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Insulating and Wallboarding the Video Production Studio

May 1, 2011 -This week the crew from ComforTemp returned and finished blowing in cellulose insulation into all the walls of the studio. They will be back next week to add cellulose to the attic (as soon as we get the ceiling up in the video production studio). We also got most of the wallboard up on all the container walls. Most walls have been taped and floated at least once, but a second layer will be added next week. 

We also got started on installing wallboard in the video production studio. This is a VERY BIG job, as the walls are 19' high and the walls are 44' x 28'.  The ceiling will be especially challenging. The entire north wall, half of the west wall and the floor will be painted a special shade of green. When we shoot a video against this "green screen" we can remove the green color and add a background photo, or video of our choice.  Building this wall (also known as an infinity wall, or cove wall) is tricky, but we had some help from videos posted on YouTube.

To get a seamless background, the walls and floors must all blend together so there are no hard edges. This is called a Cyclorama, or Cyc. When constructed properly, you get the illusion of an infinite depth of field. We did some research and found a video by Maicon Rutz showing the step-by-step procedure he used to build his cyc wall. We are going to follow most of what he shows in his video, but we have some other ideas we intend to introduce and will share them with our readers as well.

We also had the electric crew from Centerpoint out to hook up the permanent power lines to our building, but they found two code violations that will need to be fixed before they can return connect the lines. One problem involved grounding wires which was fixed quickly, but the second problem involved us using schedule 40 electrical PVC pipe for some of the lines above ground. The code calls for schedule 80 pipe (heavier wall), which we will order and install next week.

There was quite a bit of "behind he scenes" electrical and plumbing work that we got accomplished this week. Last week we added a separate electrical panel for just the lighting in the Video Production Studio, and this week we got the wires run to it. We also ran all of the 220 wires to the AC units, stove, hot water heater, and the furnace/air handlers. In a commercial building, all electrical must be encased in EMT metal conduit or BX cable (we cannot use Romex, which is typical and inexpensive) in residential building. As for the plumbing, we got the hot water heater installed, along with most of the valves for the sinks in the bathrooms and kitchen areas.

One important tip we want to pass on - before you buy cellulose insulation from a big box store, take a minute to watch this video from www.startinsulatingnow.com. Don't pay more then you need to!

Next week we will turn all our attention to getting the wallboard work done. We have windows, corners, and edges that need to be completed. We also have the ceiling of the big room to do, and that will be a challenge. When all the wallboard work is completed, we are planning to rent a heavy duty texture machine so we can get the walls textured and ready for painting.



Posted by on May 01, 2011

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Jose gets the windows covered - cellulose insulation was blown into containers 9 & 10.

ComforTemp shot the exterior walls and all bathroom walls in about an hour.

Here is how the insulation goes from bags in their truck to the walls.

The plastic bags are cut and the compressed cellulose is fed into a large hopper.

In the hopper, the cellulose is fluffed and expanded.

Close up showing the cellulose as it comes from the bag.

ComforTemp markets their insulation under the Enviro-Smart brand.

It is important to read the size of the bag for coverage information. Not all bags are the same.

This is a bag of cellulose we got from Home Depot.

Although the bags look about the same size, the amount of material is different.

Workers use scaffolding to blow insulation into the 6 and 8 inch walls of the big room.

After the wall cavity is filled, it is trimmed, vacuumed up, and the excess cellulose returned to the hopper to be used again.

Close up showing the cellulose being applied to the wall. It took 2 days to do the walls of the big room.

ComforTemp also installs fiberglass batts.

We had a worker install some fiberglass for a test.

The fiberglass when on quickly, but we were glad we decided on cellulose for our job.

After all the walls were insulated, we began adding the wallboard.

We spent a good part of Saturday just organizing and cleaning our work areas. This room has only electrical supplies in it.