
Construction
This is a doc I started writing right after the studio was done
so I would remember some of the trials.
I keep adding a line or two every now and then, but it's a work in progress...
Here's a slide show of Easy Street's Construction
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Building a new commercial studio without a very large (or unlimited) budget is an extremely difficult thing. With a very large budget, it's merely difficult. Beside the normal difficulties in building a commercial building, you have to be very diligent about every minute detail. This implies that you KNOW every minute detail! Building it was probably the most difficult thing I have ever done and maybe one of the most satisfying - after it was done.
Here are some highlights and pitfalls:
I'll start with me. I am not an engineer, or an architect, or a famous studio designer. I learned acoustics and isolation over the last 20 years from my father-in-law, (an architect/engineer with a PhD and acoustics background) and by reading every book I could find on the subject (his private library included). I practiced on a project studio I built in my own basement in 1996 - and it really worked!
One of the most significant things I learned while building this studio is that you must be able to compromise. If you are building (or involved in) a studio, you want it to be this perfect thing - it won't be. I had to learn to compromise some, and to compromise on the right things. Sometimes you compromise to save the budget, sometimes you compromise to save your sanity...and sometimes to save your marriage.
A big problem with constructing a sound studio is that seemingly minor details can have a major impact in the performance of the rooms. My mantra for the construction crew was:
"Performance is more important than appearance".
I started saying this because I found that construction crews are used to doing things a certain way, and they concentrate on it looking good and being easy, and not necessarily in that order. I wanted them to concentrate on doing it right acoustically. How it looked was secondary; how easy it was didn't matter (by the way, NOTHING about it was easy).
Design
-Rooms to fit in the hole.
The idea for the studio kind of happened by accident. I had a project studio at home and I was building a new commercial building as both a real estate venture and to house our software consulting company. In an early discussion with the General Contractor (Roschon Corp.) and the Architect (Tim McCoy), I asked how big a deal it would be to add a storage area below grade (add a basement, in English). It was fairly expensive to dig the hole in the first place, but not much more expensive for it to be big. As it turned out it in our building, 4000-sq. ft. was only about twice as expensive as 500-sq. ft.! So, the wheels began to turn and pretty soon I was trying to fit in a recording studio in this hole in the ground.
Since I was riding the edge of the WAF (Wife Acceptance Factor) and the already large building budget, I couldn't afford to go all out and hire designers and consultants to "take care" of my project for me. Also, the economics of Music/Video/Film in Minnesota do not support building a sound studio with a huge overhead. This was DIY on a major scale! I'm here to tell you, you can do it. It will be difficult and you will make mistakes, but it can be done without going the mega-buck route.
(I know I will probably be flamed by people who believe that you can't do it yourself -but I'll bet most of them have never done this, or had a large pile of "Other Peoples' Money".)
O.K. - We've got this hole in the ground and we start compromising right away. This level would need two stairways, two bathrooms, an elevator (w/elevator equip room), a fire riser room, and an equipment room (electrical, mechanical) to meet code - then I could put in the studio part...
I wanted a Control room, a Tracking (or live) room, a couple Isolation booths, and a Client area/"Green room".
The room sizes were a compromise, and since I wasn't hiring an acoustic consultant to oversee the project, I decided on rectangular rooms because it is easier (possible!) to predict the resonance modes of rectangular spaces using fairly simple calculations. Controlling those resonances is another matter, so I dimensioned the rooms very carefully within the space I had to work with. I ended up with 10'1" finished ceilings as highest I could (afford to) go with the best modal distribution. When we were building our building, each foot of height added to the below grade ceiling would add about $50,000. The 10'1" required a minimum of 12'4" bottom of deck height -already fairly high. In Minnesota, this necessitated a hole over 17 feet deep!
HVAC
- Heating, Ventilation and Air Conditioning is very critical in a sound studio. It must be very quiet, and it must move a lot of air to cool all that equipment, lighting, and talent you have in there. These are opposite requirements - the more air you move, the louder it gets. So what you must do is determine the volume of air you need to move, and lower the pressure it takes to move it. It's really the pressure that maks the noise. But if you lower the pressure a lot, you don't move as much air.
- So, think big.
- Use much larger diameter fans, supply lines and registers.
- Use Lined ducts and multiple bends in the supply and return line.
- Use a good and reputable contractor and be ready to tell them exactly what you want out of your system. Exagerate the amount of quiet you want - their idea of a quiet HVAC system is NOT ours!
