New rooms in Portugal

[Colonel Blues]

At least, you've got a laaaaaarge place to make up your ideas !!!

[Branko]

No place is large enough!

I'll also keep the updated info (probably with some more pictures) here: my blog

[Branko]

I'll try to explain some problems we had to sort out while designing the whole facility.
The first (and probably the biggest) problem is that we had to place two very different rooms next to each other - the Dubbing Theatre and the Recording Studio. In the Dubbing Theatre, we intend to produce peaks of 130 dB SPL, while in the Recording Studio we intend to keep the noise below NC10-15. Of course, there's a quick solution for this problem: just build these two rooms far away from each other, but that's something we can't afford, so we had to look for a different solution.
I have to say here that I'm a lucky person (at least when it comes to acoustic design issues), because I'm a good friend with Philip Newell and he was kind enough to accept the role of the designer in this project. Unfortunately, he's stuck with other studio construction (which he is supervising) in Spain, and can't get here to help me directly. Anyway, we keep exchanging drawings and photos. and we discuss all the problems and doubts in long phone conversations.
Phil has built hundreds of rooms in his career. That is extremely helpful, as there are practically no problems he hasn't already been through - and he remembers all of them and has them documented in his archive.
In order to reduce the transmission between these two rooms, we decided to fully float them, and even to separately float some isolation walls around them. As a consequence, the Recording Studio will be built as a bunker, with a triple shell around it. The first two walls will be made out of concrete blocks, filled with sand, and one of them will be floated on Sylomer (it's a rubber strip with excellent anti-vibration behavior), while the third wall, the inner one, will be a classical double plasterboard wall.
Both studios will be built on a separate steel-reinforced concrete slab, floated on 10cm of mid-density Rockwool.
Rockwool will also be used between walls, to prevent any direct contact through eventual cement dripping while laying down the concrete blocks.

Here are some pictures of today's activity:

[Branko]

Day two. Scaffolds and other tools were delivered and organized. Rockwool's being stored. Sylomer's been delivered, too.
We spent the afternoon measuring the space and drawing marks on the floor. Needless to say, some measures were adjusted to real conditions, most of them due to curvatures and shapes of existing structural floors and walls. We actually gained some 10cm of width to the Dubbing Theatre. At the same time, we lost some 30cm of height, but that won't be a problem, as we can comfortably reduce the space between the inner and outer ceiling to recover the lost space.
Later this afternoon, Murfor, a special wire reinforcement for masonry arrived. We will use it to increase the rigidity of all separation/isolation walls, and to prevent cracks that may appear later, due to their weight.

[JoeMilner]

Congratulations on the new venture, Branko; looking forward to watching the build!
cheers,

Joe

[Branko]

Thanks, Joe. Watch this space: just a few (!) months from now, we'll announce the opening party! I'll provide the beer for everyone.

[Branko]

Here are some new pictures, showing first concrete blocks being laid. We fill them with dry sand, to increase the mass.
In the next few days, these walls will keep growing up to 5,30m, which will be the height of the Dubbing Theatre outer shell.

[Branko]

Last day of the first week!

Four rows in place and filled with sand.

[Johnny Paez]

[Branko]

Thanks, Johnny!

[dmitri]

Congratulations, Branko! It's great when your dreams come true. Wish best luck to you and your team!

[Joao B.]

Boa sorte para o projecto

[Branko]

Thanks, Dmitri, obrigado João!

[J1mbaFr0sty]

and since you are in Portugal the build will be superior cos apparently we make good construction workers lol i might be visiting portugal soon. do you have msn or aim good sir? if so PM me please and thanks. place should look good when its done cant wait !

[Branko]

Thanks j1mbafr0sty, you're welcome!

[Branko]

Day 7, walls growing...
After each 4 layers of blocks, a Murfor wire reinforcement is added.

[Branko]

You can see the shape of the Recording Studio, limited by a floated wall.

On the other picture, Ze Luis is leveling the scaffold. We'll raise the walls to 5,30m in the next few days.

We also opened a door in the existing wall.

[Branko]

You can see the second wall laid next to the floated rec. studio wall. This second floor will divide the space in two main areas: Recording Studio and Dubbing Theatre. It is a non-floated wall, connected directly to the building structure.

There's a new opening in the control room wall - this time it's a window.


On Monday, we'll have more bricklayers, so I expect things to speed up a little bit.

[Syncamorea]

Originally Posted by Branko

In the Dubbing Theatre, we intend to produce peaks of 130 dB SPL

Yowsa...

Looking great so far!

[adassumpcao]

Nice work Branko!

I'm very curious to see the outcome of this project. I'll be closely following the updates that's for sure!

By the way, I'm also from Portugal, so as you promissed, I advise you to start filling the fridge with those beers!

Good luck!

Cheers,

Artur

[TiagoJSilva]

Triple-wall? Rock On! This is looking very nice, Branko!
Time to brush up on my copy of "Recording Studio Design" (by Phil himself).

Are you going to float the slabs on springs or elastomers?

[vegastheque]

I would like to ask what is the reason for the rockwool behind the bricks or in some cases behind gypsum walls I would like someone to share his opinion

is it for sound insulation or sound isolation and is it necessary to make gypsum(or bricks) and rockwool for acoustics ?

thanks

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Cheers

[Branko]

There are many reasons why would you put Rockwool between walls.
In this case, Rockwool behind the walls has a very simple task - to prevent cement from falling down, piling up at the bottom of the wall and creating a "short circuit" between walls and/or structural floor. Once it hardens, cement can seriously reduce the isolation characteristics of the floated wall. The distance between walls is only 5cm, and it is absolutely necessary to keep them completely separated.

Syncamorea, Tiago and adassumpcao, thanks, counting with you guys for the opening party!

[adassumpcao]

By the way Branko,

Where is it located?

Cheers,

Artur

[Branko]

It is near the Expo zone, in Av. Infante D. Henrique.

[adassumpcao]

Nice spot you pick! There's a lot of good spaces out there!

[Branko]

Approaching the end of week 3, here's the actual situation:
walls are now 2,5 m high and we'll be pouring one horizontal beam, to reinforce the structure of every wall. A smaller beam was placed above the window opening, and tomorrow we'll do the same for the door between the corridor and the Recording Studio.

I measured the dimensions of the rooms once again, to confirm we're on the right track and to fine tune the drawings of the acoustical shell, which we're going to start as soon as slabs are finished.

[Branko]

General situation as of today September 6th:

Walls keep growing.
Horizontal concrete beams are dry.
We'll reach the 5m30 wall height in a week or so. Only after that we'll close the Dubbing Theatre with rear wall and build the projection and equipment Machine Room.
After that, we'll pour the concrete slabs and, while these are drying, begin the demolition of some existing walls on the first floor.
Some pictures of today's situation.

[rhysw]

Very nice, Keep up the pics