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Sheetrock Installed - Mineral Wool Blow Onto Studio Walls - Unit #3 Leased to GTIN

March 6, 2012 - Danny Span and his crew returned this week to install the Sheetrock on the walls and ceilings of the studio. This is a BIG job, and because the walls are used as shooting backgrounds, there is no room for error.

As you can see by the photos, Danny delivered and the studio is coming back to life. When cellulose is blown into the wall cavities and attic space, the difference in ambient sound levels is profound. While just about any substance will burn if heated enough, we were kind of disappointed that the fire burned the cellulose in the space between the containers for several days before it turned into a full blown blaze. While a 100% fire proof building is not practical, we wanted to do everything possible to make sure we were protected against the possibility of fire in the future. In my earlier research, I learned about Mineral Wool insulation, and decided it was worth a closer look. 

Mineral wool, also called stone wool is a comprised of molten rock heated to a temperature of about 1600 °C. While at this temperature a stream of air or steam is blown onto the molten rock. The rock can also be spun - much like cotton candy, and results in a mass of fine, intertwined fibers.  A binder is then added which is comprised of a food grade starch along with oil to reduce dust. Rodents are not attracted to mineral wools, but if the wool becomes wet it will support bacterial growth. In a book by Woodhead Productions titled Mineral Wool Production and Properties I found this quote - "Mineral wool has the ability to save energy, minimize pollution, combat noise, reduce the risk of fire and protect life and property in the event of fire."

It is also about three times the price of cellulose. Comfortemp was able to find a source for mineral wool in Austin that would work in their equipment. When we compared it side-by-side with cellulose, it was much denser, and felt more like a fabric vs. any kind of stone. It took the guys from Comfortemp some experimenting to get just the right mix of adhesive to mineral wool, but once they got going, the application went on quickly. Unfortunately, the mineral wool was suppose to come in tinted black, but came in it's natural brown color.

For the studio ceiling, we needed it black and the only way to do it was spray paint it with latex paint. We used over 10 gallons of paint (@$23/gal), and it took almost 2 days to paint it. If you photograph the ceiling with a flash, it appears the coverage is not very good, but when you stand in the studio and look up, it looks fine. We will also have to be concerned about bumping into it in the future. As soon as the black surface paint is disturbed, the honey brown color of the mineral wool shows through. Even so, after all the insulation was done, I just sat in the studio for a few minutes by myself to enjoy how quiet it was.

We also had some good news concerning the leasing on unit #3 on the second floor. This three container 960 square foot unit is a beauty, and includes a 48' x 9' wrap-around deck (complete with ceiling fans).  An old friend, Rhese Hoylman, President of GTIN Services, stopped by to check it out, and leased it on the spot. For the past few days we have been finishing the interior as he requested.  Rhese is an expert at managed IT Services.

GIN services are provided on a flat-fee basis, and often include preventative maintenance; help-desk and on-call support; budgeting, purchasing and planning; business process assistance. They are focused on delivering technologies that reduces long term expense. GTIN will help create an effective network topology for epic and the Creative Co-Op, and also help with the configuration and installation of the CCTV security systems. We are excited to have Rhese and his team join us.

We also spent some time replacing a number of flexible hose fitting under the new sinks we installed just a few months ago. We bought these sinks from a builder who went bust in 2009, and althought the sinks were new, we think that the hoses had dried out from sitting in storage for a while. The connections were not standard, and we could not find them at the big box stores, or at the local plumbing supply company.  We did have luck on Amazon (yes they carry speciality building supplies), at a very good price.


Posted by on March 06, 2012

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The Sheetrock on the walls was installed first, followed by the ceiling.

Birdseye view of the studio from the shooting platform on the 2nd floor.

This is the last section of Sheetrock to go on the walls.

Adam adjusts the new sliding door. It replaces the glass window destroyed in the fire.

Fernando returned to install the HVAC unit on the roof above unit 11.

Fernando installs the over sized vent filters for the air return units.

Interior of Unit #3 under construction.

Cliff points to where GTIN wants their attic door.

We ordered a heavy duty set of stairs and decked the attic for GTIN.

We purchased this Milwaukee sprayer with turned out to be a dud. We replaced it with a Wagner that worked great.

Cliff makes a cut on some trim for the new roof above the Silver Rock deck.

Adam installs carpet on the stair risers to reduce sound.

Here you can see mineral wool (left) next to cellulose.

Mineral Wools comes in bags just like cellulose, but they are heavier

Black latex paint is sprayed onto the mineral wool on the walls.

The ceiling - looks bad in the photo, actually looks ok when in the studio.

Difficult plumbing fixtures we found on Amazon and replaced on all sinks.