New build small size high isolation project

#76

Yea brilliant, I look forward to it!

#77

Hooray!

Finally got to a position where we can start building the silencers!

We welded a metal frame to support the silencer while it is built, lifted and persuaded into position.

It sits on a Genie lift which will winch up and down. We’re having to build the silencers in the corridor, which has limited width (1.4m).

We quickly realised that the metal frame had better be the other way around to aid tipping and pulling it between the ceilings.

We’ve been glueing and pinning then screwing while the glue is still wet so it pulls in tight!

Got the outer 25mm MDF shell done, started sticking the MLV inside... weird stuff to use, especially in a confined space. I called the spray glue manufacturer and they couldn’t tell me if the adhesive was or wasn’t safe for use in an HVAC system which is frustrating. I’ve been searching for HVAC safe ones but the only one I came across was a worldwide company which sells large quantities... I’ll call another manufacturer tomorrow to ask if they know.

The only place I’ve been able to track down the duct liner of equivalent spec to the JM’s stuff has been slow to respond. I now have a number and I’ve been badgering them for courier delivery! Turns out they’re one of the very few manufacturers of this type and they’ll be making it to order! Should be with me at the end of the week or early next. Meanwhile we can get the outside render top coat on and plenty of other little bits done.

#78

Excellent! Looking pretty good so far, Tom.

I called the spray glue manufacturer and they couldn’t tell me if the adhesive was or wasn’t safe for use in an HVAC system which is frustrating.

The MLV is sandwiched between the other two layers, so the adhesive should not be exposed to the air flow (hopefully!). What you could do if you are concerned about that, is to seal the final inner surface before you put the duct liner on, with some type of wood sealer that is impervious to air, and also safe to use in HVAC. Maybe some type of synthetic varnish. I'm sure you can fins something like that.

PS. Some of your pictures are laying down on their sides, taking a nap! I can probably fix that, if you want...

- Stuart -

#79

Ha, if it’s pictures from the last page, that’s us between the two ceilings! Don’t think we can fix that : ) lovely space to crawl in!

#80

Hi All,

The duct liner is planned for delivery Wednesday am next week so we did what we could easily on the silencer then turned our attention outside as the weather has been dry this week!

Got the MLV stuck to the MDF, that stuff is so hard to measure accurately! It stretches and compresses so your measurement once may vary slightly by the time you cut it! We had some small bits to shave off and some small slithers to tuck in, then we siliconed the joins.

Next was the OSB. As the silencer is longer than the OSB is available, we have two sheets of 11mm so we can stagger the long joints. These were easier to measure and cut accurately. All glued, pinned then screwed but not copiously as Stuart mentioned the function of the MLV will work best if it is not held rigidly.

We tipped the box to the wall to aid installation. The metal frame shows no signs of bending yet!

The baffles were pinned and glued together and we’ll fit them next week then the duct liner and top of the box.

#81

The render went on pretty well and I got the plinth base coated with high moisture resistant basecoat suitable for below dpc and ground contact conditions as the outside level will be raised a bit.

Also managed to pull 4 x cat 6 and 1 coaxial through the duct we buried and routed it into the house along with the main power cable (16mm2 conductor SWA cable) and a water pipe (20mm MDPE). So we soon won’t need to have our phones near or out of the door to get signal! We’ll be contactable when in the build.

Here are pics of the underside of the extension I built last year with the lovely crawl space : )

#82

Purelythemusic wrote:The only place I’ve been able to track down the duct liner of equivalent spec to the JM’s ...

I for one would be pleased to know who you managed to get duct liner from. I have plans to telephone JM in Germany but I don't speak German so I may not get far. An alternative supplier might be useful.

#83

Hi Starlight,

01744 419444
U-Spec.co.uk

The actually manufacture insulation for Knauf etc, they’re not a retailer so don’t expect any of that sort of service... I’m having to over order... how many m2 do you reckon you’ll need?

#84

It's looking good, Tom. That thing is huge! It looks even bigger in real life than it did in the SketchUp model. I can't wait to see how you rotate it to horizontal in that space up the top, then slide it in. That's gonna be "fun"!

- Stuart -

#85

Purelythemusic wrote:I’m having to over order...

Don't worry too much about that. We can make use of the extra in other places in your studio. Save all of your scrap insulation, of all types, as it can be probably be used for fill, in unexpected places...

- Stuart -

#86

Soundman2020 wrote:Source of the post
Don't worry too much about that. We can make use of the extra in other places in your studio. Save all of your scrap insulation, of all types, as it can be probably be used for fill, in unexpected places...

- Stuart -

Ah ok great!

I have had another thought about the AHU location and silencer layout which may provide more storage in the corridor and make the ducting installation easier...

#87

I have had another thought about the AHU location and silencer layout which may provide more storage in the corridor and make the ducting installation easier...

I did see your e-mail about that... I'll take a look at that over the weekend, and get back to you. It might be possible....

- Stuart -

#88

Well it’s been a weird week.

I thought we’d have the duct liner on Wednesday am but it didn't make an appearance until Thursday, by which time we were busy on other bits so today was the day for duct lining.

It is tricky to get it all in as singular section as possible. You don’t want longitude joins if possible as it could lip up over time. We were careful to follow Stuarts design concept by doing the bottom face, then baffles, then ends. We didn’t compress the pieces against each other either because as far as I know this can hamper gas flow, therefore absorption?
We weren’t overy confident in adhesive along keeping fibreglass to the OSB and no companies I could find here do proprietary duct liner fixings, so we improvised with cavity wall tie insulation clips to provide extra support... ran out of adhesive, then ran out of insulation clips.... buuut:

We did pain some of the corridor, the main room walls have had a mist coat and a full coat and sorted out the services coming in and out! We now have 4 x cat6 cables to a switch in the house so we have a wifi access point...no more leaving the phones at the door! I made the power connection and terminated at the building consumer unit, fitting a few sockets for our build use on the service board. I also wired up the cable to the studio consumer unit and wired a couple of sockets and put up a couple of very bright led batten lights which will end up in the corridor!

#89

That's a really cool use of the insulation washers, nice one. I required a handful of these a few months ago but minimum economic buy was 50. Nice to know I'll be able to use them eventually!

Cheers,
Jennifer

#90

endorka wrote:Source of the post That's a really cool use of the insulation washers, nice one. I required a handful of these a few months ago but minimum economic buy was 50. Nice to know I'll be able to use them eventually!

Cheers,
Jennifer

Thanks! Yea, I did umm and ahh about it...I wondered if they might cause some turbulence, but blew across them a bit and felt that at the air speed I think we’ll have they would be fine. Also not having them could be disastrous I imagine... the fibreglass pulls apart through the middle far more readily than the glass wool facing coming off, or the bond strength to the OSB.

Soundman2020 - Studio Design Forum