 2.9m at the very ends of the rakes.
Andrew

gearjunk1e wrote:Source of the post On the "peaked" roof - yep inside rooms follow the same line - just 200mm lower. In my live room I get to a peak acoustic height of 3.2m on the flat bit and about 3.0 and 2.9m at the very ends of the rakes.
Andrew

Excellent, that has great potential. Cheers! Jennifer

Work progresses - slowly the outer layer is being built out. Spring here means lots of garden/yard time - especially this year with record rainfall so my studio construction hours are down

The reason for an "outer wall mid build post" is that I celebrated a joyous event last weekend - I actually now have a clear floor on one side of the studio area It has come at just about the right time - I've been getting very frustrated working around piles of gyprock (drywall). I've developed a number of "weapons" to enable the lifting and placement of 16mm sheets on the walls and ceilings so that I can get by generally with a little help from my wife and only then because of the risk of breaking long sheets rather than anything else. The powered hoist I bought for lifting stuff into my previous garage loft has come in handy in loading sheets on to the drywall lift

I would agree with others - green glue is easy to apply but for something that's not really a glue - its extremely sticky when you get it on the floor or tools, hands or anything else

Clearing the floor allows me to start the wall that separates the studio from my workshop - you can see I've been fitting the double top plate - fiddling around to get the right rake on the top and horizontal on the bottom to save on raking all the tops of the uprights. I need that wall built to finish this half of the ceiling (and the wall of course )...then its on the to the other side...but I will have to move the rear pile of gyprock before I can get very far

Andrew

Fast forward to April 2023 - I’m amazed how fast time goes when you are building!

Aside from rechecking and reinforcing some of the sealant work around the centre beam, my outer ceiling is complete and the outer (dividing) wall between the studio and workshop is now well advanced. I’ve been holding back on completion of that dividing wall pending some final detailed design work and to allow easy access to bring in materials for the inside skin and cabling/AC installation access.

I’ve also now decided to phase the project - prioritising work on the live room (LR) as I’m getting tired of sharing my “music room” in the house with my wife’s crafts and that room doubles as a guest room. Of course, my wife is equally unhappy with the arrangement – she naturally believes she is sharing her craft room with me!

The plan is now to get the live room up and running by end of June with the dividing wall between the studio and workshop complete the whole way across. I will put a temporary fill into the window space between the LR and CR and complete the CR by year end.

Following this I will post some further design updates on doors and the vapour barrier in the design section.

Here’s some pics of progress since my last post.