- Make sure you don't create a direct path for sound between your rooms. Don't allow vents or returns in diiferent rooms to be supplied by a common duct. If you must use a common duct, don't allow a straight path between the rooms. I used a separate unit for the live (big) room, the control room, and the ISO booths. So those three areas have no common duct work. The four iso booths are fed from a large common supply, but have flexible lined ducts that follow a toturous path (lots of bends) to each room.
- Don't underestimate the heat generated by your equipment. I have 15 tons (I think?) of air conditioning for my sound spaces. Even in Minnesota, during one of the coldest Decembers (2000) we had had in years, the air conditioning came on when we were jammin! The heat only comes on occasionally when the spaces are unoccupied. Also, heat kills electronic equipment. In my machine room, I was unable to keep the temperature below 80 degrees when everything is on unless I freeze the occupants of the control room. I just installed an 1100 cfm blower with an intake in the green room for that little (200 cubic ft) room. So, it replaces all the air in that room every 18 seconds, and will blow your hair around! It really works well, keeping the equipment at room temp with the doors closed and everything on. And fits my "Overkill is just right" theory. :-)
Electrical plan
- This is also a very critical item. (It's starting to sound like everything is critical, isn't it?)
- Think ahead. Then double it. Use the best contractor you can find and check everything.
- Use Isolated ground outlets.
- For my control room, I used 4 individual 120v/20 amp circuits - one quad outlet per breaker. I also put in a single 240v/30 amp circuit for power amps, should I decide to use them. 240 is cool because a lot of power amps can be supplied with 208/240v which cuts their current draw (and heat, and electric bills) in half ! I supplied the "live" room with 3 120v/20 amp circuits and a single 240v/30. Each of the iso booths got a single 120v/20 amp circuit with several outlets. For the machine room I used 2 120v/20 amp circuits and a 240v/30 amp.
- So it basically I used most of a 300 amp panel for juice. I'll never use that much juice at once, but it takes that many circuits to do a (medium sized?) studio.
Acoustics
Exact dimensions
Walls and ceilings
Mass that's limp
Windows
Doors
Flooring
Budget
Dig a hole
Build concrete walls
Pour sub-floors
Form floated floors
Flood basement
Form floated floors again
Pour floated floors wrong
The sledge hammer
Keep your pipes outta here!
Start building walls
Decide how to build walls correctly
Very detailed drawings
Being a jerk
Explaining acoustic and isolation principles
Air is a bad thing
Can you say CAULK?
Caulk is your friend. If there is a gap, hole, seam, joint, or crack - fill it with caulk. I used a large tube of caulk for every 4-sq. ft. of my sound spaces.
That's over 500 tubes of caulk! Several Thousand Dollars' worth of caulk, and it is the most cost effective thing you can do to isolate and insulate a sound room.
Let's do it wrong, tear it down and do it again!
This is probably the most frustrating part of constructing a sound studio. Minor details can cause major problems.
For example: When attaching the outer layer of drywall to resilient channel, the construction crew used screws that were a little bit too long. The drywall was 5/8" and the resilient channel has about 1/2" gap. Resilient channel is supposed to be RESILIENT. Meaning that it can flex, or be "springy". The overzealous drywallers (?) sunk the screws too deeply into the drywall and they went through the first layer of drywall, through the resilient channel and firmly into the layer of drywall below. This made the resilient channel not resilient. The result being that the mass that was supposed to be limp, was not. In the day it took me to notice, they had already begun taping the joints. I was only able to see between the layers of drywall in a couple of doorways that had not been finished, but every screw was driven into the first layer of drywall.
I then informed the crew supervisor that they would have to remove the mud they had put up, and replace all of the screws in every piece of drywall. They hated me...but, I had told them the correct length screws to use and why they needed to use them the day before they attached the drywall.
Has anybody seen the CAULK?
Wires for everyone
Performance 1st - Not appearance
You can make a live room dead, but you can't make a dead room live!
I've have been surprised by the number of people who walk into the "live" room and say it has a lot more echo than they expected. Or "this room is too live for what I want to do". They're right, but it's flexible. It can be very live or very dead and almost everything in between. I made various sizes of acoustic panels, (4'x8', 4'x4', 4'x2', 2'x2') that are absorptive or diffusive, by attaching various Auralex Acoustics treatments to rigid insulative boards I found at Home Depot. By placing these panels in various ways and combinations (walls and ceiling), the room is tunable to the whim of the performer. It is not a soundstage or a concert hall capable of providing airy fullness for an orchestra - but short of that it works pretty well. It's awesome on acoustic instruments, including drums.
Painting and murals
Tuning the room and Auralex
Rackin' and rollin'
Wiring and patching are for the birds
This thing actually works
TO BE CONTINUED...
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